DESIGN OF PERMANENT CATHODIC PROTECTION SYSTEM FOR GAS PIPELINE

BY RAHUL RATHORE R150209029

College of Engineering University of Petroleum & Energy Studies Dehradun April, 2011

DESIGN OF PERMANENT CATHODIC PROTECTION SYSTEM FOR GAS PIPELINE Page | 1

A thesis submitted in partial fulfillment of the requirements for the Degree of MASTER OF TECHNOLOGY IN PIPELINE ENGINEERING By Rahul Rathore

Under the guidance of

Mr.AGAM TYAGI. Assistant Professor UPES, Dehradun

Approved

.. Dean College of Engineering University of Petroleum & Energy Studies Dehradun April, 2011

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CERTIFICATE

This is to certify that the work contained in this thesis titled Permanent Cathodic Protection System for Gas Pipeline. has been carried out by Rahul Rathore under my supervision and has not been submitted elsewhere for a degree.

Under the guidance of: Mr. Agam Tyagi, Assistant Professor, College Of Engineering, U.P.E.S. Dehradun

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ABSTRACT

Corrosion is the most vital issue in the pipeline. Corrosion is the result of electrochemical reaction. The driving force for the corrosion is the free energy of the metal atoms in their metallic form. To mitigate the corrosion we adopt the technique of Cathodic Protection System. The Cathodic Protection is one of the important factors in the performance of the pipeline carrying crude, gas or petroleum products. An efficient C.P. performance keeps the life of the pipeline up to the designed life. The improperly design CP may affect badly the design life of the pipeline. This also affects the supply factor which is proportional to loss in terms of money. This project discusses about the permanent cathodic protection system for a hypothetical gas pipeline of length and diameter respectively 56 km and 12 inch. One C.P. station is requiring install which protect the entire pipeline.

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Contents
Topics Page No.

1.1.Corrosion Theory 1.1.1. Introduction 1.1.2. Corrosion Mechanism 1.1.3. How do we detect the corrosion? 1.1.4. How do we mitigate the corrosion? 1.1.5. Factors affecting corrosion reaction 1.1.6. Types of corrosion

2 3 4 5 5 6

1.2.Cathodic protection system 1.2.1. Introduction 1.2.2. Types of c.p. system 1.2.3. Comparison between impressed current and galvanic c.p. system 1.2.4. Selection of type, size and spacing of c.p. system 1.2.5. C.p. system design

8 8 8 11 12 13

1.3. Impressed current c.p. system 1.4.Ground bed design, 1.5.Hazard associated with cathodic protection 2.0. Literature Review

16 19 21 23

3.0. Theoretical development of c.p. System 3.1. estimation of current requirement 3.2. estimation of soil resistivity, 3.3. ground bed design 3.4. calculation of maximum length Protected by c.p. system 3.5. precautions for c.p. System design,

25 26 27 28 28 30

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Topics 4.0. Calculations 4.1. assumption, 4.2. Current Estimation, 4.3. Ground Bed Design, 4.4. Calculation for maximum length Protected by c.p. system 5.0. conclusion

Page no. 33 35 36 37 37

39

6.0. Bibliography

41

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List Of Figures:
Name 1. Corrosion Mechanism 2. Difference In Soil Resistivity 3. Difference in Oxygen Condition 4. Different Composition Of Electrolyte 5. Impressed Current C.P. System 6. Galvanic Anode C.P. System 7. High Silicon Cast Iron Anode 3 6 7 7 9 10 17 Page No.

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List Of Tables:
Name of The Table 1. Galvanic Series 2. Pipe To Soil Potential Reading 3. Average Coating Conductance 2 4 26 Page No.

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Nomenclature
C-Carbon Cr- Chromium Ni- Nickel Mn- Manganese Al- Aluminum Zn- Zinc C.P.- Cathodic protection System ICCP- Impressed Current Cathodic Protection System NACE- National Association Of Corrosion Engineers.

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Chapter -1 Introduction

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1.1.

Corrosion Theory:

1.1.1. Introduction Nature has given certain energy level or potential to every metallic structure. Whenever two metals with some difference in potential energy are come in contact with each other, current will flow. The direction of positive current flow will be from the metal with the more negative potential through the soil to that which is more positive. Corrosion will occur at the point where positive current leaves the metal surface.

Material

Potential Volts

Carbon, Graphite, Coke Platinum Mill Scale on Steel High Silicon Cast Iron Copper, Brass, Bronze Mild Steel in Concrete Lead Cast Iron (Not Graphitized) Mild Steel (Rusted) Mild Steel (Clean and Shiny) Commercially Pure Aluminum Aluminum Alloy (5% Zinc) Zinc Magnesium Alloy (6% Al, 3% Zn, 0.15% Mn) Commercially Pure Magnesium Table -1: Galvanic Series

+0.3 0 to -0.1 -0.2 -0.2 -0.2 -0.2 -0.5 -0.5 -0.2 to -0.5 -0.5 to -0.8 -0.8 -1.05 -1.1 -1.6 -1.7

The direction of current will be from the metal through the soil to that which is more positive. Hence corrosion will occur at that point where current leaves the metal surface.

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1.1.2. Corrosion Mechanism: Basically for corrosion to take place following four conditions must be satisfied: 1. There must be a cathode and an anode. 2. There must be an electrical potential between cathode and anode. 3. There must be a metallic path connecting cathode and anode. 4. The two electrodes must be immersed in an electrically conductive material called electrolyte.

Figure-1: Corrosion Mechanism Fe Fe ++ + 2eO2 + 2H2O + 4e- 4 OH2H2O + 2e- H2 +2OHCorrosion of most common engineering materials at near-ambient temperatures occurs in aqueous (water-containing) environments and is electrochemical in nature. The aqueous environment is also referred to as the electrolyte and, in the case of underground corrosion, is moist soil. 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.

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1.1.3. HOW DO WE DETECT CORROSION? Due to electrochemical nature, corrosion process provides chances to detect and mitigate corrosion of buried structures. Because of this we can monitor the voltages and the currents associated with the corrosion process. Whenever a metal or a piece of metal is placed in an electrolyte, such as soil, a voltage will develop across the metalelectrolyte interface due to the electrochemical nature of the corrosion process. To measure this voltage, we generally use a voltmeter. With the help of this voltmeter, we can also measure the voltage difference between a metal and a reference electrode, generally called a half-cell electrode. For buried structure, the most common reference electrode used is the coppercopper sulfate reference electrode (CSE).

Potential measurements are also an indication relative resistance of different metals to corrosion. The metals having more positive potential are termed as noble and having more resistive capacity to corrosion than the materials having less potential. Apart from this when more negative member is electrically coupled with another member having less negative member in any electrolytic environment, the more negative will become the anode and the less negative member of the couple will become the cathode in the cell. In case of buried pipeline, to detect the corrosion the most common method is potential measurement.

Table -2: Pipe To Soil Potential Reading

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1.1.4. HOW DO WE MITIGATE CORROSION? The two main methods for protection against corrosion are: 1. Coatings, 2. Cathodic protection system. Coatings are the continuous layer of insulating material over the structure to be protected. Coatings prevent the direct contact of metal with the surrounding electrolyte due to which the chemical reaction does not occur. But in actual practice coatings dont provide the perfect insulation. During the application, transportation or installation some holes are generated due to which the corrosion reaction starts. Hence coatings are not preferred for pipelines. The main function of CP is to decrease the corrosion rate of a metal surface by making it cathode. This can se achieved using either an external power source or a sacrificial anode. In the case of an impressed current system, protective D.C. current is impressed on the structure by an external power source and an anode buried in the ground. In case of sacrificial anode c.p. system D.C. current are provided from metals such as magnesium, zinc etc. which are having higher potential and placed at the active end of electromotive series. 1.1.5. FACTORS INFLUENCING CORROSION REACTIONS: 1.1.5.1.Factors Associated Mainly with the Metal
1. 2. 3. 4.

Effective electrode potential of a metal in a solution Overvoltage of hydrogen on the metal Chemical and physical homogeneity of the metal surface Inherent ability to form an insoluble protective film

1.1.5.2.Factors Which Vary Mainly with the Environment

1. 2. 3. 4. 5. 6. 7.

Hydrogen-ion concentration (pH) in the solution Influence of oxygen in solution adjacent to the metal Specific nature and concentration of other ions in solution Rate of flow of the solution in contact with the metal Ability of environment to form a protective deposit on the metal Temperature Cyclic stress (corrosion fatigue)
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1.1.6. Types of Corrosion: Basically, two types of corrosion mechanism are there: 1. Electrolytic Corrosion 2. Galvanic Corrosion 1.1.6.1.Electrolytic Corrosion: In electrolytic corrosion, the direct current from outside sources entering and then leaving a particular metallic structure by way of the electrolyte. Where current enters the structure, that part is usually protected. Where current leaves the structure, corrosion occurs. 1.1.6.2.Galvanic Corrosion: Galvanic corrosion is self-generated activity resulting from differences in energy levels or potentials which develop when metal is placed in an electrolyte. Corrosion can occur due to differences in the electrolyte. These differences may be in the soil resistivity, oxygen concentrations, moisture content and various ion concentrations. The variations produce current flow from one location, through the electrolyte, to another portion of the same metallic structure. 1.1.6.2.1. Difference in soil resistivity:Whenever a single metallic structure runs in the soil having different soil resistivity which is usually the case in the pipelines, portion of the pipeline which is in low resistivity areas becomes anodic to the one under the high resistivity areas.

Fig.-2: Difference In Soil Resistivity

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1.1.6.2.2. Difference In oxygen condition:Areas where oxygen supply is freely available are cathodic

compared to areas where air supply is restricted such as paved road crossing.

Fig.-3: Difference in Oxygen Condition 1.1.6.2.3. Different composition of electrolyte:The buried structure under clay soil is anodic to the section under the sandy soil.

Fig.-4: Different Composition Of Electrolyte

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1.2.

Cathodic Protection System:

1.2.1. Introduction: CP is a technique which is used to overcome the corrosion rate of a metal surface by making it the cathode of an electrochemical cell. In each condition that causes pipeline corrosion, anodic areas and cathodic areas are present on the pipe surface. At the anodic areas, current flows from the pipeline steel into the surrounding electrolyte (soil or water) and the pipeline corrodes. At the cathodic areas, current flows from the electrolyte onto the pipe surface and the rate of corrosion is reduced. This is what cathodic protection system does. In cathodic protection system, D.C. current is forced to flow from external source to metallic structure. When the amount of current flow is properly adjusted, it will overpower corrosion current discharging from anodic areas and there will not be current flow from the pipe surface to electrolyte. Cathodic protection has become a standard procedure for many structures such as underground storage tanks, pipelines, water storage tanks, ship hulls and interiors, lock gates and dams, water treatment facilities, well casings, trash racks and screens, bridge decks, and steel pilings.

1.2.2. Types of C.P.System: Types of C.P. system for under ground pipelines: Depending on the C.P. system requirement, generally either one or combination of two types of the following two C.P. systems is provided on the underground pipelines. 1. Impressed current system, 2. Sacrificial anode C.P. system or galvanic anode C.P. system. Cathodic protection utilizes a flow of direct current electricity to interfere with the activity of the electrochemical cell responsible for corrosion. Corrosion can be prevented by coupling a metal with a more active metal when both are immersed in an electrolyte and connected with an external path. In this case the entire surface of the metal being protected becomes a cathode; thus the term "cathodic protection."

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1.2.2.1. Impressed current C.P. system: In the impressed current C.P. system, external D.C. power source is utilized for impressing the external protective currents on the pipelines and every part is made to collect the current thereby providing the cathodic protection.

Fig.-5: Impressed Current C.P. System In this type of cathodic protection system, anodes are installed in the electrolyte and are connected to the positive terminal of a DC power source and the structure which is to be protected is connected to the negative terminal of that source. Because the power source is almost always a rectifier unit, this type of system is often referred to as a rectifier or impressed current type system.

1.2.2.2. Galvanic anode C.P. system: In case of sacrificial anode c.p. system D.C. current are provided from metals such as

magnesium, zinc etc. which are having higher potential and placed at the active end of electromotive series. As these metals gets consumed and are sacrificed to save the metallic pipeline hence the name sacrificial anode is commonly given in addition to galvanic anode.

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Fig.-6: Galvanic Current C.P. System Regardless of the type of system used, current flows from the cathodic protection anode through the soil to the structure to be protected. Where this current flows onto a structure from the surrounding electrolyte (soil), the potential of the structure is made more negative. Cathodic protection is achieved when this change in potential is sufficient to arrest corrosion. In order to prevent corrosion using cathodic protection, current must flow from the electrolyte onto the structure at all locations. If a portion of the structure does not receive current, the normal corrosion activity will continue at that point. If any of the cathodic protection current picked up by the structure leaves that structure to flow back into the electrolyte, corrosion will be accelerated at the location where the current is discharged. If a galvanic anode type system is used for protection, it may be necessary to install an anode on each pipe length or to electrically bond across each joint. If one length of pipe is neglected, that length will receive no cathodic protection and the normal corrosion activity will continue. When a rectifier type system is installed on an underground storage tank system, it is even more important that the tank and lines be electrically continuous. If there are non-continuous joints, it is possible for the cathodic protection current to leave the pipe or tank to flow around the electrically discontinuous joint causing corrosion at each point where the current leaves the pipe surface.

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1.2.3. Comparison between Galvanic and Impressed Current CP Systems: 1.2.3.1. CP System with Galvanic Anodes: 1.2.3.1.1. Advantages: 1. This requires no external source. 2. This is economical. 3. This can be easily installed and maintained 4. This can be used in areas where the soil resistivity is low. 5. Less interference with the other metallic structures is caused due to relatively low current output. 6. The current distribution throughout the structure is even. 1.2.3.1.2. Disadvantages: 1. It has limited applications compared to impressed current system due to the fact that it has limited area of influence and therefore effective pipe length which can be protected is limited. 2. Driving voltage is fixed and cannot be manipulated, except by selecting Mg instead of Zn for example. 3. 4. The cost of protection is high for bare systems (uncoated structures). As no above-ground equipment is used, it is difficult to trace the protected system, unless contact posts are provided. 1.2.3.2. CP System with Impressed Current 1.2.3.2.1. Advantages: 1. 2. 3. Rectifiers available in unlimited current output. May be designed for long lives. Possibility of variation of current to suit the changes in the system over a period of time.
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1.2.3.2.2. Disadvantages: 1. Reliable external AC power supply round the clock is essential. 2. Less economical for smaller jobs. 3. Limited to use below a soil resistivity of 3000 ohms-cm. 1.2.4. Selection of Type, Size, and Spacing of a Cathodic Protection System: Some of the questions to be resolved when planning a pipeline CP system include the following: 1. How much total current will be required to attain adequate CP? 2. What should be the spacing between installations, and what will be the current output required from each installation? 3. What provisions should be made to permit testing the completed installation? 4. Are there special conditions at certain locations that will require modifications in the general plan for CP? The needed information that will influence the decision includes such items as: 1. The corrosivity of the environment; 2. The soil structure and resistivity; 3. Whether the pipeline is bare or coated; 4. If coated, the quality and electrical strength of the coating and the presence of environmental conditions that may cause the coating to deteriorate; 5. The metal or alloy used in the pipeline; 6. The size of the pipeline and its ability to conduct CP current; 7. The presence of metallic structures from other resources (usually termed foreign structures) crossing or close to the pipeline to be protected; 8. The presence of stray current from man-made or natural sources.

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1.2.5. Cathodic protection System Design: 1.2.5.1.Criteria for cp system design: Basically there are three types of primary criteria of CP underground pipeline. 1. 850 mV (CSE)a with the cp applied, 2. A polarized potential of 850 mV (CSE) 3. 100 mV of polarization. 1.2.5.1.1. -850 mV with Cathodic Protection Applied Criterion: The full criterion states that adequate protection is achieved with: A negative (cathodic) potential of at least 850mV with the CP applied. This potential is measured with respect to a saturated copper/copper sulfate reference electrode contacting the electrolyte. Voltage drops other than those across the structure-to-electrolyte boundary must be considered for valid interpretation of this voltage measurement. Consideration is understood to mean application of sound engineering practice in determining the significance of voltage drops by methods such as: 1. measuring or calculating the voltage drop(s), 2. reviewing the historical performance of the CP system, 3. evaluating the physical and electrical characteristics of the pipe and its environment 4. Determining whether or not there is physical evidence of corrosion. 1.2.5.1.2. Polarized Potential of -850 mV Criterion: This criterion states that adequate protection is achieved with a negative polarized potential of at least 850 mV relative to a saturated copper/copper sulfate reference electrode. The polarized potential is defined as the potential across the structure/ electrolyte interface that is the sum of the corrosion potential and the cathodic polarization. The polarized potential is measured directly after the interruption of all current sources and is often referred to as the off- or instant off-potential. The difference in potential between the native potential and the off or polarized potential is the amount of polarization that has occurred as a result of the application of the CP. As previously stated, the difference in potential between the on-potential and the off-potential is the error in the on-potential introduced as a result of voltage drops in the electrolyte (soil) and the metallic return path in the measuring circuit.

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1.2.5.1.3. 100 mV of Polarization Criterion: This criterion states that adequate protection is achieved with a minimum of 100 mV of cathodic polarization between the structure surface and a stable reference electrode contacting the electrolyte. The formation or decay of polarization can be measured to satisfy this criterion. Of the three criteria, this criterion has the most sound fundamental basis. The corrosion rate decreases and the rate of the reduction reaction on the metal surface increases as the underground structure is polarized in the negative direction from the native potential. The difference between the corrosion rate (expressed as a current) and the rate of the reduction reaction is equal to the applied CP current. These processes can be shown graphically in a diagram of E versus log I, referred to as an Evans diagram. The slope of the anodic (corrosion) reaction is referred to as the anodic Tafel slope and typically has a value of 100 mV per decade of current. With this Tafel slope, the corrosion rate of a structure decreases by a factor of 10 (an order of magnitude) for every 100 mV cathodic shift in the polarized potential. An order of magnitude decrease in the corrosion rate of an underground structure typically is more than adequate to effectively mitigate corrosion. The cathodic polarization also promotes beneficial changes in the environment at the pipe surface, such as reducing oxygen, increasing the pH, and moving halides such as chlorides away from the metal surface, which further decreases the corrosion rate. These beneficial changes in the environment at the metal surface are referred to as environmental polarization, in that the environmental changes typically result in a shift in the free corrosion potential of the pipe in the negative direction. Thus, the total potential shift from the native potential (excluding IR voltage drops in the soil) includes components attributable to environmental polarization and cathodic polarization. As described in the criterion, the magnitude of the polarization shift can be determined by measuring its formation or decay. To determine the magnitude of the shift as a result of the formation of polarization, one must first determine the native potential of the underground structure at test locations before applying CP. The potential is then re-measured after the CP system is energized and the structure has had sufficient time to polarize. Typically, the on-potential is continuously monitored at one test location directly after energization the CP system, and an off-potential reading is made when there is no measurable shift in the on-potential reading for several minutes. The off potential is then compared with the native potential; if the difference exceeds 100 mV, then the 100 mV criterion has been satisfied at that location. Offpotential readings are then obtained at the other test locations to determine whether the criterion
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is met at these locations. The time required for sufficient polarization to develop is highly dependent on the nature of the structure (coating condition, underground environment, types and number of bonds, and so forth) and the design of the CP system. From a practical standpoint, it is wise to reexamine the overall structure and the CP system if a reasonable amount of polarization does not develop within a few hours of energizing the CP system. An alternative method of assessing the formation of cathodic polarization is to measure the on-potential immediately after energizing the CP system and then re-measure the on-potential after a few hours to days of operation. If the on-potential shifts in the cathodic (negative) direction by >100 mV, then one can conservatively assume that the criterion has been met. Because the applied CP current generally decreases with time, the magnitude of the IR voltage drop also decreases. Thus, the total shift in the on potential must be a result of the sum of the additional cathodic polarization and the environmental polarization of the pipeline, both of which reduce the corrosion rate of the structure and are included in the 100 mV of polarization in the criterion. If this method is used, the engineer should confirm that the applied CP current decreased with time. Measuring the positive potential shift associated with polarization decay that occurs after deenergizing the CP system is the most common method to determine the amount of polarization. When a CP system is de-energized, the pipe-to-soil potential undergoes an instantaneous positive shift as a result of elimination of the IR voltage drop in the soil. The potential measured at this time is referred to as the off potential, as previously described, and is used as the starting point for assessing the polarization shift. There may be a spike in the potential reading immediately after interruption of the CP system, a result of inductive effects of the pipeline and the CP system. Because this spike may last a few hundred milliseconds, the off-potential is typically measured 200 to 500 ms after the interruption. The potential will then exhibit an exponential decay with time in the positive direction as the capacitor across the structure-to-electrolyte boundary discharges. This component of the potential shift is the cathodic polarization of the structure as a result of the applied cathodic current. A gradual linear decay in the potential will then occur over minutes to weeks as a result of a return of the environment at the pipe surface to its native condition. This component of the potential shift is the environmental polarization. To obtain the total polarization shift, the final potential after polarization decay is measured and subtracted from the off-potential. If this difference is >100mV, then the criterion has been satisfied.
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1.3. Impressed current CP System: 1.3.1. Design procedure: We need to follow the certain steps to design the impressed current cp system. These steps are given below: 1.3.1.1. Drawing and Specification: To install the appropriate impressed current cp system, we require the drawing, dimension and specification of structure which needs to be protected. It generally contains the shape, size and surface condition of structure. Apart from this we also require a site drawing which generally contain the information regarding the location of other metallic structure in that region. 1.3.1.2. Field survey: A field survey is require to know the actual environment condition. For buried pipeline structure the soil characteristic must be known because this plays a major role in deciding the current requirement for the buried pipeline. 1.3.1.3.Current requirement : The most common method to know the current requirement for any structure is to measure the real current by installing the temporary cp system for that structure. The total amount of current can be obtained by multiplying the current density to the surface area of the structure to be protected. 1.3.1.4.Selection of rectifier: The selection of rectifier size is mainly depending on the current requirement of the structure to be protected. Circuit resistance is evaluated by ground bed design. The output voltage rating should be keep 15 to 25% more than the design calculated value in order to compensate any change in the value of ground bed resistance. When time permits, some pipeline corrosion engineers design and install impressed current ground beds before deciding on the rectifier rating. Following this procedure, it is possible to measure the installed circuit resistance and make new current requirement tests using the completed ground bed. Rectifier voltage and current ratings may be selected with full assurance that the installation will work as planned. Although results are positive, this procedure does require more time and involves additional expense for repeat visits by the construction crews to make rectifier installations. However, when ground bed designs can be prepared with reasonable accuracy, this procedure is not necessary.
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1.3.1.5.Ground bed materials for impressed current cp system: 1.3.1.5.1. Anode Type:

Most commonly used material for anode is graphite, high silicon cast iron, mixed metal oxide, platinum and steel. Since graphite is brittle in nature hence care is required to handle it. The connection between insulated anode lead and the anode is mechanical. This connection is insulated for the protection against the moisture content. Anode caps are provided to protect the connection from early deterioration. These anodes are consumed at a rate not more than two pounds per ampere per year while discharging the current into the electrolyte. High silicon cast iron anode contains 14 to 15% silicon and lesser quantity of other element.

Fig.-7: High Silicon Cast Iron Anode During the discharging of current the behavior of silicon alloy is entirely different from cast iron. Cast iron losses 20% of its iron content per ampere per year while on the other hand high silicon cast iron losses material at a much lower rate.

Variety of size and shapes are available for mixed metal oxide anode. Generally a film of mixed metal oxide is applied on the precious metal such as titanium.

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1.3.1.5.2. Anode location and size: These are installed at a depth of 10 to 20 feet in the hole. They are installed at a distance of 10 to 30 from the center. 1.3.1.6.Backfill Material: Backfill materials are used to surround the anode bed. There are three common material are used for this: 1. Coal coke breeze 2. Calcined petroleum coke breeze 3. Natural or manmade graphite particles. Carbonaceous backfill performs two actions: 1. To increase the size of anode to obtain lower resistance to earth, 2. To bear the consumption resulting from current discharge. 1.3.1.7.Cable type: Cables are also very important part of the impressed current cp system. All buried cable should be at a positive potential. It should be perfectly insulated. If not, it will discharge the current. Hence ensure the quality of the insulation. The voltage should be of the rating of 600-V. High molecular weight polyethylene (HMW/PE) is widely used for ground bed construction. This During installation the inspection of cable should be done carefully and ensure that there is no cut or scar present in the cable. Backfill should be free from sharp stones or other harmful material which can be damage the ground bed cables. In addition to the cable should be long enough to carry the intended current and also can withstand the mechanical stresses which supposed to act during ground bed construction. From the economic point of view, select a cable size based on a comparison of cable cost with current carrying ability and the cost of power loss from cable resistance when current flows through it. 1.3.1.8.Connection: Connections are the most important part of the impressed current ground bed design. Anode leads must be connected to the header cable. The connection must be insulated. Most widely method used for connection consist soft soldering, powder welding (Thermit), hard soldering, phosphorus copper brazing, compression couplings, split bolt couplings. The first four methods result in complete joining of the metals and have permanent low resistance. Mechanical methods, if used properly, also will give low resistance connections, which will remain low if
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subsequent joint insulation excludes moisture and air completely so that no corrosion films may form within the joint to introduce resistance. When using joining methods involving the use of a torch, cable insulation adjacent to the connection should be protected against heat damage. Any heat damage should be removed prior to insulating the connection.

1.4.

Impressed Current Ground Beds

Design charts for impressed current ground beds should be based on the types of anode construction adopted by the corrosion engineer for his pipeline system. Typical construction sketches will be shown to illustrate principles involved, but others may be used if found more suitable for specific pipeline conditions. The carbonaceous backfill surrounding the anode, when well tamped, serves two functions: 1. Being of a very low resistivity, it has the effect of increasing the anode size with resulting reduction in resistance to earth, and 2. Most of the current is transmitted to the backfill from the anode by direct contact so that the greater part of material consumption should take place at the outer edges of the backfill column. Since a positive potential (voltage) is impressed on the entire ground bed assembly, it is absolutely essential that all header cable insulation, anode pigtail wire insulation, the connection between anode and pigtail (a manufacturers function) and insulation of connections between pigtails and a header cable or cable runs to a test or junction be completely intact and moisture proof. If this is not maintained, current will be discharged through insulation imperfections, causing wires to corrode and sever in a relatively short period of time, thus losing connections to all or part of the ground bed. Connections between header cable and anode pigtail must be of permanent low resistance. This maybe accomplished by methods such as thermite welding, soldering, or high compression crimp-type connections. in addition to resistance to earth of the anodes, other considerations must be analyzed to determine the total circuit resistance. These include the following: 1. Back voltage between ground bed and pipeline, 2. Resistance to earth of the pipeline at the ground bed location, and 3. Resistance of cable from the pipeline to power source and from the power source to and along the anodes comprising the ground bed.
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The back voltage is that which exists between the anodes and pipeline in opposition to the applied voltage. For ground bed anodes with carbonaceous backfill, this will be, usually, in the order of 2 V. Some areas of unusual soil composition may result in higher back voltages but the 2-V figure is used commonly for design purposes unless experience in a specific area dictates otherwise. In practice, the back voltage at a working ground bed is determined by measuring the voltage between ground bed and pipeline (across the positive and negative rectifier terminals) immediately after switching the rectifier power OFF. The ground bed will always be positive to the pipeline. If the back voltage is 2 V, it means it will require 2 V of the rectifier source voltage to overcome the back voltage before current can flow through the ground bed.

Resistance to earth of the pipeline depends on the quality of the pipeline coating. The better the coating, the higher the effective resistances at the ground bed location. In the example being used, if current requirement tests made at (or in the vicinity of) the selected ground bed location had indicated that 20 A of applied current would cause a change in pipeline voltage (V) of -1:5 V to a remote copper sulfate electrode (CSE), the effective pipeline resistance would be 1.5/20 or 0.075 ohm.

Cable resistance is the additive resistance of the cable from the pipeline via the power source to the first anode of the ground bed (assuming that the line of ground bed anodes is perpendicular to the pipeline), plus effective resistance of the header cable along the line of anodes or individual anode cables. This effective header cable resistance is less than that of the full length of the ground bed because all current does not flow the full length of the ground bed but is diminished as each anode connected drains off its share of current. Although subject to variations with differences in individual anode resistance and possibly other factors, it is practical to use the resistance of one half of the ground bed header cable resistance as the effective header cable resistance.

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1.5.

Hazards Associated with Cathodic Protection.

Cathodic protection systems, like all other electrical systems, can be dangerous under some circumstances. They can, however, be safely operated under most conditions if the proper precautions are taken in their design, installation, operation, and maintenance.

1.5.1. Explosive Hazards: In areas where flammable liquids or explosive gasses may be present, consideration should be given to the proper design of both impressed current and sacrificial anode cathodic protection systems. Such areas include, but are not limited to, fuel storage farms, fuel terminals and fueling areas, refineries, ammunition depots, and manholes (sewer gas). As the protective currents used for cathodic protection flow through the environment without inherently causing arcing or appreciable resistive heating, cathodic protection can be safely used in such environments. However, cathodic protection rectifiers to be used in such applications should be special oilimmersed explosion-proof types, or should be located outside of the hazardous area. In addition, all connections should be made in explosion proof housings. In addition to explosive liquid and gas situations, currents from impressed current systems can be picked up on blasting leads and could cause detonation of the blasting caps. Impressed current cathodic protection systems should be turned off whenever there is blasting in the vicinity.

1.5.2. Bonding for Electrical Safety: Electrical bonding is often required for safety where ships, vehicles, or aircraft are fueled or loaded. Any voltage gradient in the soil can result in a potential difference between structures located at different points. These potential differences can result in dangerous arcing. Cathodic protection systems can increase the level of such voltage gradients. The normal electrical bonding used in such circumstances is sufficient to mitigate this hazard. The voltage gradients produced by cathodic protection systems can also cause arcing when, during pipeline repairs, the pipeline is severed. A temporary bond installed across the pipeline before cutting should be used to prevent this hazard. Interference caused by docking a vessel in the vicinity of a cathodically protected pier or quay wall can cause accelerated attack on the

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vessel. This problem is normally prevented by using a direct bond between the protected structure and the vessel. 1.5.3. Induced Alternating Currents: For any large structure in the vicinity of ac electrical transmission lines, ac can be induced on underground or aboveground components of cathodic protection systems, including the structure being protected. This is particularly true if the structure is well coated or isolated from the ground and is oriented parallel to the transmission lines. Pipelines using the same right of way as the transmission lines are particularly susceptible to induced ac voltages. In addition to causing corrosion damage, these voltages can be dangerous to personnel who may come in contact with the structure or cathodic protection system. The location of the ac transmission lines should be noted during the design of cathodic protection systems. The effects of induced currents and relocation of either the transmission line or the planned system should also be considered. Location of test station in areas where induced currents may exist should be particularly avoided. Induced currents should also be considered when performing cathodic protection field surveys or other electrical tests in the vicinity of ac transmission lines.

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Chapter -2 Literature Review

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1. Corrosion and cathodic protection theory By James B. Bushman. This discusses about the corrosion, causes behind the corrosion and the protection from the corrosion reaction.

2. Coatings used in conjunction with cathodic protection system- Shielding and Non shielding pipeline coating By Richard Norsworthy. This paper discusses about the cathodic protection on coated pipeline. It also discuss about the compatibility of different types of coating with the cathodic protection system.

3. Design and optimization of pipeline cathodic protection system by Marius purcar. This discuss about to determine and predict corrosion mechanisms and to develop effective protection technique. 4. Cathodic Protection Anode Selection The purpose of this Public Works Technical Bulletin (PWTB) is to transmit current information on selection criteria for both Galvanic and Impressed Current Anodes that may be installed with new or existing Cathodic Protection Systems. 5. Electrical Engineering Cathodic Protection This manual is intended for use in the design and construction of cathodic protection systems for the mitigation of corrosion of buried or submerged metallic structures.

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Chapter- 3 Theoretical Development Of Cathodic Protection System

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3.0. 3.1.

Theoretical Design of Cathodic Protection System Estimation of current requirement:

To calculate the current requirement we need some data related to: 1. Expected leakage conductance in 1000 ohm cm, type of coating used. 2. Pipeline is used for which service i.e. transportation pipeline, gas distribution etc. 3. Soil resistivity of the areas.

Average coating conductance Quality of work Siemens/ft2 Siemens/m2

Long pipeline with few fittings Excellent Good Fair Poor Bare pipe (2 to 12) (5 cm to 30 cm) <1 * 10-5 1 * 10-5 to 5 * 10-5 5 * 10-5 to 1 * 10-4 >1 * 10-4 4 * 10-3 to 2 * 10-2 <1 *10-4 1 * 10-4 to 5 * 10-4 5 * 10-4 to 1 * 10-3 >1 * 10-3 4 * 10-2 to 2 * 10-1

Gas or Water Distribution with Many Fittings Excellent Good Fair Poor Bare pipe (2 to 12) (5 cm to 30 cm) <5 * 10-5 5 * 10-5 to 1 * 10-4 1 * 10-4 to 5 * 10-4 >5 * 10-4 4 * 10-3 to 2 * 10-2 <5 10-4 1 * 10-3 to 5 * 10-4 1 * 10-3 to 5 * 10-3 >5 * 10-3 -2 4 * 10 to 2 * 10-1

Table -3: Average Coating Conductance

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3.1.1. Algorithm to calculate the current requirement for C.P. system:

1. Calculate the total surface area for proposed pipeline. AS = DL Where, AS = Total surface area of proposed pipe, D= Diameter of the pipe,

2. Calculate estimated leakage conductance.

G= g* A Where, g = coating leakage conductance per unit area, G= Average coating leakage conductance

3. Calculate the resistance. Resistance = 1/conductance 4. Calculate the current required from Ohms law.

I =E/R 3.2. Estimation of soil resistivity: The resistivity of soil is calculated by: = 6.28 SR Where, = resistivity (ohm-cm) S = spacing between pins (cm)

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R = resistance measured (ohms) If the spacing measured in foot then the expression will be: = 191.5 SR 3.3. Ground bed design:

The resistance of the ground bed can be formulated by: =

Where, = Average soil resistivity, L= length of ground bed, d = Diameter of ground bed, h = Depth of ground bed

0.005 4 {ln + ln( /) 2 + (2/)}

3.4.

Calculation of maximum length protected by cathodic protection system:

3.4.1. Formula used for maximum length protected by C.P. system: ln = Where, EA :- voltage change at drain point, ET: - Voltage change at the end of finite line, L: - length of the line in meter. : - Attenuation Constant.

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This can be calculated by the relationship:

= Where, RS :- resistance per km, RL :- coating leakage resistance per km,

Now to calculate Rs, Rs = :- Steel Resistivity, LP: - unit length of pipe, a :- cross section area of pipe,

RL can be calculated by: RL = Where, g: - Coating leakage conductance a1:- Unit surface area per meter of pipe
1
1

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3.5.

PRECAUTIONS FOR CATHODIC PROTECTION SYSTEM DESIGN

3.5.1. Introduction: Cathodic protection systems depend upon the application of electrical currents to counterbalance the natural tendency of metals to revert to their low energy combined states. In addition to the hazards involved with the operation of any electrical device, cathodic protection systems may, through the flow of current in undesirable paths, accelerate the corrosion of other structures in the vicinity of the structure being protected. Potentials exceeding above the standards can result in system damage. Potentials less than those required for complete protection usually result in some protection on most areas of the structure and do not result in attack at rates greater than for completely unprotected structures of similar materials and conditions . 3.5.2. Excessive Currents and Voltages

Flow of current in undesirable paths is proportional to the total amount of current flowing in the cathodic protection system, all other factors being equal. Thus, protection of well coated structures that require small amounts of current for protection will cause fewer problems than protection of poorly coated or bare structures that require substantially more current. Assuming that damaging potential levels such as those resulting in coating damage or hydrogen embrittlement are not reached, excessive currents will not cause deterioration of the structure being protected but can cause severe localized attack of adjacent structures.

3.5.3. Interference: The flow of current in undesirable paths resulting in accelerated attack of adjacent structures is called "interference." The adjacent structures are commonly called "foreign" structures. There are two type of mechanism. In first case the undesired current flows through two buried pipelines in the vicinity of the protected system. Corrosion is accelerated at locations where positive ions are forced to enter the environment from the metal surfaces. Although corrosion is not usually accelerated on the protected structure, cathodic interference can disturb the desired current distribution on the structure being protected and can reduce the amount of protection being received in some areas to a level below that required for complete protection. Corrosion occurs where the current leaves the structure and enters the electrolyte. In some models of electricity, the
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flow of positive ions in the electrolyte is used to establish the flow of imaginary positive charges in the metallic path used to describe conventional "current flow." However, conventional current flow is widely used in the cathodic protection industry and the flow of ions (positive) through the electrolyte should be described for each situation in order to avoid confusion. This description of electron and ion flow will be used throughout to explain what is actually happening. In second case the potential gradient surrounding an impressed current anode results in an electron flow along a foreign structure. This flow is described as positive ion (conventional) current flow from the anode, through the electrolyte, to the pipe (cathode) and continuing on along the pipe (imaginary) to the point of discharge (anode area) where accelerated corrosion occurs.

3.5.4. Effects of High Current Density. Excessive current density can result in hydrogen embrittlement or coating disbondment. In many cases, improper location of the ground beds in an impressed current system or interference from foreign structures can result in uneven current distribution on the protected structure. In order to achieve protective potentials in some areas of the structure, excessive potentials are experienced in other areas of the structure. This situation can be corrected by installing additional anodes or relocating the anode bed to achieve a more even current distribution. In some cases, the structure can be separated into sections and the current distribution improved by the installation of resistive connections between the structure and the rectifier. Excessive potentials are seldom experienced in sacrificial anode systems but if experienced can usually be corrected through the installation of resistors in selected anode lead wires.

3.5.5. Effects of Electrolyte pH: Aluminum and lead should not be cathodically protected in some environments where the pH is greater than 8.0. In tight soils such as clay, the alkali formed around the cathode by cathodic protection will increase the pH to very high levels and cause severe chemical attack on lead and aluminum. Where the electrolyte is water which is moving and exchanged, the alkali formed by cathodic protection can wash away and the adverse effects of cathodic protection on lead and aluminum are reduced. Some types of protective coatings, particularly the alkyds, can also be
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damaged by highly alkaline environments Low pH (acidic) conditions can also cause problems with both corrosion and cathodic protection. In soils with a pH lower than 3.0, current density requirements for the protection of steel can be up to 10 times as high as those required for protection of steel in neutral soil. These excessive current requirements make cathodic protection in such environments difficult and costly. The use of high quality coatings in conjunction with cathodic protection in such environments is essential.

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Chapter 4 Calculations

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4.1.

Assumption:

Some assumptions are made: 1. Grade of the pipeline: X- 42 2. Coating used for pipeline: three layer polyethylene 3. Length of pipeline: 56 * 103m, 4. Diameter of the pipeline: 30.48 * 10-2 m 5. Average leakage conductance unit area: 50 * 10-6 MHOS/m2, 6. Average potential shift: -0.450 volts 7. Steel Resistivity: 2.2 * 10-7 ohm-meter, 8. Soil resistivity: 1000 ohm- cm, 9. Loop impedance: 0.5 ohm 10. Length of ground bed: 15 m 11. Depth of ground bed: 1.0 m 12. Diameter of ground bed: 50*10-2 m

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4.2.

Current estimation:

4.2.1. Calculate the total surface area for proposed pipeline. AS = DL, As = * 30.48 * 10-2*56 * 103 As = 53623.21669 m2

4.2.2. Calculate estimated leakage conductance.

G= g* A G= 50 * 10-6 * 53623.21669 G= 2.6811608 Siemens

4.2.3. Calculate the resistance. Resistance = 1/conductance Resistance= 1/2.6811608 Resistance = 0.3729 ohm 4.2.4. Calculate the current required from Ohms law.

I =E/R I= .45/0.3729 I= 1.2067 amp

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4.3.

Ground Bed Design: Resistance of ground bed can be calculated by: = 0.005 4 {ln + ln( /) 2 + (2/)} 0.005 1000 4 15 {ln + ln( 15/1) 2 + (2/15)} 15 50 102

R = 0.59724 ohm 4.4. Calculation for maximum length protected by C.P. system: Length of the pipeline: 56* 103 km Outside diameter: 12 inch or 30.48 * 10-2 m. Thickness of the pipe: 0.25 inch or 0.635 *10 -2 m Coating leakage conductance/ m2 (g):- 50*10-6 MHOS/ m2 Now, =
100

RL = 5010 6 .6351 RL = 100255.08 ohm

Now, = RS = /4{.3048 2 .29845 2 } Rs =7.3124* 10-5 ohm

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2.211 7

Now,

7.3124 10 5 100255 .08

= 2.7007 * 10-5 Finally,

Taking potential at drainage (EA) = -1.25 V Taking potential at the end of drainage point = - 0.45 V Taking protection from two directions: ET/2 = 0.45/2 ET/2 =0.225 V
.225 L = 2.7007 10 5

ln

1.25

L = 63.5 Km.

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Chapter -5 Conclusion and Result

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5. Result : In the present context, pipeline is the modern mode of the transportation of the petroleum products. The effective performance of the pipeline is the major concern for any industry. Cathodic protection system is one of the technique which can additionally improve the performance of the pipeline. This technique may also increase the life pipeline from getting deteriorated. The focus is projected on the to design the permanent c.p. system for gas pipeline from haridwar to dehradun. With the help of some basic data like length of pipeline, diameter of the pipeline etc. and from the calculations, it is noted that: The current required to protect the pipeline is 1.2067 amp and the resistance of the ground bed on the basis of assumption made is 0.59724 ohm. In 12 OD and three layer polyethylene coated pipeline one cp station cover the distance up to 63.5 km. Hence one cp station is required to install for the pipeline of the length of 56 km.

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Chapter -6 Bibliography

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Books Referred 1. Marshall E Parker and Edward G. Peattie ; Pipeline Corrosion and Cathodic Protection System; Gulf Professional Publishing, Third Edition, 1999. 2. A.W.Peabody; Control Of Pipeline Corrosion, NACE Press, Second Edition, 2001. 3. Donald L. Basham; Electrical Engineering Cathodic Protection, 2004. 4. L.L. Shreir, R.A.Jarman; Corrosion 1(Metal/ Environmental Effects). Butterworth-Heinmann Publications, 2000. 5. L.L. Shreir, R.A.Jarman; Corrosion 1(Corrosion Control). Butterworth-Heinmann Publications, 2000. Journal Referred 1. James B. Bushman; Corrosion and cathodic protection theory. 2. Richard Norsworthy; Coatings used in conjunction with cathodic protection systemShielding and Non shielding pipeline coating. 3. Marius purcar; Design and optimization of pipeline cathodic protection system. 4. DNV RP b401- Cathodic Protection System Design. 5. NACE M-503- Cathodic Protection Design.

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