 1909 tubular foundation Piles

 15 above ground storage tanks

 1 buried vessel
 Buried pipeline network (non-EHT)
Degradation of metal by its chemical reaction with a non-metallic matter
such as oxygen, sulfur etc.

Return of metal to the form in which it originally existed as an ore with

complete loss of its metallic properties.

The corrosion process involves the removal of electrons

(oxidation) of the metal and the consumption of those electrons by
some other reduction reaction, such as oxygen or water reduction.
 Selection of Materials
 Coatings & Linings
 Cathodic Protection
 Chemical Treatment
 Widely applied and successful technique to
mitigate corrosion of steel structures buried in
soil or immersed in water

 Extends useful life of steel structures upto a

factor of 4
 pipelines, storage tank bases, well casings
 ship’s hull, offshore platforms & jetties
 Foundation piles, steel in reinforced concrete
 Internal surface of tanks, ship ballast
HOW DO WE DETECT CORROSION?
HOW DO WE DETECT CORROSION?
The electrochemical nature of the corrosion process provides
opportunities to detect and mitigate corrosion of underground
structures.We can monitor the voltages and the currents associated
with the corrosion process.
When a piece of metal is placed in an electrolyte, such as soil, a
voltage will develop across the metal–electrolyte interface because of
the electrochemical nature of the corrosion process.
We also can measure the voltage difference between a metal and a
reference electrode, commonly called a half-cell electrode.
Another use for corrosion potential measurements is to establish
whether galvanic corrosion is likely to occur. When two metals are
electrically coupled in an environment,the more negative (active)
member of the couple will become the anode in the differential
corrosion cell, and the more positive (noble) member of the couple will
become the cathode in the cell.
Practical Galvanic Series for Materials in Neutral Soils and Water
Material Potential Volts (CSE)a
Carbon, Graphite, Coke +0.3
Platinum 0 to -0.1
Mill Scale on Steel -0.2
High Silicon Cast Iron -0.2
Copper, Brass, Bronze -0.2
Mild Steel in Concrete -0.2
Lead ° -0.5
Cast Iron (Not Graphitized) -0.5
Mild Steel (Rusted) -0.2 to -0.5
Mild Steel (Clean and Shiny) -0.5 to -0.8
Commercially Pure Aluminum -0.8
Aluminum Alloy (5% Zinc) -1.05
Zinc -1.1
Magnesium Alloy (6% Al, 3% Zn, 0.15% Mn) -1.6
Typical potential normally observed in neutral soils and water, measured
with respect to copper sulfate reference electrode.
Steel in Soil/Water ANODIC
Earth/Water CATHODIC

AS A RESULT:
Steel loses electrons and hence corrosion

TO REVERSE THE ABOVE:

Make Steel CATHODIC

Water/Earth ANODIC
Cathodic Protection with Galvanic Anodes.
a) Magnesium Anodes
b) Zinc Anodes
c) Aluminium Anodes

Cathodic Protection with Impressed current Anodes.

a) High silicon chromium cast iron Anodes
b) Mixed Metal Oxide Anodes
c) Graphite Anodes
Use of DC Current from an External
Source to oppose the discharge of
corrosion current from anodic areas of the
structure.
1) -850 mV (CSE) with CP applied

2) A polarized potential of -850 mV (CSE)

3) 100 mV of polarization formation or decay

O OVERVIEW OF CP SYSTEM FOR TANK BOTTOM

 CLOSE ANODE SYSTEM – consisting of MMO ribbon anode & titanium conductor mesh,
with power feeds and permanent Cu-CuSO4
reference cells.

 MONITORING SYSTEM – Anode Junction Box cum Test Post (WP & EEXe )

 TRANSFORMER RECTIFIER – single / multiple channel, variable output,

equipped with in-built interrupter

A
 Weather Proof AJB

Close Anode System

for Tank Bottom
EEXe type AJB
MONITORING SYSTEM FOR TANK

 Each tank is provided with 5 nos. reference cell to monitor tank to soil potential
and 3 nos. power feeds to monitor current

 The positive header cable (from T/R) and negative drain cable (& monitoring cable)
from the tank are terminated inside the AJB cum TP.

 The reference cells are terminated inside the AJB cum TP. This facilitates
measurement of tank to soil potential.

 The power feeds are terminated inside AJB cum TP. Each circuit has a shunt to
monitor the current. Shunts are rated at 100 mV / 10 A. This implies a potential
drop of 46 mV across the shunt indicates a current of 4.6 A.
ALUMINUM ANODES (SACRIFICIAL CP SYSTEM) HAVE BEEN UTILIZED TO
PROTECT THE INTERNAL WETTED SURFACE OF CRUDE OIL TANKS (36 nos.)
AND PRODUCED WATER SKIM TANKS (11 nos.).

MONITORING CAN BE DONE BY SUSPENDING REFERENCE CELL FROM THE

NOZZLE (AS SHOWN BELOW)
O OVERVIEW OF CP SYSTEM FOR VESSEL

 CLOSE ANODE SYSTEM – consisting of MMO canister anode.

 MONITORING SYSTEM – Anode Junction Box cum Test Post

 TRANSFORMER RECTIFIER – single channel, variable output,

equipped with in-built interrupter

A
O OVERVIEW OF CP SYSTEM FOR FOUNDATION PILINGS

 DISTRIBUTED ANODE SYSTEM – consisting of MMO canister anode installed at 12 m

depth, in 32 different locations in FPF
 MONITORING SYSTEM – Anode Junction Box
Positive Distribution Box
Negative Distribution Box

 TRANSFORMER RECTIFIER – 50 V / 70 A, variable output, with in-built interrupter

A
PD B Anode Installation

NDB AJB
NEGATIVE DISTRIBUTION BOX

 The negative header cable (from T/R) and negative drain cable from the piles are
terminated inside the NDB for each CP station.
 Each circuit has a variable resistor to control the current and suitably rated
shunt to monitor the current.

POSITIVE DISTRIBUTION BOX

 The positive header cable (from T/R) and header cable from the AJB are terminated
inside the PDB.

ANODE JUNCTION BOX

 The header cable (from PDP) and cable from the anodes are terminated inside the AJB.
 Each circuit has a shunt to monitor the current.
O OVERVIEW OF CP SYSTEM FOR BURIED PIPELINES

 GALVANIC ANODE SYSTEM

– consists of Magnesium anode installed at 3 m depth and at a distance of 3m from
pipeline
– 12” PW pipeline consists of 3 anodes per GB location (4 GB’s)
– OD lines consists of 1 anode per GB location

 MONITORING SYSTEM – Anode Junction Box cum Test Post

 DC POWER SOURCE – No DC power source is required as the Mag Anode has

high driving voltage

A
 Encapsulated cable to pipe connection

Anode Junction Box

Cum Test Post
Mag Anode Installation
MONITORING SYSTEM FOR BURIED PIPELINES

 Each anode location is provided with an AJB cum TP with variable resistor

 The cable connection (from pipeline) and anode cable(s) are terminated
inside the AJB cum TP.

 AJB cum TP facilitates measurement of pipe to soil potential

 AJB cum TP facilitates measurement of anode to soil potential

 AJB cum TP facilitates measurement of galvanic current by measurement of

potential drop across the shunt

 The variable resistor can be used to control the galvanic current

TRANSFORMER RECTIFIER

 Used in a Cathodic Protection system to provide a variable DC output

GENERAL FEATURES OF CP TR AT ADAR FPF

Variac Control Voltmeter and Ammeter

GENERAL FEATURES OF CP TR AT ADAR FPF

Lightning Arrestor Spare Fuses

MMONITORING OF CP SYSTEM

Economic and safety considerations require close supervision and maintenance of all cathodic
protection systems. Monitoring can be divided into three categories

 Monthly Monitoring

 Quarterly Monitoring

 Annual Monitoring
MONTHLY MONITORING

 Recording drain point potentials

 T/R output and T/R settings

QUARTERLY MONITORING

 Recording Structure to Electrolyte Potential at measurement location.

(Only ON potentials to be recorded)

 Reports to be generated.

Annual Monitoring
 Recording Structure to Electrolyte Potential at each measurement location.
(Both ON & OFF)
 Evaluation of Anode Condition
 Reports to be generated with comparison with quarterly and monthly reports
Amran Establishment is an ISO 9001: 2000 Certified
Company for Design, Development, Installation
supervision, Testing and Commissioning of Cathodic
Protection Systems and related site Surveys.

Amran Establishment is also ISO 14001: 1996 Certified

for Environmental Management System and 18001:1999
for OHSAS.
Comprehensive corrosion control services on a turnkey basis.

 Site Survey
 Design
 Procurement
 Installation Supervision & Inspection
 Testing and Commissioning
 Post Commissioning O & M Services
 Special surveys like CIPL and DCVG
 AC Interference Mitigation Surveys.
Petroleum Development Oman L.L.C (PDO)

ORC
Tender Board

OGC

Qatar General Petroleum Corporation (QGPC)

Abu Dhabi company for Onshore Oil Operations (ADCO)

Abu Dhabi Water & Electricity Authority (ADWEA)

National Petroleum Construction Company (NPCC)

Kuwait National Petroleum Company (KNPC)