CORROSION RATE INVESTIGATION DUE TO STRAY CURRENT

AHMAD FARIS WAHID1 AND ZAINAL ZAKARIA2

1
Faculty of Chemical and Natural Resources Engineering, Universiti Teknologi
Malaysia, 81310 UTM Skudai, Johor.
2
Lecturer of Chemical & Natural Resources Engineering Faculty, Universiti Teknologi
Malaysia, 81310 Skudai, Johor.

Email: afaris4@mail.com

Abstract

Failures in gas pipelines due to stray current can have severe environmental
and economic consequences. Large investments have been made in studies on corrosion
stray current for gas pipelines. Important research is being conducted to investigate
corrosion rate (weight loss of metal) different pair of metals with under different stray
voltage (external voltage) and corrosion rate based on between several set pair of metals
based on electromotive series with constant stray voltage. Besides, the corrosion rate of
metal being categorized to its classes. Therefore, different pair of metals (steel and
platinum, steel and steel, zinc and steel, copper and steel, copper and brass) was
examined in term of corrosion rate pair of metals due to stray voltage (external voltage
supply) and distance between anode and cathode in electromotive series. All the samples
were examined based on electrolytic cell in a test solution of pH7. It was found that the
corrosion rate will increase due to increase of stray voltage (external voltage) and at
constant stray current, distance between anode and cathode inside the electromotive
series will affect the corrosion rate of the metal.

Keywords: Corrosion rate, stray current, steel and platinum, steel and steel, zinc and
steel, copper and steel, and steel and brass, electrolytic cell.

Abstrak
Pada masa kini, kegagalan paip gas disebabkan aliran arus sesat mengakibatkn
kesan terhadap persekitaran dan terhadap ekonomi. Banyak pelaburan telah dilakukan
untuk mengkaji kesan arus sesat terhadap paip gas. Kajian dilakukan untuk melihat kadar
pengaratan berdasarkan kehilangan berat logam beberapa pasangan logam paip terhadap
arus sesat yang dibekalkan dan juga untuk melihat kadar pengaratan arus sesat pasangan
logam berdasarkan jarak antara anod dan katod di dalam siri keelektomotifan logam
dengan membekalkan arus yang tetap.Selain itu, kadar pengaratan logam juga
diklasifikasikan ke dalam kelas pengaratan. Oleh demikian, beberapa pasangan logam
telah dipilih (besi dan platinum, besi dan besi, zink dan besi, kuprum dan besi, dan besi
dan loyang) untuk melihat kadar pengaratan pasangan logam disebabkan arus sesat dan
kesan jarak antara anod dan katod di dalam siri keelektomotifan logam terhadap
kehilangan berat. Kesemua pasangan logam (besi dan platinum, besi dan besi, zink dan
besi, kuprum dan besi, dan besi dan loyang) diuji berpandukan sel elektrolitik dimana pH
elektrolit adalah 7. Didapati kadar pengartan akan meningkat jika arus sesat meningkat
dan semakin jauh kedudukan anod dan katod dan wujudnya arus sesat di dalam siri
keelektromotifan logam akan meningkatkan kadar pengaratan.
.
Kata kunci: Kadar pengaratan, arus sesat, besi dan platinum, besi dan besi, zink dan
besi, kuprum dan besi, dan besi dan loyang , sel elektrolitik.

1.0 INTRODUCTION

Corrosion is usually defined as the deterioration of a metal or its properties caused

by a reaction with its environment. Protection occurs at the point where current returns to
the metal surface (reduction or cathodic reaction). The corrosion process consists of an
anodic and a cathodic reaction. In the anodic reaction (oxidation) the metal is dissolved
and transferred to the solution as ions. The electrons released by the anodic reaction are
conducted through the metal to the cathodic area where they are consumed in the
cathodic reaction. A necessary condition for such a corrosion process is that the
environment is a conducting liquid (an electrolyte) that is in contact with the metal. In
accordance with the conditions this dissolution process is called wet corrosion, and the
mechanism is typically electrochemical .Corrosion is express and measure in term of
corrosion rate. Normally, there are three main methods that are used to express the
corrosion rate. The corrosion rate is express in term of thickness reduction of the material
in unit time, weight loss per unit area and time and corrosion current density [1]. The
most related for this study is determining the corrosion rate by measuring weight loss per
unit are and time.
Stray currents are currents flowing in the electrolyte from external sources. Any
metallic structure, for example a pipe line, buried in soil represents a low resistance
current path and is therefore fundamentally vulnerable to the effects of stray currents.
Stray current tends to enter a buried structure in a certain location and leave it in another.
It is where the current leaves the structure that severe corrosion expected. . There are a
number of source of undesirable stray currents, including foreign cathodic protection
installations, dc transit systems such as electrified railways, subway systems, and
streetcars, welding operations, and electrical power transmission systems.Corrosion
damage induced by stray current effects has also been referred to as electrolysis.
Electrolysis process is a production of chemical changes in the electrolyte by the passage
of current through an electrochemical cell. An electrochemical cell can either drive an
external electrical device (load) or be driven by it (power supply), depending upon the
relative electromotive forces applied by the cell and the device. An electrochemical cell
can be described as galvanic, reversible, or electrolytic. For the study and understanding
of stray current effects it is important to bear in mind that current flow in a system will
not only be restricted to the lowest-resistance path but will be distributed between paths
of varying resistance, as predicted by elementary circuit theory. Naturally, the current
levels will tend to be highest in the paths of least resistance [2]. Besides, for this study the
focus of the study in determines the rate of corrosion due to stray current is based on
electrolytic cell.
The objective of the study is to investigate the rate of corrosion due to stray
current. The scope for this research are to investigate corrosion rate under variety of stray
current (external voltage )between several pair of metals and to investigate corrosion rate
due to stray current between several set pair of metal based electromotive series with
constant external voltage supply.

2.0 LITERATURE REVIEW

Literature and research supports the position that the steel in the gas pipelines can
and does carry electric current, often when the pipeline is within a high power electric
line easement, near an electric station or other source of high voltage Induced AC current
is not grounded adequately, the AC discharge on the pipeline can in the long term, cause
serious metal loss on the pipe wall and leaks [3].Corrosion by stray currents is usually
related directly to Faraday’s Law. If current(I) amps passes, the amount of corrosion
suffered will be I/F gram-equivalents per second(F, the Faraday, 96500 coulombs per
gram equivalent) thus 1 ampere flowing for one year will corrode approximately 20Ib of
iron, 22Ib of copper or 75Ib of lead [11]. Figure 2.1 shows stray current electrolysis,
return current from streetcar divides, part going back to substation along rails, and part
leaking off rails onto pipeline. Near the substation this current flows from the pipe line
through the soil to the rail system, causing corrosion of the pipe. Installation of a metallic
bond from the pipe to the negative bus at the substation will avert the damage in
simplified form the route taken by the current. Stray currents can be classified into
numerous types [4]. Typically, direct stray currents come from cathodic protection
systems, transit systems, and dc high-voltage transmission lines. Stray current need to be
control in a way to prevent the pipeline or others metal instrument being corroded. Using
electrical bonding is the establishment of an electrical connection between the interfering
and interfered with structure is a common remedial measures as shown Figure 2.2, the
use of cathodic shielding the aim is to minimize the amount of stray current reaching the
structure at risk as shown in Figure 2.3 and using sacrificial anodes can be installed at the
current discharge areas of interfered-with structures to mitigate stray current corrosion as
shown in Figure 2.4.
Figure 2.1 Stray current electrolysis Figure 2.2 Use of drainage and electrical
bonding

Figure 2.3 Using extra sacrificial anode

Figure 2.4 Principle cathodic shields

3.0 METHODOLOGY

There are five set of electrodes being used for this experiment. The first set is
between steel (anode) and platinum (cathode). The second set is between steel (anode)
and steel (cathode). The third set is between zinc (anode) and steel (cathode). The fourth
set is between copper (anode) and steel (cathode). The last set is between steel (anode)
and brass (cathode). Every set of metal will being tested based on scope stated. Every
metal will be measured the weight for initial weight and final weight. For investigation
corrosion rate under variety of stray current (external voltage) between several pair of
metals, the test solution pH 7 shall be prepared. For this scope, the experiment involves
all set. Figure 3.1 shows the example to connect the electrodes. The first metal of the cell
is anode while the second metal is cathode. For every variation of external voltage such
as 2V, 3V and 4V, the set need to be leave for 3 days. The weight losses for the metal
need to be count for corrosion rate in millimeter per year (mm/yr) calculation. For
investigation corrosion rate due to stray current between several set pair of metal based
electromotive series with constant external voltage supply (2V, 3V and 4V). Second set,
fourth set and fifth set will be eliminated for this investigation. The weight losses for the
metal need to be count for corrosion rate calculation. Figure 3.1 shows the corrosion
study kits that going to use to run the experiment for this study. Figure 3.2 shows the
example of metal plate being connect where positive terminal connecting to the anode
and negative terminal to cathode).

Figure 3.1 Corrosion kit

Figure 3.2 Pair of metal steel and
platinum

4.0 RESULTS AND DISCUSSION

4.1 Effect of Stray Voltage (External Voltage)

Figure 4.1 shows the corrosion rate of anode metal in millimetre per year (mm/yr)
to the stray voltage (external voltage). Corrosion rate anode metal (mm/yr) is
proportionally to the stray voltage supply. As mentioned before, oxidation reaction will
happen in anode metal and where the corrosion happens here. The highest the stray
voltage, the highest will be the corrosion rate of anode metal. As shown in the Figure 4.1,
steel-platinum metal has the highest corrosion rate. At 4V, the corrosion rate of steel-
platinum at anode (steel) metal is 2.26mm/yr follow by copper-copper 1.2mm/yr, copper-
brass 0.94mm/yr, copper-steel 0.58mm/yr , and zinc-steel 0.48mm/yr. It is due to the
potential difference between the pair of metal. Steel-platinum metal has the highest
potential difference +0.75V, follow by copper-copper 0V, copper-brass -0.01V, copper-
steel -0.11V and zinc-steel -1.21V. When the stray voltage supply, it add more voltage to
the potential difference and hence increase the corrosion rate anode metal [5].

Figure 4.2 shows the corrosion rate of cathode metal in millimeter per year
(mm/yr) to the stray voltage (external voltage).Corrosion rate cathode metal (mm/yr) is
proportionally to the stray voltage supply. Basically, cathode will be protected which
mean will be having less corrosion due to cathodic reaction. The highest the stray
voltage, the highest will be the corrosion rate. As shown in Figure 4.2, the zinc-steel has
the highest corrosion rate. At 4V, the corrosion cathode rate of zinc-steel is 0.28mm/yr
follow copper-steel 0.23mm/yr, copper-brass 0.19mm/yr, steel-steel 0.01mm/yr and steel-
platinum 0.006mm/yr. It is due to the potential difference between the pair of metal.
Steel-platinum metal has the highest potential difference +0.75V, follow by copper-
copper 0V, copper-brass -0.01V, copper-steel -0.11V and zinc-steel -1.21V. For zinc-
steel metal, steel as the cathode has the highest corrosion cathode because of the pair of
metal has the negative potential difference and the ability for the cathode metal to protect
anode become less.

12

2
10

1.5 8
Corrosion Rate (mm/yr)

Corrosion Rate (mm/yr)

6
1

4
0.5

0
0 2 4 6 8 10 12
0
Voltage (V) 0 2 4 6 8 10 12

Steel-Steel Zinc - Steel Voltage (V)

Steel-Platinum Steel-Steel
Copper - Steel Copper - Brass
Zinc - Steel Copper - Steel
Copper - Brass

Figure 4.1 Corrosion Rate of Anode Figure 4.2 Corrosion Rate of

Metal. Cathode Metal.

4.2 Effect of Stray Voltage (External voltage) to Electrochemical Series

 The histogram in Figure 4.3 shows the corrosion rate of the pair of metal with
supply constant voltage at 4V due to the arrangement in electrochemical series. This
involves only two pair of metals which are steel-platinum and zinc-steel. At 4V the pair
of steel-platinum metal gives the highest corrosion rate for anode (steel) metal which is
2.26mm/yr but the lowest corrosion rate in cathode (platinum) metal which is
0.006mm/yr. As the distance in electrochemical series is high between anode and cathode
metal the anode metal will be sacrifice more and cathode metal will be protected more
[6]. This is also due to the potential difference that occurs between the pair of metals.

2.3 2.26

2.1
1.9
1.7
Corrosion Rate (mm/yr)

1.5 Steel Anode

Platinum Cathode
1.3
1.1 Zinc Anode
0.9 Steel Cathode
0.7
0.48
0.5
0.3
0.1
Pair of Anode-Cathode at 4V

Figure 4 Corrosion Rate Pair of Metal due to Arrangement in

Electrochemical Series at Constant External Voltage 4V

5.0 CONCLUSION

The corrosion rate is proportionally to stray current (external voltage). As the stray
current (external voltage) increased the corrosion rate will follow to increase. The
external voltage in the cell will boost up the electrolytic corrosion process and this will
give rapid corrosion to occur. For the distance between anode and cathode inside the
electrochemical series, as the distance increase, the corrosion rate will be significantly
high at anode metal while the corrosion rate at cathode metal will be less. This is also due
to the potential difference that occurs between the pair of metals.

6.0 REFERENCES

[1].Bardal, Einar. (2003). Corrosion and Protection. Springer.

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Characterisation of Molten Glass Corrosion Behaviour By Use Of Electrochemical
Techniques,Journal Corrosion Science and Engineering, Volume 6 Paper HD24.

[4].Rogers, T. Howard (1968), Marine Corrosion, William Clowes And Sons.

[5].Marshal, E. Parker(1954). Pipe Line Corrosion And Cathodic Protection . Gulf

Publishing Company.

[6].Robles Hernándeza,F.C., Plascenciab G., and Kocha,Kevin (2008). Rail base

corrosion problem for North American transit systems. Engineering Failure Analysis
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[7].Smart, Osstendorp and Wood, (1999). Journal Induced AC Creates Problems For
Pipe Lines In Utility Corridors,Pipe Line & Gas. Industry, Vol. 8.

[8].Gaillard-Allemand, B., Littner, A., Podor, R.,Rapin, C., and Vilasi M.(2003).
Characterisation of Molten Glass Corrosion Behaviour By Use Of Electrochemical
Techniques,Journal Corrosion Science and Engineering, Volume 6 Paper HD24.
[9].Jury gives $ 700,000 to dairy farmers for losses blamed on 'stray voltage', (1999,April
21), Associated Press.

[10]. The Columbia Encyclopedia. (2009).Columbia University Press.

[11]. Bertolini,Luca.,Carsana,Maddalena.,and Pedeferri,Pietro.(2006). Corrosion

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(2007) 1056–1068.

[12]. Rogers, T. Howard (1968), Marine Corrosion, William Clowes And Sons.

[13]. Sheir, L.L. (1968), Corrosion Science and Technology, Newnes International
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[14]. Graver, D.L. (1985). Corrosion Data Survey-Metals Section,NACE International,

Houston.