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This document discusses corrosion and cathodic protection of pipelines. It covers the basics of corrosion, forms of corrosion, and methods of corrosion prevention including coatings and cathodic protection using sacrificial anodes or impressed current systems. Factors that influence corrosion are also discussed such as soil resistivity, coatings, potentials, and interference sources. Surveys to monitor cathodic protection systems are also summarized.
This document discusses corrosion and cathodic protection of pipelines. It covers the basics of corrosion, forms of corrosion, and methods of corrosion prevention including coatings and cathodic protection using sacrificial anodes or impressed current systems. Factors that influence corrosion are also discussed such as soil resistivity, coatings, potentials, and interference sources. Surveys to monitor cathodic protection systems are also summarized.
This document discusses corrosion and cathodic protection of pipelines. It covers the basics of corrosion, forms of corrosion, and methods of corrosion prevention including coatings and cathodic protection using sacrificial anodes or impressed current systems. Factors that influence corrosion are also discussed such as soil resistivity, coatings, potentials, and interference sources. Surveys to monitor cathodic protection systems are also summarized.
energy state Requirement Metal oxidation and environment M=> M++ , O2 =>OH- , H+=>H2 Forms of corrosions Uniform Pitting Crevice Galvanic Stress corrosion cracking Hydrogen Embrillement Corrosion prevention Coating of pipe line Sacrificial anodes Impressed current system Passivation Type of coatings 1. Coal tar enameled coatings 2. Extruded polyethylene and polypropylene coating 3. Fusion Bonded epoxy coating
Note:- Each has different cathodic
requirenments Criteria for Cathodic protection with standard Copper sulphate cell Piping potential between -.85 and 1.2 volts measured within 1 second after simultaneous switching off all TR1:4 ON /OFF time 100 mV polarization in case drop in case of uncoated pipe lines Effects of various factors Low P.S.P. corrosion High P.S.P. Hydrogen disbonding For high temperature and aerobic nature the minimum P.S.P. should be -.95 Volt Soil resistivity Area Severity of corrosion Resistivity ( ohms-cm ) Average Moderate 1000 to 2000
Tidal Corrosive 500 to 1000
Clay Very Less than 500
Sandy loam Mildly 2000 to 10000
Desert Non corrosive 10000
Galvanic series If two dissimilar Mg -2.34 metals are Al -1.67 connected Zn -0.76 electrically and dipped Fe -0.44 in solution In -0.34 More Active Ni -0.25 material will H2 0.00 dissociates Cu 0.34 into ions Ag 0.80 leading to is corrosion Au 1.68 Electrical Circuit of corrosion cell ea ec Ic ra rc rm
IC= Corrosion current
e = Potentials R= resistances Copper Sulphate half cell requirenment Standardisation High resistance > 1000 m-ohms meter Crystals of copper sulphate Copper electrode Porous plug Anodes for Galvanic CP system Zinc 11.8 kg /Ay Magnesium ( Galvomag ) 7.9 kg/Ay Aluminum ( Galvalum I , II , III 3.4 kg/Ay Backfill for Galvanic anodes Gypsum 75% Bentonite clay 20% Sodium sulphates 5% Impressed Current CP System Scrap iron 10kg/Ay High Silicon Anodes - .3kg/Ay Mixed Metal oxide titanium 1mg/Ay Palatalized titanium anode 10 mg/Ay Magnetite anodes Impressed Current Anodes Chemical resistance to low pH Low passive current Low oxygen over voltage Wide temperature range Good cast ability & mechanical strength Good resistance to abrasion Good current discharge capability Resistance to localized corrosion Backfill for impressed current system Metallurgical Coke Breeze Calcined petroleum coke breeze Various terminolgies Insulated joints Grounding cells Surge diverter Corrosion Coupons Stray Current Interference CP units D.C. traction system HVDC Transmission system Telluric Current A.C. Current effects Capacitive coupling Inductive coupling Resistive coupling High induced voltage Basic requirement of pipe line coating Ease of application Good Adhesion to pipe line Good impact resistance Flexibility Resistance to soil stress Resistance to flow Resistance to moisture Electrical resistance Chemical & physical stability Resistance to soil bacteria , marine organism Current densities required for cathodic protection mA/m2- life Year/Mat 0-5 5-15 15-30 Coal tar 0.040 0.100 0.200 Butyl .010 0.020 0.050 rubber tape, coal tar Polyethylen 0.002 0.005 0.010 e, Polypropyle ne Recommended off potential for coatings Coal tar -1.5V FBE coating -1.2 V 3LPE coating -1.5V Field surveys on CP systems Close Interval Potential Logging Current Attenuation Test Survey Direct Current Voltage Gradient Survey AC / DC Interference Survey CPL survey 0.75 5 meter interval ON/OFF 4:1 timing Data logging Lateral potential gradients Locates deffects Pearson & CAT surveys Audio frequency transmitter CAT locator Locates pipe & depth Electrical contact between pipe and metallic structure Signal strength v/s distance curve DCVG survey On / OFF potential Two balanced reference anodes 2mtrs apart Sources of Power for cathodic protection A.C. Power from grid Solar Power Wind Power Thermoelectric generators & CCVT Accessories GPS based based interrupter Synchronized interrupters Permanent half cells Data logger Bonding diodes Bonding cables Remote bed