protection cathodic (2) (2).pdf

8/19/2019 protection cathodic (2) (2).pdf

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Cathodic Protection

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D€finition of Corrosion

The chemical or electrochemical reaction between a material and its environments

that produces a deterioration of the material and its properties

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problem

Degradation of technical qualities of the system

Activation in neutron flux corrosion products

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€ Choice of metal or alloys

€Reagent external environment adaptation

€ metal insulation

€Imposed current protection

€Chemical (water purity, Ph)

Solutions

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Cathodic protection

Cathodic protection controls corrosion by making the whole metal surface a cathode of an electrochemical

cell

Cathodic protection can be achieved in two ways:

€ By Sacrificial Anodes.

€ By Impressed Current.

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Sacrificial Anode

In this method, Metallic structure is connected to more anodic metal.

The more active metal so employed is called sacrificial anode.

Galvanic series

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Applications of sacrificial method

•Protection of buried pipelines.

Sacrificialanode

Backfill

Pipeline

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Water tanks

Sacrificial Anode

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Marine structures

Sacrificiel anode

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Pipe lines

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Metals like (Zn, Mg, Al) are used for making anode because they are more active €lowelectrochemical potential• as compared to steel.

Zinc

‚generally used for the protection of pipelines, where the effects of burial along

with the high duty coating tend to give low anode current densities.

‚high efficiency

‚low current output

‚driving voltage diminishes with increasing temperature ‚ virtually ineffective at

temperatures of about 60o c.

Choice of Galvanic Anode Material

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‚high capacities

‚ capable of operating at high temperatures upto

100o c.

‚alloy compositions relatively tolerant of trace

impurities

‚offer an economic solution to sea water protection.

Aluminium

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‚dissolves vigorously in sea water ‚ use restricted only to soil applications or

estuarine waters (high resistivity)

‚high rate of intergranular corrosion ‚ especially in low resistivity soils

‚high current output

‚low current output efficiency

Magn€sium

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Anode Recommended Electrolyte

Magnesium (Mg) Soils & hot water

Zinc (Zn) Soils & fresh / sea water

Aluminum (Al) Sea waters

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Prepackaged Sacrificial Anode

Mg

For soil applications: prepackaged Mg & Zn anodes

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Carbonaceous backfill

€ Low resistivity to reduce anode to earth resistance.

€ High porosity to allow gases produced at the surface of the anode to escape.

€ Low density to provide high permeability with cost effectiveness.

€ In addition, the backfill should flow easily, and be of high purity.

Backfill

Property 218-L 4518

ƒ Resistivity,

ohm-inch0.02 0.01

ƒ Resistivity,

ohm-cm0.05 0.03

ƒ Carbon (L.O.I.

method)99.0 99.9%

ƒ Moisture 0.10% 0.02%

ƒ Ash 0.35% 0.10%

ƒ VCM 0.30% 0/22%

ƒ Sulfur 3.75% 4.3%

ƒ Bulk Density(lbs/ft3)

46-50 62-66

ƒ General Sizing

+ 4 Mesh

+ 8 Mesh

- 8 Mesh

+4M < 10%

+8M > 90%

-8M < 10%

4M 10%

+20M > 80%

-20M 10%P

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sacrificial anode properties

Potentiel CuSO4

(V)

Potentiel Ag/Agcl(v) Consumption rate

(kgper/A/year)

Current capacity(Ah/kg)

Magnƒsium -1.50( standard) - 7.3 1100

-1.70(high

potentiel)

- 7.3 1230

Aluminium - -1.1( Beralin ) 3.27( Beralin ) 2680( Beralin )

- -1.12(Becalin) 3.45 (Becalin) 2550( Becalin)Zinc -1.00 -1.05 11.5 760

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Les formes de anode Aluminium et Zinc

Slender ( stand-off )

Straight flat bar

Double crank flat bar

Application

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Flush mounted

Application

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Bracelet

Half-Shell Bracelet Anode segmented Bracelet Anode

Application

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Magnesium and Zinc Ribbon anodes

Application

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Spherical

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Type of anode Value of Utilization Factor

Long-slender tand off (L>4r)

Short -slender tand off (L4r) 0.85

Short-flush mounted (L


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Impressed Current

‚ ICCP systems use anodes connected to a DC source.

‚For lar ger structures, galvanic anodes can€t economically deliver

enough current to provide complete protection.

‚The negative terminal of DC is connected to pipeline to be protected.The anode is kept in back fill to increase the electrical contact with the

surrounding soil.

‚This current is given to insoluble anode like graphite, stainless steel or

scrap iron buried in soil.

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The anodes are classified into 2 large families

„consumables( produits ferreux, acier,fonte)

„No consommables (graphite imprƒgnƒ , ferro-silicuim ,magnƒtite ,Mixed Metal oxide (MMO),High-silicium cost iron (HSCI ), titane platinƒ

,niobium platinƒ)

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consumables( ferreux ,acier)

Tubular Tubular

Place Consumption rate Current density Density

Water, soil 9kg/A.year No limitƒ 7.8g/cm3

ƒ Are the most common impressed current anodes

ƒ Are used in soil, water or sea water

ƒ Come in two grades; FeSi and FeSiCr for sea water applications

ƒ Cable connection to anode shall be handled with great care.

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No consumable

Anode Type

For seawater applications

1.Mixed metal oxide ‚ coated titanium.

2. Platinised titanium/niobium.

3. Lead-silver-antimony.

4. Silicon iron with chrome.

5. Magnetite.

For buried applications

1.Mixed metal oxide ‚ coated titanium.

2. Scrap iron

3. Lead-silver-antimony.

4. Silicon iron with chrome.

5. Graphite

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Mixed Metal oxide (MMO)

Is corrosion proof anode coat Ir and Ta on titanium substrate pevided ,Ribbon,Mesh and tubular

By it„s form used to prevent corrosion for storage tank bottom,pipe and offshore structures

Forme Weight Application Avantages et d€savantages

Ribbon ,

Mesh et tubular

, wire ,rod

27kg pile, tank

bottom,

Tend to use MMO anode

Light weight

High durability , variaty form

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Types MMO anodes

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MMO-Ribbon Anode

RibbonRibbon

Tableau de Dimensions

Consumption r ate Out put current Current d ensity Design life

0.5-4 mg/A/year 0.45mA/m 3A/m… 50 years

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Application

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MMO-Mesh Anode

Tableau de Dimensions

Consumption r ate Out put current Current d ensity Design life

- 3.5mA/m 110A/m… 100 years

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Application

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Anode MMO-Tubular

Environement Size anode Out put current

(A/m)

Current

density(A/m…)

Design life

Diameter(m

m)

Length(mm)

Carbounacious

Brakfill 25

500 4 50 20

1000 8

Calcined

petrolum coke

25 500 4 100 20

Fresh water 25 1000 8 100 20

Brackich water 25 1000 8 100-600 20

Sea water 25 500 25 600 20

1000 50

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Application

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MMO-wire Anode

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Application

•TANKS above ground

•Underground Storage Tanks

•TANKS WATER

•Shallow horizontal•NATURAL WATER

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MMO-ROD Anode

Dimeter(inch )

Length (inch) Out put current (A/inch) Current density

(A/m…)

Design life

Carbounacious

Brakfill

0.125

0.25

0.50

0.75

39.37 0.035

0.069

0.140

0.210

50 20 years

Calcined petrolum coke

-

0.125

0.25

0.50

0.75

39.37 0.035

0.069

0.140

0.210

100 20 years

Freshwater

-

0.125

0.25

0.50

0.75

39.37 0.044

0.088

0.167

0.270

100 20 years

Brackichwater

-

0.125

0.25

0.50

0.75

39.37 0.123

0.245

0.490

0.740

100-300 20 years

Sea water

0.0006 to 0.006

0.125

0.25

0.50

0.75

39.37 0.123

0.245

0.490

0.740

600 20 years

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Application

•PUMPS

•CONDENSERS and water boxes

•Water intakes

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high-silicon cost iron (HSCI)

Tubular Anode Rod sitck Anode

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Rod sitck Anode

Environement Current density(A/m…)

soil 10-30

Sea water 10-50

Fresh water 10-30

Tubular Anode

Consumption rate : 0.45kg/A/year, utilization factor : 0.65

Consumption rate : 0.25kg/A/year, utilization factor : 0.85

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Application

Avantages & d€savantages

€Most universal matƒriel

€Strong fragility

€Bad construct ability

underground piping

underground tank

the tank bottom

inside of the water tank

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Flexible anode

‚PROTECT MULTIPLE PIPELINES IN A CORRIDOR †

‚EASY TO INSTALL ALONG WITH PIPE IN THE SAME TRENCH.

‚MULTIPLE LINEAR ANODES CAN BE DEPLOYED TO ENSURE

Diameter (mm) Length (m) Out put current

(mA/m)

Backfill weight weight

38 500-1000 52-1000 1.15kg/m 1.5kg/m

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Application

Parallel Anode Pipeline CP

Underground Cable Ducts CP

New Construction Tank Bottom CPReplacement Tank Bottom CP

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Graphite anode

Avantages D€savantages

€Readily available in a variety of sizes

relatively inexpensive

€ A good conductor of electricity

€ high ratio of surface area to weight

improve low current density current

discharge and low resistance

electrolyte€ chemically resistant

€Do not form a high resistance layer

corrosion products

€ Easy to machine

€Operating at low current density

€lower mechanical strength, very fragile

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Consumption rate& current density

Dimensions

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Magn€tite Anode

Characteristic of Magn€tite anode •operates at high current densities with

extremely low dissolution

•not susceptible to ripple in DC supply

•no limit on DC voltage output

•light weight and easy to install, removable for

inspection and reinstallment

•centre cable-to-anode connection for uniform

current distribution and consumption of anode

surface

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Type of magn€tite anode

Applications :shallow groundbeds, deep groundbeds

Place: neutral soil and water without chlorine and sulphate content

Place :chlorine and/or sulphate containing soil or stagnant water

Applications:shallow groundbeds, deep groundbeds

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Coke brackfill

CANISTER FOR TYPE: MA-U + TYPE: MA-CS

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Application

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Place : flowing seawater or brackish water

Applications: platforms, jetties, harbours

Place :chlorine containing soil or stagnant water

Applications: deep groundbeds open hole, deep groundbeds closed

hole, water tanks

Place : chlorine containing soil or stagnant water

Applications: deep groundbeds open hole, deep groundbeds closed

hole, water tanksP

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Platinised Titanium/Niobium

Pt/Ti-Nb- Rod anodes

Screw-in type Pt/Ti-Nb rod anodes with pressure

resistant head structure are widely used for internal

protection of condensers and other process equipment

Niobium (Nb)

Passive film formation, high cost, high

breakdown potential, fair conductivity.

Titanium (Ti)Passive film formation, low cost, low

breakdown potential, poor conductivity

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Pt/Ti-NbMesh anodes

Pt/Ti-Nb mesh anodes are used for the protection

of reinforced concrete structures.

Pt/Ti-Nb Wire anodes

Pt/Ti-Nb wire anodes are used for the internal protection of water

tanks and pipelines.P

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Electrochemical characteristics of impressed current anodes

Anode Materiels Consumption

Rate (g/Ay)

Maximum current

(A/m•)

Maximum

voltage(V)

MMO-Seawater-

MMO-buried-

0.0006 to 0.006

0.006to 0.008

400to 1000

80to100

8

Platinised

titanium-

seawater-

0.004to 0.012 500to 1000 8

Platinised

Niobium-seawater-

0.004to0.012 500to1000 50

Lead silver-

seawater-

15to75 150to250 24

Silicon iron

chrome-buried-

100to300 10to30 50

Magnetite-buried 2to 3 80to100 50

Graphite ‚buried- 200to500 5to15 50

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Transformer rectifier

The rectifier transformers are used for current cathodic protection systems imposed from undergroundstructures or submerged.

Transformer rectifier int€rieur Transformer rectifier ext€rieur

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Types of transformers rectifier

Transformers rectifier ‚ Air cooled ƒTransformers rectifier ‚ oil cooled ƒ

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Air cooled ‚ standard Line ƒ

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Air Cooled „UT & SW Series…

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Air Cooled Gas Station Series

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Oil Cooled & Explosion Proof

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Oil Cooled & Explosion Proof

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ORD Oil Cooled & Explosion Proof

Rugged smaller rectifiers for lower output

applications under severe conditions

Maximum 200 watts & 20 amps single phase

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Air Cooled ES Line

Low output, low cost, lightweight cathodic protection

rectifiers for underground

storage tanks and other low DC power cathodic

protection applications maximum 200 wattts & 10amps

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Example of transforms rectifier forms

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Manual Rectifier

At each regular cycle operator confirm type potential

value and manually adjust voltage and current in order

to maintain target potential value.

For maintaining initially set type potential value such

value is feed back by rectifier automatically thusvoltage and current is controlled accordingly.

Automatic Rectifier

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Rectifier

Transformer

Characteristic of transformers rectifier

Tension entr€e Tension sortie Courant sortie Type de

redresseur

Fr€quence

230v AC/400v

AC

12,16,24,48,75,

100V DC

5,10,15,25,50,1

00,150,200,250,

300,400,500,60

0A DC

Silicium diode

Thyristor

50Hz/60Hz

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Anode jonction box

‚Specifically construted for CP system installations

‚Sufficient number of terminals ( five terminals minimum) with associated hardware for number and size

of cables

‚Equipped with variable resistors of adequate electrical rating for each anode

‚Equipped with combination bracket for pole or wall mounting

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Example of junction Box order form

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Test stations

• Specifically constructed for CP system installations

•Post is 7 foot ‚ long -3inch-diameter polyvinyl chloride (PVC) with a1/2 inch-diameter, solid PVC cross bar unless other

wire specified

•Sufficient number of terminal ( five terminal minimum)with associated hardware for the number and size of cable

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Vent Pipe

…Nominal 1-inch inside diameter

at surface

…Pipe below surface can be larger

than 1 inch in diameter and sized

as needed for depth of well and

per CP specification section

…The vent pipe should be slotted

within the coke backfill column and

non slotted outside the limits of

the coke backfill column

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Remote Monitoring Test Box

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Remote Monitoring Test Box

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cathodic protection system installation

Definition of Ground bed

System of buried or submerged anodes connected to positive terminal.

.

Types of ground beds

‡ Deep-well GB

‡ Horizontal shallow GB

‡ Vertical shallow GB

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Deep-well GB

One or more anodes installed vertically at a nominal depth of 50 m or more below the

earth's surface.

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Anode and vent pipe installation

„Attach the first anode to centralizer

„The vent pipe should be installed with the first anode by attaching it to one of

the centralizer straps with a stainless clamp as shown in

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„coke backfill materiel should be introduced into the bottom of the drill hole using a pipeis the length of the anode hole and a pumping action to fill the drill hole

„five feet of sand backfill placed on top of the coke backfill

„No anodes should be buried until the Earth has inspected the placement of anodes

and given permission to backfill

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The individual or multiple anode groundbed resistances can be determined using Dwight

formula or can be determined graphically

Shallow vertical groundbed ( depth 3m-5m)

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Shallow horizontal groundbed( depth 3m-5m)

Sometimes due to unfavorable soil conditions shallow horizontal groundbeds are preferred.

Again earth resistances can be determined by calculation.

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Avantages Disavantages

•Shallow ground beds are less expensive to install than the deep

ground beds.

• Current requirement tests that accurately simulate actual

installation are easy to conduct.

•Shallow ground beds may be installed with anodes either in

vertical or in horizontal position. Vertical anode ground bed has

slight edge over the horizontal ground bed in terms of resistance

and current spread. However, field condition lead to the

selection.

•Compaction of backfill material around the anode in a shallow

ground bed is easy to achieve.

•Anodes may be added in a shallow ground bed after installation

if required, provided there is capacity in the power supply and

the cable.

• Inspection, replacement or repair of ground bed components is

easy.

• Determination of shallow ground bed performance is easy and

fairly accurate.

•Shallow ground bed resistance is higher in areas of high

resistivity surface soils.

• Shallow ground beds are more affected by seasonal variations

than deep ground beds

• It may not be possible to install a shallow ground bed in

congested areas and areas of interference.

• Shallow ground bed may results in higher anodic potential

gradients to other structures than a deep ground bed.

Avantages & disavantages groundbed

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Cable Connections

… Cable † to - cable connection

… Cable † to - pipe connection

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straight joint

Low Voltage 1kV (1000v), Telecommunication

and Signalisation

- Underground, above ground, under water

Application

Cable † to - cable connection

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Jointing resin

€Very high resistance against UV, chemicals and earth alkaline & sea water

€High impact resistance

€Low curing temperature

€No toxic emission

€Good adhesion to all cable materials (PVC, PE, PP and XLPE)

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Application

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Cable † to - pipe connection

For cable-to-pipe connection :

1- Thermite ( Cad / Exothermic ) Welding

2- Pin Brazing

3- Mechanical connection ( for gas pipelines )

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Thermite welding

Cartridge

Crucible

Disks

Cartridge

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Thermite Plastic Weld Cap

„No Liquid Primer Needed

„ Easy Field-Applied Corrosion Protection

„Ideal for Keyhole Applications„Elastomeric Compound Encases Weld

Profile

„Serrations Conform to Small Diameter

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Application

Thermite Welding

1

2 3

4 5 6P

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Protecting the Thermite Weldment

http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/


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Protecting the Thermite Weldment

1 2 3

Self-adhesive

Handy-cap

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Pin Brazing

Pin Brazing Unit Pistol / Gun

Pins & FerrulesLug

Grinder

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1Clean the surface

2 Load gun with pin &ferrule

3 pin braze

4 Test connection

Application

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Mechanical Connection : recommended for drain point connection of gas

pipeli nes

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Electrical Isolation(Insulation)

Isolation joint Flange kit

•AC Fault Currents

‡ Mitigation of induced AC Voltages

‡ Lightning

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Type „E… GasketsType „F… Gaskets

Type "F" gaskets are made without

bolt holes, to fit tightly inside the

overall bolt hold circle of the flange

faces. The outside diameter of the

gasket fits tightly in place, assuring a

well centered position.

Type €E• Gaskets extend to theoutside diameter of the flange.

They feature precision located

bolt holes, to automatically center

the gasket, and offer maximum

protection against foreign

material €shorting-out• the flange


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http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/


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Polarization cell

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Monoblock joints

€Resistance in air: greater than 5 Mˆ

€Testing voltage: 3 000 V - 50 Hz€ Hydraulic test pressure: 1.5 x PN

€Temperature: up to 70‰ C

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Surge Protection

Type HGS 100 EX EC-Type Examination Certificate

DC Spark-Over Voltage 400 ‚. 750 kV

AC Spark-Over Voltage (50Hz) > 500 Vrms

Impulse Spark-Over Voltage at 5kV/-for 99% of measured values (Wave 1.2/50, 6kV)

< 1500 V

Max. Impulse Discharge Current (wave 8/20) 150 kA

Nominal Impulse Discharge Current (wave 8/20) 75 kA

Max. Lightening Impulse Current Iipm (10/350) 100 kA

Charge 50 As

Specific Energy 2500 kJ/

Insulation Resistance at 100VDC > 1 GCapacitance at 1MHz 5 pF

Weight 535 g

CasingKorundum/ binary resin with an external

Steel Coat, resistant to climatic effects

Degree of Protection IP66

Operating and Storage Temperature -40‚.+90oCOrdering Code 100 04

Specification

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Application

http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/http://localhost/var/www/apps/conversion/tmp/scratch_2/

8/19/2019

Date post:	08-Jul-2018
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