Cathodic Protection For MSV

Resource provider : Shri Ramesh Yadav

Team : 1 Chandrakant Shend
2. Arun Nayak
CORROSION
Electro- Chemical process,
metallic structures electrodes
Soil - electrolyte

Potential difference arise between parts of U/G metallic

structure due to various conditions of electrolyte

Current flows from higher potential to lower potential

thru electrolyte

Point at which current leaves is called anode and the

metal ions reacts and dissolves into the electrolyte leaving
pits and leaks on the surface.

Corrosion rate depends on the soil resistivity

CORROSION
Electro- Chemical process,
metallic structures electrodes
Soil - electrolyte

Potential difference arise between parts of U/G metallic

structure due to various conditions of electrolyte

Current flows from higher potential to lower potential

thru electrolyte

Point at which current leaves is called anode and the

metal ions reacts and dissolves into the electrolyte leaving
pits and leaks on the surface.

Corrosion rate depends on the soil resistivity

FACTORS WHICH INFLUENCE CORROSION RESISTANCE

ELECTROCHEMICAL

PHYSICAL
CHEMICAL CORROSION RESISTANCE METALLURGICAL

THEMODYNAMIC
BASIC CORROSION PROCESS
THE LESS NOBEL METAL BECOME ANODE (POSITIVE ELECTRODE)
WHILE MORE NOBLE METAL ACT A CATHODE( NEGATIVE ELECTRODE)

ANODIC REACTION DISSOLUTION OF METAL M++ + 2e-

CATHODIC REACTION DEPOSITION OF IONS N++ + 2e- N

REACTION AT ANODE WHICH CAUSES DISSOLUTION OF METAL LEADS

TO CORROSION OF METAL M
Corrosion Cell

electrical path

electrolyte (soil)

cathode anode
Conventional current
 HOW CORROSION TAKES PLACLE
Conventional current flow ( + to v)

Electron migrations (e-)

e- e-
e- e- e- H2 Fe(OH)2 OH- Fe+
e- H+
e-
cathode
e- e- H2
H+ e-
Iron anode
Fe(OH)2 OH- Fe+
 At Anode:
2H2O (OH)- +H + + 2e-
FE + + 2(OH) - FE(OH)2
FE(OH)2+ FE + + (OH) - FE2(OH)3

At Cathode
2e- + H + H(atom)
H +H plarisation film
 CARROSSION CONTROL METHODS
Passive method : Coating
Continuous film of Electrically insulating material over the metal
surface to isolate it from surrounding electrolyte

Active Method: Cathodic Protection

Superimposed DC current thru external source (TR unit) is fed in the
corrosion
Perfect coating is not possible as coating have defects called
Holidays from where corrosion process starts
There is limitation to feed DC current
Hence combination of both methods is employed for u/g Pipelines
and MSV
 Cathodic Protection
Sacrificial Anode Cathodic protection
Generally employed for small section of metallic surface
No external source is required

Impressed Current Cathodic Protection

Generally employed for large section of metallic surface protection
External source is required
 ICCP Design-Protection Criteria
To maintain the steel at a potential between (-) 0.85 to (-) 1.5V w.r.t. Cu-
CuSO4 reference cell

Potential lesser than (-) 0.85 under protection

Potential higher than (-) 1.5 over protection

It induces hydrogen embitterment of high CS used in fabrication of bullets
 TYPICAL CP UNIT
Ground bed

Anode

Anode Cable

+
CP unit
-

Cathode Cable

Protected Pipe Pipe

Anodic Area
 Cathodic Protection Design for MSV

Primary Protection:
Coating

Impressed Current Cathodic Protection

Long line conductive polymeric anode
Laid around the periphery of the MSV from distance of 500mm from
the outer surface
 Cathodic Protection Design for MSV
1 : Surface Area Calculation:
Diameter , length TL -TL, fitting area (3.2% piDL)

2 : Current requirement
30% of the surface area (considering bare area), current density @10mA/Sqmt

3: Anode flex Selection and length calculation (50 years design life)
Anode flex (1500-1 ) standard rating 52mA/mt for 20 years
Anode flex derated to 20.8mA/mt for 50 years
Length calculated and distributed in no. of strings (33mt Hazira)

4: Ground Bed Resistance Calculation

Soil Resistivity , length and diameter of anode, depth of burial of anode, anode

5: Total circuit Resistance Calculation

Anode and cathode tail cables and header cable resistance

6: Transformer Rectifier Rating Calculation and Selection

 CP System Configuration
1: Anode flex System
Long line , conductive polymer anode,
Copper Conductor sealed in tough flexible polymer and cable packed with Coke freeze

2: Transformer Rectifier Unit

Operates on Single phase supply , battery back provided
Three modes of operations Auto reference mode, CVCC , Manual

3: Anode Junction Box

Interconnecting Anode lead cable from MSV to main Positive header cable

4: Cathode Junction Box

Interconnecting Anode lead cable from MSV to main Positive header cable

5 : Zinc Reference Cells

Input for TR unit Auto operations.

6 : Monolithic Isolating Joints :

To isolate CP system from pipelines /fitting to prevent drainage of current
CP SYSTEM OPERATIONS AND MAINTENACE
1: Record of
Long line , conductive polymer anode,
Copper Conductor sealed in tough flexible polymer and cable packed with Coke freeze

2: Transformer Rectifier Unit

Non Hazardous, Air cooled , IP65 constructed panel
Operates on Single phase supply , battery back provided
Three modes of operations Auto reference mode, CVCC , Manual

3: Anode Junction Box

Interconnecting Anode lead cable from MSV to main Positive header cable

4: Cathode Junction Box

Interconnecting Anode lead cable from MSV to main Positive header cable