Академический Документы
Профессиональный Документы
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System
Operation and Maintenance
Feng Hongchen
HuangHua Risen CorrStop Ltd.
August 2007
Cathodic Protection
Level II Training Course
Company Profile
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Corrosion is Disastrous
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Content
Level I
Nature of Corrosion
Factors Affecting Corrosion
Cathodic Protection Principle
Cathodic Protection Methods
Pipeline Coatings
Sacrificial Anode Cathodic
Protection
Impressed Current Cathodic
Protection
Isolating Joints vs Grounding Cell
Cathodic Protection Criteria
Coating and Cathodic Protection
Reference Electrodes
IR drop and IR Drop Free
Measurement
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Level II
Soil Resistivity
Ground Bed Design
Cathodic Protection Design
Pipeline Cathodic Protection
Design
Tank Cathodic Protection Design.
Heat Exchanger & Oil Well Casing
Cathodic Protection
Stray Current Interference
Cathodic Protection Shielding
Cathodic Protection System
maintenance
Pipeline Coating Survey
Concrete cathodic protection
In Line Inspection, Corrosion
monitoring
Nature of Corrosion
Corrosion Concept and Conditions
What is Corrosion:
According to the definition of BS7361, corrosion is the chemical
or electrochemical reaction of a metal with its environment,
resulting its progressive degradation ,or destruction.
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Nature of Corrosion
Definitions
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Nature of corrosion
current
cathode
anode
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Nature of Corrosion
Corrosion Concept and Conditions
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Nature of Corrosion
Corrosion Concept and Conditions
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current
cathode
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anode
10
1.
2.
3.
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A section of the
pipeline has been
replaced because
of corrosion
damage.
The new section
will fail sooner than
expected.
Mild steel (rust):
-0.2v- -0.5v
Mild steel (clean):
-0.5v- -0.8v
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Concrete
encasement of
pipe will cause
differential
corrosion cell.
Pipe section
without concrete
encasement is
anode and being
corroded.
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If the anode is
relatively small,
corrosion will be
severe.
If the anodic area is
relatively large
compared with the
cathode, corrosion
will be relatively
mild.
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11
Cathodic Protection
Principle
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Nature of Corrosion
Carbon,graphite,coke:
0.30v
Platinum:
0 to 0.1v
Mill scale on steel:
-0.20v
High silicon cast iron:
-0.20v
Copper,brass,bronze:
-0.20v
Mild steel in concrete:
-0.20v
Lead:
-0.50v
Cast iron:
-0.50v
Mild steel (rusted):
-0.20v to 0.50v
Mild steel (clean and shiny):
-0.50v to 0.80v
Commercially pure aluminum:
-0.80v
Aluminum alloy (5% Zn):
-1.05v
Zinc:
-1.10v
Magnesium alloy (6%AL,3%Zn,0.15%Mn): -1.60v
Commercially pure magnesium: -1.75v
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current
cathode
anode
current
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Pipeline Coatings
The function of external coatings
1.
2.
3.
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Pipeline Coatings
Requirement to Coatings
1.
1.
2.
3.
4.
5.
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Pipeline Coatings
Coating Selection
1.
2.
3.
4.
5.
6.
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1.
2.
3.
4.
5.
1.
2.
3.
4.
Desirable Characteristics:
Over 80 years of use
Minimum holiday susceptibility
Low current requirement
Good resistance to cathodic disbondment
Good adhesion to steel.
Limitations
Limited manufacturer
Limited applicators
Health and air quality concerns
Change in allowable reinforcements.
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16
1.
2.
3.
4.
1.
2.
3.
Desirable Characteristics:
Over 30 years of use
Low current requirement
Excellent resistance to cathodic disbondment
Excellent adhesion to steel.
Limitations
Strict application control
Low impact and abrasion resistance
High moisture absorption.
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1.
2.
3.
4.
5.
1.
2.
3.
Desirable Characteristics:
Over 30 years of use
Minimum holiday susceptibility
Low current requirement
Easy of application
Good adhesion to steel.
Limitations
Shielding CP from soil
Stress disbondment
Handling restrictions.
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19
1.
2.
3.
4.
5.
1.
2.
3.
Desirable Characteristics:
Over 30 years of use
Low current requirement
Excellent resistance to cathodic disbondment
Excellent adhesion to steel.
high impact and abrasion resistance
Limitations
Strict application control
Possible shielding of CP current
High initial coast.
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20
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r
e
h
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se
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cn
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rv
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CL
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1.
1.
1.
2.
1.
2.
3.
Application:
It is by making use of corrosion cell of
dissimilar metals.
Advantage:
It can be used flexibly , easy installation
and less maintenance work.
Limitations:
Small current out put,used in place where
current is small.
Used in low soil resistivity area.
Anode materials:
Magnesium anode
Zinc anode
Aluminum anode
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21
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W= anode weight,
I= Current out put
t = Design life
U = Using factor
Z = Current capacity
Q = Anode efficiency
I t 8766
W=
U Z Q
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kg
(Amps)
Yr
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22
Magnesium Anodes
Materials used are magnesium alloy, aluminum alloy
and zinc. Neither magnesium nor aluminum alloys
should be used in situations where sparking may
cause explosion.
The potential difference between magnesium alloy
and steel is greater than that between zinc or
aluminum, enables it to be used economically at a
relatively higher soil resistivity(above 30ohm.m) while
aluminum anode is mainly used for offshore
structure.
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Magnesium Anode
Chemical Composition
Aluminum
Manganese
Copper
Silicon
Iron
Nickel
Others, each
Magnesium
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0.01% max
0.50 - 1.3%
0.02% max
0.05% max
0.03% max
0.001% max
0.05% max
Remainder
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23
Magnesium Anode
Chemical Composition
Aluminum
Manganese
Copper
Silicon
Iron
Nickel
Others, each
Magnesium
5.0-7.0% max
0.15% min
0.10% max
0.30% max
0.03% max
0.003% max
0.30% max
Remainder
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Magnesium Anode
Electrical Property
Q = Current efficiency
Z = Theoretical Current Capacity
U = Anode usage factor
Open circuit potential:
high: -1.75V CSE
low: -1.55V CSE
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(0.5)
(2200 Ah/kg)
(85%)
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24
Magnesium Anode
Electrical Property
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Magnesium Anode
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Magnesium Anode
Configuration (Cast Magnesium Anode)
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Magnesium Anode
Extruded Magnesium Anode
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Zinc Anode
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Zinc Anode
Chemical Composition
Al
Cd
Fe
Pb
Cu
Zinc
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0.1 - 0.5
0.02 - 0.07
0.005 max
0.006 max
0.005 max
Remainder
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27
Zinc Anode
Electrical Property
Q = Current efficiency
Z = Theoretical Current Capacity
U = Anode usage factor
(0.9)
(827 Ah/kg)
(85%)
-1.1V
below 50C
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Zinc Anode
Application
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Zinc Anode
Anode Configuration
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Zinc Anode
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Aluminum Anode
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Aluminum Anode
Chemical Composition
Zn
Si
In
Cu
Fe.
Other Each
Aluminum
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2.8-6.5
0.08-0.21 Max.
0.01-0.025
0.006 Max.
0.12 Max
0.02 Max
Remainder
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30
Aluminum Anode
Electrical property
Q = Current efficiency
Z = Theoretical Current Capacity
U = Anode usage factor
T = Environment Temperature
(0.9)
(2000-27(T-20))
(85%)
( C)
-1.05V CSE
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Aluminum Anode
Application
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Aluminum Anode
Tank Bottom Application
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The design of a
galvanic ground bed is
similar to impressed
ground bed
The driving voltage
available to force
current from anode to
electrolyte is the open
circuit potential less
the polarized pipeline
potential.
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Sacrificial anode is
usually placed 1-1.5m
from the pipeline.
Several anodes can be
installed in a group.
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Anode
backfilled on
site.
The backfill
can fill
completely
all of the
voids in the
auger hole.
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Mg or Zn ribbon
anode may be
plowed in
parallel to the
pipeline along
sections of bare
of poorly coated
line where
continuous local
protection is
required
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1.
1.
1.
2.
1.
2.
3.
Application:
Current from out side source is impressed
on the pipeline by using of a groundbed
and a power source.
Advantage:
It can be used in high soil resistivity with
large current demand..
Limitations:
Need power source and more
maintenance work.
Corrosion interference can be a problem.
Anode materials:
Silicon iron
Mixed metal oxide
Platinized titanium etc.
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Anode Materials
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Anode Materials
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Anode Materials
Silicon anode
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Anode Materials
Silicon anode
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Anode Materials
others
Graphite anode
Scrip iron anode
Platinized
niobium/Titanium anode,
it is used for steel
vessel internal cathodic
protection.
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Acrylonitrile el.
NBR 70
EXTERNAL COAT.
Twopack
solventless
Epoxy resin
200 m DFT
INTERNAL
LINING
Epoxy Resin
200 m DFT
INSULATING
FILLER MATERIAL
Cold cured
Epoxy resin
ADHESIVE
SEALANT
Silicone
SECOND SEALING
Isolan
elastomer
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Grounding Cell
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Grounding Cell
6mm
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Tape
Zn Rod35x35x1000mm
BackfillGypsum75%Bentonite20%Sodium Sulfate5%
Cotton Sack
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1.
2.
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1.
2.
3.
4.
0.300v
0.241v
0.250v
-0.80v
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It is
made of
pure zinc
and
mainly
used in
sea water.
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In practical engineering
onshore, we normally use
CSE electrode .
If the potential of the
protected structure reaches
0.85V CSE, we regard the
structure being properly
protected.
Relative to this criteria, other
reference electrode
potentials are as the right
column.
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Copper/copper
electrode:
-0.85V
Silver/silver
electrode:
-0.8V.
Zinc electrode:
+0.25V.
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Permanent reference
electrode installed for
potential monitoring of
buried pipelines.
It is installed near the
pipeline surface.
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Reference electrode
for under ground
fuel tanks
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1.
2.
3.
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20
40-100
4000-8000
10000
40000
ohm.cm
ohm.cm
ohm.cm
ohm.cm
ohm.cm
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1.
2.
3.
4.
5.
6.
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5-30mA/m2
10-30mA/m2
65mA/m2
45-55mA/m2
160mA/m2
10-30mA/m2
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1.
2.
3.
4.
5.
6.
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X=
0.00159 IP
Vx
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2.
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3-layer Coating:
0.01 mA/m2
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80
4 L
Ra =
ln
1
2 L r
Ra = Grounding resistance
(ohms)
= Soil resistivity (ohm-m)
L =Anode length
(m)
r = Anode radius
m
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0.00159 P 8 L
2L
1+
Ln 0.656 N
Ln
NL
D
S
P:
N:
L:
D:
S:
R:
ohms
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1.
1.
2.
3.
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0-1
1.0 mm2
1-5
4.0 mm2
5-10
10 mm2
10-25
16 mm2
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1.
2.
3.
4.
5.
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1.
2.
3.
4.
5.
6.
7.
8.
9.
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1.
2.
3.
4.
5.
6.
7.
Computations
External surface area of the pipeline : S = D L =38000x3.14x0.159=16975
m2.
Current requirement: I = S Cd Cb =16975x10x1%=1697mA.
Calculate the number of the anodes:for 25 cm by 150cm packaged canisters
with 4 mm by 120cm MMO anode rod, current output of such an anode is 1.2A.
According to the current capacity, two anodes are sufficient to supply the
required current.
Calculate the grounding resistance of a single anode:R=6.1 ohm.
To meet Max. 2.0 ohm resistance requirement, 4 no anodes will be needed.
Consider the anode mutual interference among the anodes, calculate the
resistance again with the formula for multi-anodes, it works out that 5 anodes
will be needed while their spacing is 3m.The actual grounding resistance is
1.71 ohm.
This is quite close to the required 2.0 ohm resistance, so, 6 anodes are
selected for variation in soil resistivity, wire and pipeline to soil resistance.
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1.
2.
3.
4.
5.
6.
7.
8.
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1.
2.
3.
Computations
W=
4.
5.
I t 8766
U Z Q
4 L
Ra =
ln
1
2 L r
Check the anode number per grounding resistance. Single anode grounding
resistance is calculated according to the above formula: If the packaged dimension of
the anode is 760mmx250mm, the grounding resistance of each anode is 9.2 ohm.
Assume the polarized potential of the pipeline is 0.9v, the open circuit potential of
the Mg anode is 1.75V CSE, the driving voltage will be 0.85v. Single anode current
out put is 0.85/9.2=92mA. To achieve a current out put of 1697mA,18 pieces of
anodes will be needed, which is less than the number calculated from current capacity.
So, 21 no. anodes will be used.
The anodes will be distributed along the pipeline evenly.
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Mg anode
ribbon is often
used for small
tank bottom
cathodic
protection.
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1.
2.
3.
1.
2.
3.
4.
5.
6.
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Calculation:
Protected area:=3.14x112=380 m2
Protected bare area: 190m2,
Currents needed is :1900mA
W=
I t 8766
U Z Q
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89
W=180kg
Ribbon
length:=180/0.36=500m.
Grounding
resistance=0.42ohm.
Mg potential: -1.75V CSE.
Polarization potential 0.90V CSE.
Driving voltage:=0.85V.
Actual current
output:=0.85/0.42=1.9A.
2.02>1.9. Ok
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The anode
grid is formed
by MMO
ribbon
connected by
Titanium
conductor bar.
They are spot
welded at the
intersection
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It can provide a
very uniform
current to the
tank bottom
No interference
current will be
produced with
this kind of
anode bed.
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91
It has along
design life of over
40 years.
The grounding
system of the
tank need to be
retrofitted.
The site
installation is very
simple and the
quality is easy to
be guaranteed.
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S2=3.14x60x1.5=282m2
Total area: 282+2826=3088m2.
Current:=160x3088x10%=4941mA, 5 A.
Current efficiency:2000-27(T-20)=1325
Anode weight:=432kg
If we choose 4.5 AL anode,96 pieces will be used.
The anodes will be distributed evenly on the tank
bottom.
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By using the
MMO wire anode,
the system can
be easily installed.
Pay much
attention to the
cable connection
seal.
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1.
2.
3.
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95
1.
2.
3.
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1.
2.
3.
General
Because of the high water temperature and the heavy
current requirement, ICCP is recommended for cathodic
protection of box coolers, although the space available for
anodes is small and their number and dimensions must be
limited.
The high water temperature prevailing in box coolers, often
over 40 degree which makes the self-corrosion of Mg anode
too high to be used satisfactorily.
Zn anodes are unsatisfactory because they supply too low
current at a high temperature and their polarity with respect
to steel may be reversed over 60 degree.
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1.
2.
3.
4.
Current Requirement
With sea water as the cooling medium and the water
temperatures up to 45 degree, the current density required
for cathodic protection of steel is 110mA-220mA/m2.
The wall of the cooler box are usually gunited and the
current required for protection is then negligible.a calculation
using the data given above is sufficient for current
calculation.
Because of the close proximity of the anodes to the
cathodically protected tubes, tube to water potentials
should be used with caution, and the points where these
check measurements are taken should be as remote as
possible from the anodes.
The tube to water potential should be maintained at 0.85V
CSE.
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1.
2.
3.
Anode materials
As stated above, since the space available is small,
platinized titanium anodes are particularly suitable
for use in box coolers with either fresh or salt
water.
Lead-alloy anode are unsuitable for use in fresh
water.
Facilities for measuring current in the leads to
anode should be provided.
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97
1.
2.
General:
The cause of casing corrosion may be sulphate
reducing bacteria, acidic water, or corrosion cells
set up between formations containing water of
different salt content or between casing and flow
lines.
Cathodic protection prevents corrosion only on the
outside surface of the casing.
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1.
Current requirement:
The current density required for protection varies
from 5 to 30 mA/m2 of casing surface. Average
values of protection currents for wells of different
depth are as following:
Approx. Depth (m)
Current (A)
900
1500
2400
30
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2.
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1.
2.
3.
4.
5.
6.
7.
Test procedures
Measure the native potential of the well head.
Increase the current with 0.1A at every two to three
minutes.
Measure the instant off potential.
The current interruption should last no more than 2
seconds, then a higher current applied onto the casing.
Casing to soil potential and current applied should be
plotted on a semilogrithmic graph paper.
The current required is taken at the intersection point.
A simple way in practice is to maintain the well head off
potential at 1.15V CSE. Current density falls into the
range between 5-30mA/m2.
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Sacrificial anodes
Magnesium anodes can be used when a low current is
required. In general, they are suitable for protecting
only the upper 60-90m of a well.
Unprotected wells situated within about 450m of a
protected well or its groundbed, should therefore be
protected against stray current by connecting via a
resistor to the cathodic protection system so as to
drain out 1.0 A current or by installing magnesium
anodes.
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3.
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Potential Survey
Pipe-to-soil potential measurement are performed by
placing the reference cell over the pipeline
In extremely dry area, it may be necessary to moisten the
earth around the electrode with fresh water to obtain good
contact.
Newly laid coated pipeline may have an average native
potential in the range of 0.5V to 0.7V, whereas old bare
steel lines may have an average potential more in the range
of 0.1V to 0.3V.
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Groundbed Maintenance
Surface anodes
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Groundbed Maintenance
Surface anodes
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Groundbed Maintenance
Deep anodes
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Groundbed Maintenance
Galvanic anode
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Typically a measuring
device, with light wire for
continuous contact to the
pipeline, is used with a
data logger to capture
data as the survey is
being performed.
The location of each
reference position is
recorded with the
observed potential.
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In Line Inspection
1.
2.
In line inspection is
mainly for pipeline
geometry
measurement and
metal lose
measurement.
There are tow kind of
intelligence pigs which
is mainly in use:
Magnetic flux leakage.
Ultrasonic tool.
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In Line Inspection
Magnetic flux leakage
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In Line Inspection
Magnetic flux leakage
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In Line Inspection
Magnetic flux leakage
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In Line Inspection
Ultrasonic Inspection Pig
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In Line Inspection
Ultrasonic Inspection Pig
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In Line Inspection
Ultrasonic Inspection Pig
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In Line Inspection
Ultrasonic Inspection Pig
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In Line Inspection
Ultrasonic Inspection Pig
Ultrasonic Pig
25
74
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In Line Inspection
Gauge Pig
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In Line Inspection
Gauge Pig
Foam Scout Pig The foam scout pig is a flexible softbodied monolithic pig. This tool is generally the first pig
through the pipeline system. The foam scout pig serves
several functions; first, it is able to confirm if a pig will
pass through the line. It also will indicate basic and
potential diameter discrepancies or protrudences. By close
examination of the material bought out by the pig, it can
be used to determine the type and estimate the volume of
the debris present in the line. The type and amount of
debris dictates the cleaning regime to be employed. The
Foam Scout pig generally contains an electronic location
transmitter to find the pig if it becomes stuck.
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In Line Inspection
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In Line Inspection
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In Line Inspection
Tool propulsionpumped
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In Line Inspection
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In Line Inspection
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