Documente Academic
Documente Profesional
Documente Cultură
2 0 1 6;5(4):367376
www.jmrt.com.br
Original Article
Roland Tolulope Loto a,c, , Roy Olakunle Loto b , Cleophas Akintoye Loto a
a Department of Mechanical Engineering, Covenant University, Ota, Ogun State, Nigeria
b Department of Metallurgical and Materials Engineering, University of Lagos, Lagos, Nigeria
c Department of Chemical, Metallurgical & Materials Engineering, Tshwane University of Technology, Pretoria, South Africa
a r t i c l e i n f o a b s t r a c t
Article history: The cathodic protection system analysis as tools for one-dimensional pipelines and risers
Received 14 January 2016 was modeled and derived incorporating the relevant resistance terms. The new expres-
Accepted 21 May 2016 sion pertains to pipelines with superimposed anodes. Comparisons were made between
Available online 1 August 2016 the potential attenuation projected by the new expression, the classical equation of Uhlig
and the boundary element modeling technique. It was conrmed that the newly derived
Keywords: equation is more conservative than the boundary element modeling technique due to its
Alloys consideration of the metallic path resistance and the Uhlig equation because of its consid-
Corrosion resistance eration of the anode resistance.
Cathodic polarization 2016 Brazilian Metallurgical, Materials and Mining Association. Published by Elsevier
Electrochemical property Editora Ltda. This is an open access article under the CC BY-NC-ND license (http://
Coatings creativecommons.org/licenses/by-nc-nd/4.0/).
Corresponding author.
E-mail: tolu.loto@gmail.com (R.T. Loto).
http://dx.doi.org/10.1016/j.jmrt.2016.05.008
2238-7854/ 2016 Brazilian Metallurgical, Materials and Mining Association. Published by Elsevier Editora Ltda. This is an open access
article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).
368 j m a t e r r e s t e c h n o l . 2 0 1 6;5(4):367376
portion of petroleum production platforms [10,11]. How- (2) Determination of the total anode mass (kg) required from
ever, the one-dimensional nature of pipelines entails the a modied form of Faradays law
use of coatings combined with cathodic protection. In the
former case (petroleum production platforms), the fundamen- 8760im T
M= (2)
tal parameters important in cathodic protection design are uC
the anode resistance and structure current density demand.
On the other hand, for metallic pipelines, the coating qual- where T is the design life (years), C is the current capacity
ity and metallic path resistance must be taken into account of an individual anode (A h/kg), u is the utilization factor,
from a general point of view. Cathodic protection systems can im is the mean current density to polarize the pipeline.
be of the impressed current type or the galvanic anode type
[1215]. Impressed current cathodic protection (iccp) systems 8760 h in 365 days. Finally, the number of anodes, N, is deter-
are mainly used for buried onshore pipelines but not feasible mined as shown below;
for offshore pipelines. In both cases the limiting distance to
which the corrosion protection can be effected is a function Ia
N= (3)
of the voltage drop along the metallic pipeline, which arises ia
in conjunction with the current return to ground. Another
factor that affects the distance to which corrosion protection where Ia is the total current required and ia is the current
is afforded is the quality of the protective coating. Thus, the output from an individual anode.
higher the coating quality, the less the current demand of the However, for marine pipeline cp retrots, marine pipelines
pipe and, as a result, the less the voltage drop for a pipeline of deployed by reeling with subsequent anode sled placement,
a given length. However, coating quality of marine pipelines buried onshore pipelines with iccp systems, anode spacing
is considerably less than that of buried onshore counterparts as mentioned above, is likely to be large and metallic path
so that this distance of protection is considerably less in the resistance signicant. For these situations, numerical meth-
former case than in the latter. To maximize the distance, to ods such as boundary element modeling (BEM) are commonly
which protection is achieved, the region of the pipeline near used; rst principles based equations of Morgan and Uhlig
the rectier and anode may be overprotected [16,17]. This are also used [22,23]. These equations are used to project the
can cause coating damage in the form of blistering and dis- potential attenuation along the pipeline in order to deter-
bondment, which in turn increases the pipe current demand. mine the polarization at any point along the pipeline. This
Because of these factors, corrosion control of the majority therefore enables the calculation of the protection distance
of marine pipelines is provided by galvanic anodes, i.e., gal- of the cathodic protection system along the pipeline, which
vanic anode cathodic protection (gacp). This is invariably of in turn enables the determination of a conservative anode
the bracelet type for structural, economic and installation spacing, which will provide the desired protection economi-
considerations. cally. They are also used to calculate the anode current output,
The design normally assumes a certain percentage of coat- which helps in calculating the life span of the anode (in case
ing bare area and employs galvanic bracelet anodes spaced of gacp system), or the current consumption (in the case of
about 250 m apart. This relatively short spacing emanates iccp system). With the Morgans equation and also the Uhligs
because of the limitations on the size of the bracelet anodes equation, anode resistance is not taken into consideration
that can be deployed from a lay barge and the fact that the and there are levels of uncertainty associated with the cal-
current density demand is relatively high and service lives of culated magnitude of polarization at the drainage point, the
2530 years are needed. For the buried onshore pipeline on the mid-anode spacing and at a variable point z from a drainage
other hand, the higher coating quality combined with the iccp point. There are also levels of uncertainty associated with the
system is such that the metallic path ground return resistance current density demand projected by the equation.
is the controlling factor and as a result the anode ground bed The BEM on the other hand incorporates anode resis-
spacing of 50100 km can be realized [18]. tance and expresses the closed circuit cathode potential as
For offshore pipelines with closely spaced galvanic anodes, a function of distance from the drainage point but it does
common on new installations, the metallic path resistance is not accommodate the metallic path resistance [21]. Hence it
negligible and the design process has historically involved the predicts a constant polarization beyond the eld of the anode
following steps [19,20]: whereas, theoretically given the fact that the pipeline has a
nite resistivity, the polarization will decrease with distance. It
(1) Calculation of the net pipe current demand from the is therefore possible for the polarization at some point to have
expression: risen above 0.80 VAgCl with the BEM projecting a signicantly
higher value [24,25]. This means that there are situations
where the potential at a point along the pipeline is affected by
Ic = Ac fc ic (1) all four resistance terms earlier described. Using any of these
methods would give results that incorporate some amount of
error. In light of the limitations of the methods described, this
where Ic is the net pipe current density demand [21], Ac is research aims to derive a rst principle based attenuation
the pipe surface area, fc is the coating breakdown factor equation that incorporates all the four resistance terms
(the ratio of bare area to total pipe surface area), ic is the (anode resistance, coating resistance, polarization resistance
current density demand. and metallic path resistance). This is to accurately calculate
j m a t e r r e s t e c h n o l . 2 0 1 6;5(4):367376 369
the pipeline polarization behavior and the pipe current to remote earth of the bracelet anode and the sphere anode
demand. are the same. Therefore, the equivalent sphere anode for a
given bracelet anode can be calculated by referring to McCoys
formula [27]. For a bracelet anode of a given surface area, the
2. Methodology
approximate resistance to remote earth is given by McCoys
formula as
The modeling research was carried out in two parts: (i)
development of an inclusive potential attenuation model for 0.315e
R= (8)
pipeline cathodic protection and (ii) verication of the atten- A
uation model.
where e is the resistivity of the electrolyte, A is the exposed
2.1. Development of an inclusive potential attenuation surface area of the bracelet anode. By assuming a sphere of
model for pipeline cathodic the same surface area to the bracelet anode, the equivalent
sphere radius ra (eq) is calculated as
2.1.1. Protection
According to Pierson et al. [26], the electrode (pipeline or riser) Sa
ra (eq) = (9)
potential can be represented as the charge gradient associated 4
with an electric double layer or
or
Ec (z) = Em (z) Ee (z) + Kref (4)
ra (eq) = 0.282 Sa (10)
where Em (z) and Ee (z) are the potentials of the metallic pipe
where Sa is the sphere surface area.
and electrolyte respectively, at a distance z from the drainage
Ee (z) is considered to be the product of the resistance Re (z)
point of an offset anode or the centreline of an anode super-
between the anode and a radial outward distance d in the elec-
imposed on the pipeline in which the anodes are identical
trolyte and the net current in the electrolyte
(Ia (z)) at that point
and equally spaced and Kref (constant) is the potential of the
in accordance with Ohms law where d z2 + y2of
reference electrode. In addition,
where Ecorr is the free corrosion potential and c (z) is the The potential difference between two points r1 and r2 is
degree of polarization from the free corrosion potential. By given by the classical equation for potential drop associated
taking the second derivative of Eqs. (4) and (5) and substituting with a spherical electrode in an electrolyte of resistivity e as
for Ec (z) the expression below is obtained. r2 r2 1
e I e I 1
Er1 r2 = e dr = dr = (12)
4r2 4 r1 r2
c (z) = Em (z) Ee (z) (6) r1 r1
2.303(Ecorr Eo )
z1 icorr = Aa io exp (19)
ba
ra
to Eq. (7). The terms were brought together and rearranged the next iteration step (iteration step m + 1) based on the values
thus providing an expression for the potential attenuation of the present iteration step (iteration step m) at the nodes.
along a pipeline as: The representation of the boundary conditions at the end
nodes was done using
e rp
1 1
where
is very difcult to polarize, to that which is likely to be met
d2 3z2 in practice. Other parameters for the hypothetical system are
Q =d (32)
d5 listed in Table 1. The potential attenuation along the pipeline
obtained by these three methods for each value of k was plot-
e rp
H= (33) ted as a function of distance along the pipeline from the anode
k
(i.e. as a function of z) to verify the accuracy of Eq. (27).
2rp Rm Using the same parameters in Table 1 for k = 100 m2 but
B= (34) with L = 3000 m, the attenuation proles from BEM and Eq. (27),
k
neglecting metallic path resistance (i.e. assuming m = 0), were
where n is the number of nodes on the cathode between the plotted. This was done to show the effect of the metallic path
anode surface and midpoint (the number of elements of length resistance, which is not considered by the BEM, on the polar-
dz plus 1), m is the iteration step and i refers to the internal ization of a pipeline in situations where it is not negligible. By
node over the length of the cathode between the anode sur- relating c (z) to the current density demand of the pipe, the
face and the midpoint. Eq. (30) provided an explicit means for anode current output was determined by Eq. (27) using the
calculating the cathode polarization at each internal node for pipe and electrolyte parameters that are in Table 1 and the
372 j m a t e r r e s t e c h n o l . 2 0 1 6;5(4):367376
0.60
Table 1 Pipeline and electrolyte parameters for a
hypothetical system used in analysis [27]. 0.65
Potential,V(Ag/AgCl)
0.75
Pipeline outer radius, m 0.136
Equation 27
Pipeline inner radius, m 0.128 0.80 BEM
Anode spacing (2 L), m 244 Uhlig Eqn.
0.85
Coating breakdown factor 0.04
Equivalent sphere radius of anode, m 0.201 0.90
Electrolyte resistivity, m 0.30
0.95
Pipe resistivity, m 1.7 109
Free corrosion pipe potential, VAg/AgCl 0.65 1.00
Anode potential, VAg/AgCl 1.05
1.05
0 20 40 60 80 100 120 140
Distance, m
result obtained was plotted against k. The results obtained for
the Uhlig equation and the BEM were also plotted on the same Fig. 2 Comparison of potential proles projected by Eq.
graph for comparison. (27), BEM and Uhligs equation.
100
0.55
Equation 27
BEM
10 Uhlig Eqn.
Potencial, V(Ag/AgCl)
0.65
Current output, A
0.75
1
0.85
Equation 27
0.1
Equation 27
0.95 wfo resist
BEM
0.01
1.05 0 200 400 600 800 1000 1200
0 500 1000 1500 2000 2500 3000 3500
Distance, m k
Fig. 3 Comparison of potential projected by Eq. (27) and Fig. 4 Comparison of anode current output as projected by
BEM where the former exhibits the presence and absence Eq. (27), BEM and Uhligs equation.
of the metallic path resistance term.
0.60 300
0.65
250
0.70
Potential, V(Ag/AgCl)
Current output, mA
0.75 200
0.80
150
0.85
0.90 100
Equation 27
0.95 Equation 27
BEM
50 BBM
1.00
1.05 0
0 2000 4000 6000 8000 10 000 12 000 0 200 400 600 800 1000 1200
Distance, m
Half anode spacing, m
presents attenuation proles for semi-anode spacing ranging which had a lesser magnitude. The difference is also due to
from 1000 to 10,000 m with k = 1000 m2 projected by the same the BEM not considering the metallic path resistance.
two methods. Fig. 9 presents a plot of difference in potential at the
Figs. 5 and 6 indicate that potential proles projected by midpoint between the value projected by Eq. (27) and that pro-
Eq. (27) is different from that projected by the BEM and the jected by the BEM as a function of k for various anode spacing
magnitude of this difference is directly proportional to (1) the between 250 and 10,000 m. The curves show that, except for
distance from the anode (2) the semi-anode spacing and is the largest anode spacing (10,000 m), the difference in poten-
inversely proportional to the polarization resistance. Eq. (27) tial increases with decreasing k. This trend arose due to the
is considered to be the more accurate of the two methods espe- anode current output increasing with decreasing k with the
cially when the metallic path resistance is signicant because BEM not accounting for the increasing voltage drop along the
it incorporates the term. It follows that on pipe for instance, pipeline as a result of the increasing anode current output.
the BEM can indicate protection along the entire length of the However, a reverse trend was observed for 2 L = 10,000 m and
pipeline, whereas the pipe is under-protected beyond a certain k < 600 m2 . This was due to the fact that as a result of the
point. Figs. 7 and 8 show the plots of anode current output as a relatively low k and the large potential drop from the anode
function of semi-anode spacing for the same conditions used to the mid-anode point, the polarization at the midpoint was
for Figs. 5 and 6, respectively. The plots show that the BEM and very small for both the BEM and Eq. (27) and the difference in
Eq. (27) are in good mutual agreement for relatively short spac- potential projected by the two was small.
ing. However, for longer semi-anode spacing, the BEM projects Fig. 10 presents the percentage difference in anode current
that the current increases whereas, Eq. (27) projects that the output between the BEM and Eq. (27) as a function of k for the
current increases to a maximum and then decrease. The latter same anode spacing used in Fig. 9. It will be observed that, for
phenomenon is more prominent than the lower polarization all the values of anode spacing, the difference decreased with
resistance case. The lower anode current output projected by increasing value of k. This trend is particularly signicant in
Eq. (27) in Figs. 7 and 8 compared with the BEM corresponds
with the potential projected by the former in Figs. 5 and 6,
Mid-anode spacing potencial difference, V
0.07
0.06
3500
0.05
3000 10 000 m
0.04
5000 m
1000 m
Current output, mA
2500
500 m
0.03 250 m
2000
1500 0.02
1000 0.01
Equation 27
BEM
500 0
0 200 400 600 800 1000 1200
0 k
0 500 1000 1500 2000 2500 3000 3500
Half anode spacing, m
Fig. 9 Plot of the difference between potential projected by
Fig. 7 Anode current output as projected by Eq. (27) and Eq. (27) and BEM at the mid-anode point for different anode
BEM as a function of half anode spacing and for spacing as a function of k. A positive difference indicates a
k = 100 m2 . relatively positive potential projected by Eq. (27).
j m a t e r r e s t e c h n o l . 2 0 1 6;5(4):367376 375
60 1.000
Percentage difference in anode current
1.005
50
1.010
Potential, V(Ag/AgCl)
1.015
40 10 000 m
1.020
5000 m
output
30 1000 m 1.025
500 m
250 m 1.030
20
1.035
1.040 Equation 27
10
1.045 BEM
0 1.050
0 200 400 600 800 1000 1200 0 200 400 600 800 1000 1200
k Distance, m
Fig. 10 Plot of the percent difference in anode current Fig. 12 Potential attenuation proles for a 0.272 m
output as projected by Eq. (27) and BEM as a function of k. A diameter pipeline with e = 0.15 m, k = 100 m2 , and
positive difference indicates relatively greater current 0.340 m diameter equivalent spherical anode offset at 1 m,
projection by BEM. 5 m and 10 m.