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cor?
The fact that metals corrode should not be a matter
of surprise
ENERGY
ENERGY RELEASE
We can say it again that
unless we use ways and
means to prevent its
reformation back to rust,
we are corroding away
our plants infrastructure.
cost
Cost of Corrosion
Studies through out the world have shown that
Corrosion directly cost the national economy
approximately 4% of its GNP. In Pakistan this cost
could very well be in excess of 2 billion dollars
annually.
THE ABOVE LOSS OF MONEY INCLUDES
Plants and pipelines
Bridges
Automobiles
Sea going vessels
Building materials
how
1. Structures exposed to Atmosphere
Expensive alloys, Various kinds of
paints, epoxies coatings,
Galvanizing
2.Structures buried or submerged
Combination of coating and
Cathodic Protection
The use of coatings alone can reduce the
metal loss in tonnages but it will not prolong
the service life of equipment. This is
because no coating is perfect and there will
always remain bare areas in the shape of
pinholes and other minor defects.
In fact, you are better off without coating if
you do not intend to apply CP, because
corrosion then, instead of spreading
uniformly, will be concentrated at the
coating defects and time to failure will be
A recent example is several corrosion leaks in an LPG plant
within 10 months after commissioning.
The plant had a buried pipeline corridor just 500 feet long.
There were six lines ranging from 2 to 6. Coating was of
very good quality. No insulating flanges were provided to
isolate the buried sections of the lines from plants copper
grounding.
Consequently, these lines became anodic with respect to the
plants grounding system.
Pipe-to-soil potentials ranged between -300 to -400mV which
was significant proof that lines were undergoing anodic
reaction.
Soon after installing insulating flanges at both ends of this
corridor, the PSP steadily shifted to -600 to -700 mV which is
the normal natural potential of steel.
When a pipeline is buried, coating will begin to
deteriorate immediately after burial because
of
Debris in the trench
Growth of roots and shrubs
Abrasion because of line movement
Bacteria in soil
Aging with time
Unless we supplement protection
provided by the coatings with
cathodic protection accelerated
corrosion at coating defects will
occur.
Why combination of
cathodic protection
and coatings is
necessary?
The question sometimes asked is that if
we are protected by coatings then why
use cathodic protection or if we use
cathodic protection then why coatings?
The answer is, coatings are never
perfect and require protection
supplemented by cathodic protection.
The use of cathodic protection without
coatings can not be practical.
EXAMPLE: 12 20 KM LONG BARE
PIPELINE.
CD = 1mA/ft2
SA=20,600 SQFT
I = SA * CD/1000 = 206A
Linier resistance of pipe=0.382 ohms
Voltage drop in pipeline = 0.328*206 = 80 volts
With 1V required at far end, the drain point
voltage will have to be 81V..this is by far not
practical
CONSIDER THE SAME LINE WHICH IS
NOW WELL COATED
CD = 0.002 mA/ft2 (500 times less)
I = 0.4A (instead of 206A)
90
Voltage attenuation
Bare Pipeline
70
50
Volts
Bare Pipeline
30
10
Coated Pipeline
20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
-10
KM Frin drain point
A BRIEF HISTORY
OF CATHODIC
PROTECTION
History
In 1824 he found out
that by attaching zinc
plates to copper
cladding, the copper
corrosion was mitigated.
He stated that copper is
cathodically protected
Thus, Sir Humphrey
Davy became the
inventor of cathodic
protection and is known
as the father of cathodic
protection
In 1837, a French civil engineer (Sorel)
patented a process of coating steel by
dipping it in molten zinc metal. He named
the process Galvanizing.
C S
O T
P E
P E
E I
R
-
+
DISSIMILAR METAL
CELL IN REAL
WORLD
STORAGE
TANK
GROUNDING
WIRE (BARE
COPPER)
CURRENT FLOW
ELECTRICAL GROUNDING
SYSTEM (COPPER)
OXYGEN OXYGEN
CONCENTRATION STARVATION
C
A A
T N
DIRECTION OF
H CURRENT FLOW O
O D
D E
E
+ -
IRON IRON
LOOSELY COMPACTED
COMPACTED
BACKFILLED SOIL
SOIL
SOIL
C A
A N
T O
H D
CURRENT FLOW
O E
D
E
LOW pH
HIGH pH
- +
LOW METAL IONS
HIGH METAL IONS
A N
T O
H D
CURRENT FLOW
O E
D
E
ELECTROLYTE A ELECTROLYTE B
DIFFERENTIAL ELECTROLYTES
CORROSION CELL DUE TO
MECHANICAL FORCES
ANODE
CONCRETE
PIPE PIPE
ANODIC ANODIC
CATHODIC
OLD PIPE/NEW PIPE CORROSION CELL
NEW PIPE
ANODIC
Polarization is a
phenomenon, which
tends to restrict or slow
down the rate of cell
reaction.
It is primarily due to
hydrogen film formation
on the surface of the
cathode. This does two
main things.
1. It reduces the surface area of the cathode
in direct contact with its surrounding.
EC
EA
Ec
B
MAX MIN
CORROSION
CURRENT
Cells driving voltage!
How is this voltage created?
Every metal when immersed in a
solution, exhibits a potential with
reference to a standard electrode.
This is called the natural or
corrosion potential of that electrode
NatP
Natural electrode potential of an
element is a relative value.
It is assigned to it by comparing
the potential of the pure metal in
a standard solution of its own ions
under standard laboratory
conditions against a standard
hydrogen electrode.
These potentials are in fact the
half-cell potentials of the metals.
2.74V
ZERO
REFERENCE
H
Mg
Cu
+.34V -2.4
ELECTRO MOTIVE SERIES OF METALS
METAL ION POTENTIAL
Potassium K+ -2.92
Barium Ba++ -2.90
Calcium Ca++ -2.87
Sodium Na+ -2.71
Magnesium Mg++ -2.40
Aluminum Al+++ -1.70
Zinc Zn++ -0.76
Chromium Cr++ -0.56
Iron Fe++ -0.44
Tin Sn++ -0.14
Copper Cu++ +0.34
Silver Ag+ +0.80
Platinum Pt++++ +0.86
Cold Au+ +1.50
Metal Volts
Magnesium; Pure -1.75
Magnesium Alloy (6%Al,3%Zn) -1.60
Zinc -1.10
Aluminum Alloy (5% Zinc) -1.05
Pure Aluminum -0.80
Mild Steel (shiny) C -0.5 to -0.8
Mild Steel (rusted) Z
A -0.2 to 0.5
I
Cast Iron N
R -0.50
Lead C
B -0.50
Mild Steel in Concrete O -0.20
N
Copper, High Silicon Cast Iron -0.20
Carbon +0.30 - +0.40
FORMS
OF
CORROSION
Forms
FOUR MOST COMMON
FORMS OF CORROSION
ARE: -
1. Uniform corrosion
2. Pitting corrosion
3. Crevice corrosion
4. Galvanic corrosion
Uniform or General Corrosion
Attack proceeding evenly over the entire surface
or a large fraction of the entire surface.
General thinning until failure
High tonnage wasted
Easily measured and predicted
Uniform corrosion is relatively easily
measured and predicted, disastrous
failures are relatively rare. As
corrosion occurs uniformly over the
entire surface of the metal, it can be
practically controlled.This can be done
by cathodic protection, use of coatings
or paints, or simply by specifying a
corrosion allowance.
UNIFORM CORROSION
Pitting Corrosion
Pitting corrosion is a localized form of
corrosion by which cavities or "holes" are
produced in the material. Pitting is
considered to be more dangerous than
uniform corrosion because it is more
difficult to detect, predict and design
against. Corrosion products often cover the
pits. A small, narrow pit with minimal
overall metal loss can lead to the failure of
an entire engineering system.
PITTING CORROSION
Crevice Corrosion
Crevice corrosion is also a localized form of corrosion
usually associated with a stagnant solution on the
micro-environmental level. Such stagnant
microenvironments tend to occur in shielded areas
such as those formed under: -
Gaskets
Washers
insulation material
fastener heads
surface deposits
disbonded coatings
Threads
lap joints
clamps etc.
CREVICE CORROSION
Galvanic Corrosion
It occurs when two or more different
metals are immersed in an electrolyte and
are coupled together by a metallic path.
What is Cathodic Protection?
It is an electrochemical method of reducing or
eliminating the corrosion of a metal structure.
It requires flow of electrical current through the
electrolyte and onto the structure being protected.
Current may be provided by sacrificial anodes which
require no external DC power source or by ICCP
anodes in combination with external DC power source
DC CURRENT
CP?
PIPE ANODE
How does CP work?
C
A steel structure when buried or
immersed in soil or water develops P A
numerous corrosion cells which are I
formed by anodic (A) and cathodic
P C
(C) areas on its surface. The anodic
areas discharge current into the E
surrounding environment and A
corrode while the cathodic areas
pickup current from the
C
surrounding environment and do
not corrode. Furthermore, anodic
A
and cathodic areas keep changing
places
If, we now impress
sufficient current on the GROUNDBED
1000
500 Leaks
No CP Applied CP Iinadequate
100 104 Leaks
Adequate Protection
11 Leaks Achieved
10
4 Leaks
1
0 2 4 6 8 10 12 14 16
Years
Actual case history of a gas distribution system in downtown
Houston
Comp
IMPRESSED CURRENT
SYSTEM
1. DC Power Sources
2. AC Power Source in case of T/R
3. Anodes (consumable)
Anode
4. Anodes (Inert)
5 ANODE CABLE JUNCTION BOXES
6- CURRENT DISTRIBUTION BOXES
7- INTERFERENCE CONTROL BOXES
8- INSULATING FLANGES OR JOINTS
19- INSULATING SPOOLS IF THE
PROCESS FLOW IS CONDUCTIVE
THERMOELECTRIC
GENERATORS
Potential difference is created across
the terminals of a thermocouple when
heated. Current begins to flow as a
result of this potential difference.
These units are available from 15 to
550 watts with voltage ranging from
2.5V to 48V.
NODE CABLE JUNCTION
BOX
CURRENT DISTRIBUTION BOX
metal coatings are usually expensive metal oxide like Ir, Ta, Ruthenium
Substrate of MMO anodes is usually
Titanium or Niobium.
Break down voltage of Titanium oxide is 9 to
11 volts (recommended 8V). When it is
imbedded in chloride free environment such
as tightly packed coke breeze in which case it
can be operated at as high as 100 volts. In
aqua solutions with high content of chlorides,
Niobium substrate is used. Its breakdown
voltage is 100V
PLATINIZED ANODES
The other inert anode is the Platinum
anodes. Thin film of platinum is
applied over Titanium or Niobium
substrate. The consumption of
platinum is 8 mg per amp per year
POLYMERIC CABLE ANODE
AS PER VENDOR;
MINIMUM 20 YEAR LIFE AT 16mA/LF
GALVANIC
ANODES
Magnesium or Zinc
packaged Sacrificial anodes
Current efficiency varies with current density. Efficiency decreases when the
CD is 300 mA/sqft of bare metal and increases at lower current densities
Approximate data for zinc anode in earth
Specific gravity 7
Pounds per cubic foot 440
Theoretical amp hours per lbs 372 (1)
Theoretical pounds per amp per year 23.5
Current efficiency percent 90 (2)
Actual amp hours per pounds 335
Actual pounds per amp per year 26
Open circuit potential in earth (w.r.t. CSE) 1.1V
3 2 2 27 9 31 5 9S2
4 3 3 13.5 9 17 6 9S3
5 2 2 51 17 55 5 17S2
6 3 3 21.5 17 30 6 17S3
7 2 2 60 20 62.5 5 20S2
8 3 3 45 32 61 8 32S3
9 5 5 21 32 30 6 32S5
10 3 3 60 40 64 6 40S3
11 5 5 31 48 34 8 48S5
12 4 4 60 60 64 6.75 60S4
Zinc Ribbon (Super)
Consumption rate is 23lbs/A/yr
Weight per LF=2.4lbs
3/8
5/8
5/8
ZINC ANODE DATA
5 2 2 30 30 36 5 HZ30
6 2 2 45 45 51 5 HZ45
7 2 2 60 60 66 5 HZ60
INSULATING FLANGESW
INSULATING KIT
INSULATING SPOOL L=RA/p Where,
R=5 ohms (to be achieved)
A= cross sectional area of
CURRENT DRAIN pipe (cm)
CABLE
p = Resistivity of fluid in
L (cm) pipe in ohm-cm
FLANGES WITH
FLANGES INSULATION KIT
WITHOUT INTERNALLY
INSULATION COATED PIPE
Fe Fe++ + 2e
(Iron Iron ion + 2e)
Fe++ + 2(OH)- Fe (OH) 2
Reduction
e-
This reaction takes e-
place at the cathodic
site where excess
electrons neutralize
the hydrogen ions to
hydrogen atoms
which forms
hydrogen gas.
IN CHEMICAL LANGUAGE
2e + 2H H2 (gas molecule)
Other reactions that also occur are
2H2O + 2e- H2 + 2OH-
O2 + 2H2O + 4e- - 4OH-
Both, the oxidation and reduction
reactions are simultaneous and are
manifested by the flow of DC
current in a corrosion cell (ionic
movement).
I=E/R
In the electrochemical language, the DC current is defined
as that quantity of current which when passed through a
solution of Silver Nitrate (AgNO3) in accordance with
certain specifications, will deposit silver at the rate of
0.001118 grams per second.
Design Considerations
Selection of type of system
Galvanic System
ICCP System
CP Des
Cathodic Protection Design
Considerations
When a pipeline or a terminal facility is built, it represents a
huge capital investment. If we do not safeguard this investment,
we may expect corrosion failures which may result in: -
Loss of product
Loss of production
Damage repair cost
Spillage clean-up costs
Third party damage cost
Possibility of loss of human life
To safe guard the investment against corrosion damage,
coating is used as the primary barrier between the
structures and its environment. But this corrosion
prevention method does not guarantee 100% protection.
On the contrary, this method may accelerate time to
failure of an engineering system if used alone.
0.159 p ln 8L 2L
- 1+ ln0.656N
NL d S
p = Soil Resistivity (1000)
N=Number of anodes = 5:
L= Length of anode = 48.3cm (20 inch)
d= Diameter of anode = 16.5cm: (6.5 inch)
S= Spacing = 152.4 cm (5 feet)
GRADE LEVEL
CADWELD
CONNECTIONS
GALVANIC ANODE BACKFILL
MG ANODES
75% Gypsum
20% Bentonite
5% Sodium Sulfate
ZINC ANODES
50% Gypsum
50% Bentonite
ADVANTAGE OF BACKFILL
1. It provides uniform environment for the anode
which results in its uniform consumption
2. It decreases anode to earth resistance
3. It retains moisture and thus low anode to earth
resistance is maintained
4. It acts as a depolarizing agent
Advantages of galvanic system
1. Low initial (when current demand is low)
2. uniform current
3. Virtually maintenance free
4. Over protection is minimized
5. Interference is negligible
6. No extra land procurement required
Disadvantages of galvanic system
1. High cost per ampere basis
2. Not adjustable to compensate for
increase in the current demand
3. Not cost effective where current
demand is high
4. May not be effective in soil resistivities
over 5000 ohm-cm
IMPRESSED CURRENT
SYSTEMS
Impressed current systems are of
two different types: -
1. Remote Ground Bed
2. Close Ground Beds
GROUND BED
PIPE
VOLTAGE GRADIENT
CURRENT
REMOTE GROUND GROUND BED
BED SYSTEM REMOTE
POS. CABLE
NEG CABLE
VOLTAGE
GRADIENT
PIPELINE
ICCP Advantages
1.500
Neg.Volts
1.000
0.500
-0.850V min.
0.000
-9E-15 6 11 17 22 28 33 39 44 50
Distance in Km
From the attenuation curve, it is obvious
that using the calculated current, only
25km is protected by installing the CP
system at one end of the line.
SOLUTION
1- Install the CP system at the midpoint of
line or
2- Install two smaller units at each end of
the line
GROUND BED DESIGN
Anode 2 x 60 High silicon chromium (SiCrFe)
cast iron 44 lbs
Anode is packaged in coke filled canister 8 x 84
Consumption rate =1 lb/amp-yr.
Life of a single anode at 10A
= 44 lb/(10A* 1 lbs) = 4.4 yr
Minimum Number of anodes required = 20/4.4
=4.5 say 5 anodes.
Resistance of a group of 5 anodes = 5.4
ohms
Power source min voltage
I * ( Rg +Rs )+Back emf
= 10*5.4+.003+2 = 56 V
Recommended Power Source is 60V
30A
COST COMPARISON ICCP VS GALVANIC
1. Soil Resistivity
2. Anode type and maximum allowable current
per anode (2A)
3. Spread of protection per anode determined
by either current drain test or Rudenberg
equation.
0.038 Ip ( y + y 2+ x 2 )
Vx = log10
Pi y x
X = Distance from anode
Vx = Voltage change at distance X
Y = Length of anode
EXAMPLE
Two lines in parallel. Length 600 feet. Soil 500 ohm-cm
Spread of protection from one anode as per
Rudenberg Equation=15+15 =30 ft
Ground Bed Gradient
1000
900
800
Millivolts
700
600
500
400
300
200
100
0
1
7
12
18
23
29
34
40
45
51
Distance from Ground Bed (feet)
30 feet
15 ft
15 ft 15 ft 15 ft
Total number of anodes = 600/30 = 20
Total current = 40A
Resistance of one anode in 500 ohm-cm soil = 1.5 ohm
Cable resistance to farthest anode = 0.15 ohm
Total Resistance of one anode = 1.65 ohm
Power Source rating = E=RI+ back emf (2V) = 3.3V
Recommended power source rating = 5V-60A min.
Life of each anode weighing 44 lbs with consumption
rate of 1 lbs per amp-yr = 22 years
SUMMARY
Corrosion control is essential to the efficient long-term
performance of capitalized infrastructure in the oil and
gas industry. Once a corrosion control program is
undertaken, the economic benefits become apparent.
Elimination of many pipeline failures and corrosion
related equipment failures reduce maintenance costs,
and ensures un-interrupted product delivery to the
customer. Basic survey techniques and methods to
identify and mitigate the corrosion processes in the oil
and gas industry is presented in the technician level
section that follows
END OF ADVANCE LEVEL
TecLev
The importance of regular monitoring cannot be over
emphasized. Often, once a cathodic protection
system has been designed and constructed, owners
begin to believe that their troubles are over. System
designer usually provides an operating manual
giving certain guidelines for monitoring and unless
the persons responsible for monitoring are not
sufficiently trained, the results can be drastic.
An oil producing company in Northern Pakistan began
experiencing corrosion problems on a facility only 5
years old. Potentials had routinely been monitored by
in-house electricians and reported each month to the
engineering manager who felt relieved by simply
viewing the results, which seemingly had always met the
minimum criterion of protection. It was only after leaks
had begun to spring that the company called in a CP
consultant who found that 90% of the buried pipelines
were inadequately protected. Excessive soil IR drops
and the influence of ground bed gradients had mostly
been responsible for producing erroneous data falsely
indicating adequate protection.
Ideally every foot on the structure should be
monitored. This however, is not practical.
Therefore, only locations where CP test
station exist or where the structure is
physically accessible are monitored
routinely.
CIPS is recommended once each year
Recognize factors which can affect the
validity of the monitored data.
1. Half-cell to earth contact resistance
2. Meter negative to structure contact
resistance
3. Half-cell near a ground bed
4. Half-cell over another protected line
5. Stability of half-cell
COPPER SULFATE REFERENCE ELECTRODE
ELECTROLYTE
Decrease in concentration
Contamination
TEMPERATURE effect
Positive shift of 0.9mV/deg C (0.5mv/deg F)
Example
Criteria of Protection
When a steel structure is placed under cathodic
protection there must be some means to verify
the adequacy of protection afforded.
1) 100mV Polarization
2) 850 mV PSP with CP current interrupted
3) 850 mV PSP with CP current applied (not
reliable in high resistivity soils)
Generally practiced maximum limit
Maximum Limit (Ferrous metals)
NACE has not specified any maximum PSP value
Different schools of thoughts exist on current-off potential
limits
3- Clamp-on-Ammeter
A TYPICAL VOLTMETER
L.C. Display
Various Function
0.005
Buttons
Selector Switch
AMPS
A mA - + Positive Terminal
Common Terminal
Tong Tester for current measurement
The important requirement of the meter
is its high input impedance. When
potential measurements are made, some
amount of current flows through the
internal circuit of the meter causing
internal IR drop error.
Because of this error, the measured value
is less than the actual value.
EXAMPLE-1 VM
Easily maintainable
Easy to use in field work and/or
laboratory work
Does not polarize when measuring
potential of another electrode
Resists contamination when in use
Portability
A TYPICAL REFERENCE ELECTRODE
The most
commonly used
reference
electrode is the
copper sulfate
half-cell
CARE OF INSTRUMENTS
VOLTMETER
Before use, check accuracy by comparing against a
known good instrument or a standard voltage cell.
CLAMP-ON-AMMETER
Compare instrument against a suitable shunt.
IF IN ERROR
Calibrate
HALF-CELL:The half-cell
should be checked for accuracy
prior to commencing each
survey.
This is done simply by
comparing the half-cell in use
against an unused (new) half-
cell.
HALF=CELL CALIBRATION METHOD
A mA - +
+ -
1.Routine Monitoring
2.Detailed Monitoring
ROUTINE MONITORING
Frequency 1 to 3 months
2 5 3 0.6
3 5.5 4 0.7
4 5.5 4 0.7
5 5.5 4 0.7
6 6 5 0.8
7 6 6 1.0
8 6 8 1.3
9 6 10 2.2
GB Resistance plot
5.0
RESISTANCE
3.0
2.0
1.0
0.0
1 2 3 4 5 6 7 8 9 10
TIME IN YEARS
TRANSFORMER/RECTIFIERS
(T/R)
Monitoring and data management
ELECTRICAL MEASUREMENTS
1. DC Current & Voltage (Panel meter)
2. DC Current across shunt & Voltage across
terminals
3. AC Voltage (Circuit Breaker)
4. AC Current at Circuit Breaker
PHYSICAL CHECK OF T/R
1. T/R case temperature
2. DC terminal temperature & Tightness
3. Earth connection tightness
4. Silica Gel Condition (Color)
5. Oil level & condition
6. General condition (dusty or clean)
UNIT NO------- LOCATION-----------------------------------------
STRUCTURE PROTECTED----------------------------------------
DATE-----------
DC OUTPUT 5A -3V
(PANEL METERS)
DC OUTPUT 4.8A 3,2V
(ACTUAL)
AC INPUT 380V 0.3A
(BREAKER)
CASE TEMP NORMAL
EARTH CONN OK
OIL LEVEL OK
CONDITION DUSTY
PSP
Importance of
minimizing IR drop
error
INSTRUMENT
+ -
TEST LEADS
2 1
3
-
1 0.850mV
2 0.900mV
3 0.800mV
STRUCTURE
mV
-930
-935
-939
-964
-1004
ANODE -1109
ACTUAL CASE HISTORY
5V
GRADE LEVEL
3.3V
2.0V
0.9V
1650
1450
1250 Cur r ent On
1050 Instant of f
850
650
450
1 2 3 4 5 6 7 8 9 10
1 400
NEG. MILLIVOLTS
1 1 00
1 000
900 Mi ni mum Pr otecti on
800
Pon
700
Pof f
600
500
400
300
200
1 00 Paved Road
0
0 10 20 30 40 50 60 70 80 90 1 00 110 1 20 1 30 1 40 1 50 1 60 1 70 1 80 1 90 200
DISTANCE IN FEET
IR DROP EXAMPLE
A FERTILIZER PLANT IN SINDH
3500
CURRENT ON
3000 PSP
2000
-m V
1500
1000
0
74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90
CP TEST POSTS
Permanent reference electrodes are
usually provided at the time of
construction of the facility.
Experience has shown that they are
not as dependable as claimed by the
manufacturers.
Unless annually calibrated, they
cannot be depended upon.
Calibration is simple
PERMANENT CELL CALIBRATION
Turn off all DC Power Sources
Connect one terminal of VM to permacell and the other terminal
to portable reference contacting the earth. Measure the potential
difference. Keep this data along with polarity on records.
TEST LEADS
GRADE LEVEL
PIPE
REFERENCE
COUPON
GRADE LEVEL
`
PIPE
COUPON
CP COUPON POTENTIALS
1800
1600
ON
1400 OFF
1200
1000
-mV
800
600
400
200
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
TP NUMBERS
INTERFERENCE
Undesirable flow of
current in a structure
INTERFERENCE ON FOREIGN LINE
FOREIGN LINE
ACCELERATED CORROSION
ARROWS INDICATE
DIRECTION OF
CURRENT FLOW
PROTECTED LINE
GROUNDBED
- +
T/R
INTERFERENCE TESTING
Testing for detection of interference is done
by measurements of on/off potentials on the
foreign line while the protected line T/R is
interrupted.
If interference is present, potential shift on
the foreign line will be towards more negative
values each time current is turned off.
For mitigating
interference RHEOSTAT
0-5 OHM
an
interference
control
bonding
station is
installed.
Foreign line Protected line
Foreign pipeline
BOND ADJUSTMENT
Connect bond with full
Variable resistance of rheostat in
Resistance circuit
Bond
Check off potential on the
Protected foreign line
Pipeline
If interference is still
present, progressively
decrease resistance until
interference is completely
eliminated
SPECIALIZED
SURVEYS
PIPELINE
CURRENT
MEASUREMENT
AT CURRENT DRAIN POINT
1 3
ON/OFF
SWITCH
mV
200 FEET
1-Measure mV between inner leads. Record value indicating polarity + or shown on the
meter
2- Energize current say 20 amps
3- Measure mV again between inner leads
4- Calculate delta mV and and determine span current per mV
5- Multiply span length by current per mV to obtain current flowing through span.
CALCULATION EXAMPLE
mV at zero current applied = 5mV with meter polarity
minus (mV1)
mV at 3 amp current applied = 2 mV with meter polarity
plus (mV2)
The resultant change is( mV1) (mV2) =( -5) (+2) =
7mV due to 3amp current
Current per mV=3/7= 0.43 amps
Span length is 200 feet and resultant change=7mV
Therefore the current flowing through 200 ft span is
200 * 0.43A = 86A
GROUND BED
RESISTANCE
TEST
GROUND BED CURRENT (I) = 50A
CURRENT ON mV = 7.5 R=E/1 = .005/50=0.1
INSTANT OFF mV = 2.5 OHMS
mV
ANODE CABLE JB
REMOTE HALF-CELL
GROUND BED
PIPELINE COATING RESISTANCE
Almost all of the resistance of pipe to earth is
the coating resistance.
Therefore, the procedure for measuring the
coating resistance is identical to the previously
described procedure for ground bed
resistance
PIPELINE mV
CLOSE
INTER PSP
SURVEY
1. PROVIDES DETAILED
STATUS OF
PROTECTION
2. LOCATES COATING
DEFECTS
CIPS: FLOWLINE D6 SS
SHEET 1 OPF 2
SURVEY FROM WELL HEAD TO FENCE VALVE
1200
1100
1000
TEST STATION
M ILLIV OLTS
900
850
800
700
WELL HEAD TOWARDS
FENCE VALVE
600
0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
DISTANCE IN FEET
SOIL
RESISTIVITY
SURVEYS
1. DC CURRENT METHOD
2. AC CURRENT METHOD
E1 = Current Off E2 = Current On
E = E2 - E1
R = E I
DC
S = Pin separation in feet METHOD
ohm-cm= 191.5 * R * S
P1 P2
AC C1 C2
SOIL RESISTIVITY
METER
METHOD
p= R * Multiplier
P1 P2
C1 C2
SOIL RESISTIVITY
METER
SOIL BOX
SOIL RESISTIVITY CLASSIFICATION
V A
T/R OUTPUT
T/R
+ - 50V 0A AJB
C
A B
D
NJB
PIPE
ANODES
MAIN ANODE CABLE
FAILURE
V A
T/R OUTPUT
T/R
+ - 50V 0A AJB
A B C
A TO GROUND 50v
<1v
D C TO GROUND
NJB
PIPE
ANODES
GROUND BED
FAILURE
V A
T/R OUTPUT
T/R
+ - 50V 0A AJB
B C
A
A TO GROUND 50V
C TO GROUND 50V
1V
D B TO GROUND
NJB D TO GROUND 1V
PIPE
ANODES
MAIN NEGATIVE CABLE
FAILURE
V A
T/R OUTPUT
T/R
+ - 50V 0A AJB
C
A B
B TO GROUND 50V
D TO GROUND <1V
D
NJB
PIPE
ANODES
CABLE CONNECTION
TO PIPE HAS FAILED
V A
T/R OUTPUT
T/R
+ - 50V 0A AJB
C
A B
B TO GROUND 50V
D TO GROUND 50V
D
NJB
PIPE
ANODES
Possibility often exists that even the best equipment may fail to
detect cable breaks accurately. For instance, if a buried cable
runs parallel to a pipeline or other buried cables for that matter,
the signal strength received will not drop appreciably even when
the operator reaches the fault area. If this happens, the location of
cable break can only be narrowed down by digging test holes as
shown in figure below
VM
TR
JB
A GRADE LEVEL
C
B CABLE
Fault (if V=<1V)
Fault if V=V at T/R
ISOLATING
JONTS
To determine effectiveness of joint
isolation
1. Shutdown CP Power source
2. Measure Potential on both sides of the joint
and record
3. Turn CP back on
4. Measure potentials again on both sides and
record
1. If the change in potentials on the unprotected side
equals the change in potentials on the protected side,
then the isolation is 100% defective.
VM
A B
For a partially defective isolation, percentage of defect may be
estimated by the following equation.
Example