Corrosion Management on

Pipeline with Cathodic

Protection

Ilmu Bahan dan Korosi

Outline
Pipeline Risks and Corrosion
Cp Technique : Galvanic Sacrificial
Anode (Principle, Installation)

Cp Technique : Impressed Current

(Principle, Installation)
Case Study

: Sacrificial Anode

Case Study

: Impressed Current

Risks on Pipeline
The product of the frequency with which
an event is anticipated to occur and the
consequence of the event outcome.

RISK = PROBABILITY x SEVERITY

Risks on Pipeline
PRESSURE
DROP

LEAKAGE

CORROSION

Corrosion Control
Coating : insulation
Cathodic Protection: DC current
injection towards pipeline, result:
pipeline is shifted as cathode.
Sacrificial anode
Impressed current

Galvanic Sacrificial Anode Principle

Metal

Driving voltage (Vd)

Negative Vd = active metal =tendency

to corrode

Pipeline: connected with active metal

Anode: Mg, Zn

Cathode: pipeline

Corrosion on Mg, Zn hence sacrificial

Galvanic Sacrificial AnodePrinciple

Material

Driving Voltage (V)

Silver (Ag/Ag+)

+0.8

Copper (Cu/Cu2+)

+0.34

Water (O2+H20+4e- = 4OH-)

+0.401

Hydrogen (H2)

Iron (Fe/Fe2+)

-0.44

Zinc (Zn/Zn2+)

-0.76

Magnesium (Mg2+)

-2.36

(cathodic)

(reference)

(anodic)

Galvanic Sacrificial AnodeInstallation

(Source: Peabodys Control of Pipeline Corrosion)

Galvanic Sacrificial AnodeInstallation

(Source: Peabodys Control of Pipeline Corrosion)

Impressed Current

(Source: Peabodys Control of Pipeline Corrosion)

Minimum potential: -0.85V

Reference electrode: Copper Sulfate

Galvanic Sacrificial AnodeDesign

Calculate total area to be protected (Ap)

Determine the current density ()
Calculate total protection current (Itot = .Ap)
Calculate R per anode : R = f(d,l,)
Calculate Ia per anode : (Vd-0.85/R)
Calculate total anode needed :
Initial : N=Itot/In
Lifetime: N = f(mass,lifetime,A/poundyear)

Impressed Current-Principle
Rectifier

Variable voltage, variable current

Higher current density (> 1 A)

Higher soil resistivity (> 104 cm)

Impressed Current-Installation
Types of anode:
Graphite : big CR (pound/A/year)
High Silicon Cast Iron : medium CR
Platinum & niobium : small CR
Rectifier rating:
Voltage, Amperes, Watt, Freq.
Cooling System : Air, Oil
Efficiency
CR: Consumption Rate

Impressed Current - Installation

(Source: Peabodys Control of Pipeline Corrosion)

Impressed Current - Design

Calculate total area to be protected (Ap)

Determine curent density ()
Calculate total protection current (Ip)
Calculate total anode needed (N)
Initial
Lifetime
Calculate total anode resistance (Rtot =
f(N,,d,L,spacing))
Calculate rectifier specification (Vdc, Idc, Pdc =
f(Rtot,Ip)

Pipeline Cathodic Protection

Case Study

Galvanic Sacrificial Anode

Case Study

Variabel

Nilai

Pipe Diameter (d)

a. 2 inch = 0.0508m
b. 1 inch = 0.0254m

Pipe Length (l)

a. 2 inch pipe: 300m

b. 1 inch pipe: 1300m

Soil Resistivity (average)

4500 cm

Current Density ()

9mA/sqmm

Type of Anode

Magnesium, weight 9 pon, r = 8.89cm, l = 53.54cm

Coating efficiency (n)

50%

Lifetime

20 years

Galvanic Sacrificial Anode

Case Study
Step 1: surface area of pipeline

Step 2: total protection area

Ac n Ap 50% 151,613m 2 75,806m 2

Step 3: total protection current

Ip Ac 9mA / sqm 75,806m 2 682,254mA 0,682 A

Galvanic Sacrificial Anode

Case Study
Step 4: Anode resistance (Dwights Equation)
0,159 4 L
0,159 4 53,54
R
ln
1 4500
ln
1 29,15

L r
53,54
8,89

Step 5: Current per Anode

Ia

DrivingVoltage Polariseds teelVoltage E 1,55 0,85

0,024mA
Re sis tan ceAnodeElectrolyte
Rae
29,15

Galvanic Sacrificial Anode

Case Study
Step 6: Total Number of Anode
Initial

Lifetime

Ip 0,682 A

28.41anodes
Ia 0,024mA

Lifetime Ip
20 682,254

30.75anodes
49,3 AnodeWeight
49,3 9

Selected number of anodes: 31.

Galvanic Sacrificial Anode

Case Study
Step 7: Distribution and Layout
Distribution

Ac 75.806
A

2.445m 2
N
31
Layout
Type of Pipe

Effective Surface (Ac)

Number of Anode
(Ac/A)

Diameter 2inch
(0.0508m)

0.5 0,0508 300 23.935m 2 23,93 : 2,445 10

Diameter 1inch
(0.0254m)

0,5 0,0254 1300 51.87m 2

51.87 : 2,445 21

Total

31

Impressed Current
Case Study
Variabel

Value

Pipe Diameter (d)

6 inch = 0,1524 m

Pipe Lengyth (l)

6800 feet = 2072 m = 2,072 km

Soil Resistivity (average)

2000 cm

Current Density ()

30mA/sqmm

Type of Anode

Stated in next section

Coating Efficiency (n)

50%

Coating Impedance

25000/m2

Maximum Groundbed
Resistance

Lifetime

15years

Impressed Current
Case Study
Step 1: surface area of pipeline

Ap dl 0,1524 2072 992,03m

Step 2: total protection area

Ac n Ap 50% 992,03m 2 496,015m 2

Step 3: total protection current

Ip Ac 30mA / sqm 496,015m 2 14880,45mA 14,88 A

Step 4: determine type of anodes

Iron Silicon Chromium. Weight: 110 pon, cross section 4 sqft (0,371m2),
diameter 10 inch (0,833 feet = 2,54cm), length 84 inchi (7 feet = 20,32cm)

Impressed Current
Case Study
Step 5: total number of anodes

Current limit (silicon: 10.76 A/m2)

N

Ip
14,88 A

Ai Ic 0,371m 2 10,76 A

Lifetime
N

3,72anode
m2

Lifetime Ip
15 14880mA

2,02anode
1000 AnodeWeight 1000 110 pon

Total anodes: 4.

Impressed Current Case

Study
Step 6: groundbed resistance calculation
Resistance limit: 2 (to limit rectifiers spec)
Spacing: S = 30 feet , Anode Length: L = 7 feet
Anode Diameter: D = 0.8333 feet

0.00521
8L
2L
(ln
1
ln 0.656 N )
L N
d
S
0.00521 2000 8 7
27

ln

ln
0
.
656

74
30
0.833

1.36

Rg

Groundbed resistance is below limit.

If not, choose longer spacing.

Impressed Current Principle

Step 7: rectifier specification

Vrec Ip Rg 14,88 1.36 20,237V .

Srec Vrec Ip 301,123W
Specification: 21VDC, 302W .

Final Results:
Anodes : Iron Silicon Chromium, 4 anodes.
Rectifier : 21VDC, 302W.