Corrosion Management on

Pipeline with Cathodic

Protection
Ilmu Bahan dan Korosi
Outline
Pipeline Risks and Corrosion
Cp Technique : Galvanic Sacrificial
Anode (Principle, Installation)
Cp Technique : Impressed Current
(Principle, Installation)
Case Study : Sacrificial Anode
Case Study : Impressed Current





The product of the frequency with which
an event is anticipated to occur and the
consequence of the event outcome.
Risks on Pipeline
RISK = PROBABILITY x SEVERITY

LEAKAGE
CORROSION
PRESSURE
DROP
Risks on Pipeline
Corrosion Control
Coating : insulation
Cathodic Protection: DC current
injection towards pipeline, result:
pipeline is shifted as cathode.
Sacrificial anode
Impressed current
Galvanic Sacrificial Anode -
Principle
Metal Driving voltage (Vd)
Negative Vd = active metal =tendency
to corrode
Pipeline: connected with active metal
Anode: Mg, Zn Cathode: pipeline
Corrosion on Mg, Zn hence sacrificial


Galvanic Sacrificial Anode-
Principle
Material Driving Voltage (V)
Silver (Ag/Ag
+
) +0.8 (cathodic)
Copper (Cu/Cu
2+
) +0.34
Water (O
2
+H
2
0+4e
-
= 4OH
-
) +0.401
Hydrogen (H
2
) 0 (reference)
Iron (Fe/Fe
2+
) -0.44
Zinc (Zn/Zn
2+
) -0.76
Magnesium (Mg
2+
) -2.36 (anodic)
Galvanic Sacrificial Anode-
Installation
(Source: Peabodys Control of Pipeline Corrosion)
Galvanic Sacrificial Anode-
Installation
(Source: Peabodys Control of Pipeline Corrosion)
Impressed Current
Minimum potential: -0.85V
Reference electrode: Copper Sulfate
(Source: Peabodys Control of Pipeline Corrosion)
Galvanic Sacrificial Anode-
Design
Calculate total area to be protected (Ap)
Determine the current density ()
Calculate total protection current (Itot = .Ap)
Calculate R per anode : R = f(d,l,)
Calculate Ia per anode : (Vd-0.85/R)
Calculate total anode needed :
Initial : N=Itot/In
Lifetime: N = f(mass,lifetime,A/poundyear)


Impressed Current-Principle
Rectifier
Variable voltage, variable current
Higher current density (> 1 A)
Higher soil resistivity (> 10
4
cm)


Impressed Current-Installation
Types of anode:
Graphite : big CR (pound/A/year)
High Silicon Cast Iron : medium CR
Platinum & niobium : small CR
Rectifier rating:
Voltage, Amperes, Watt, Freq.
Cooling System : Air, Oil
Efficiency
CR: Consumption Rate
Impressed Current - Installation
(Source: Peabodys Control of Pipeline Corrosion)
Impressed Current - Design
Calculate total area to be protected (Ap)
Determine curent density ()
Calculate total protection current (Ip)
Calculate total anode needed (N)
Initial
Lifetime
Calculate total anode resistance (Rtot =
f(N,,d,L,spacing))
Calculate rectifier specification (Vdc, Idc, Pdc =
f(Rtot,Ip)
Pipeline Cathodic Protection
Case Study
Galvanic Sacrificial Anode
Case Study
Variabel Nilai
Pipe Diameter (d) a. 2 inch = 0.0508m
b. 1 inch = 0.0254m
Pipe Length (l) a. 2 inch pipe: 300m
b. 1 inch pipe: 1300m
Soil Resistivity (average) 4500 cm
Current Density () 9mA/sqmm
Type of Anode Magnesium, weight 9 pon, r =8.89cm, l = 53.54cm
Coating efficiency (n) 50%
Lifetime 20 years
Galvanic Sacrificial Anode
Case Study
Step 1: surface area of pipeline


Step 2: total protection area

Step 3: total protection current



2 2
806 , 75 613 , 151 % 50 m m Ap n Ac = = =
A mA m sqm mA Ac Ip 682 , 0 254 , 682 806 , 75 / 9
2
= = = =
Galvanic Sacrificial Anode
Case Study
Step 4: Anode resistance (Dwights Equation)



Step 5: Current per Anode






O =
(

=
(

= 15 , 29 1
89 , 8
54 , 53 4
ln
54 , 53
159 , 0
4500 1
4
ln
159 , 0
r
L
L
R
mA
Rae
E
ctrolyte ceAnodeEle sis
e teelVoltag Polariseds tage DrivingVol
Ia 024 , 0
15 , 29
85 , 0 55 , 1
tan Re
=

=
A
=

=
Galvanic Sacrificial Anode
Case Study
Step 6: Total Number of Anode
Initial

Lifetime

Selected number of anodes: 31.








anodes
mA
A
Ia
Ip
N 41 . 28
024 , 0
682 , 0
= = =
anodes
t AnodeWeigh
Ip Lifetime
N 75 . 30
9 3 , 49
254 , 682 20
3 , 49
=

=
Galvanic Sacrificial Anode
Case Study
Step 7: Distribution and Layout
Distribution


Layout










2
445 . 2
31
806 . 75
m
N
Ac
A = = =
2
935 . 23 300 0508 , 0 5 . 0 m = t
10 445 , 2 : 93 , 23 =
2
87 . 51 1300 0254 , 0 5 , 0 m = t 21 445 , 2 : 87 . 51 =
Type of Pipe Effective Surface (Ac) Number of Anode
(Ac/A)
Diameter 2inch
(0.0508m)
Diameter 1inch
(0.0254m)
Total
31
Impressed Current
Case Study
Variabel Value
Pipe Diameter (d) 6 inch = 0,1524 m
Pipe Lengyth (l) 6800 feet = 2072 m = 2,072 km
Soil Resistivity (average) 2000 cm
Current Density () 30mA/sqmm
Type of Anode Stated in next section
Coating Efficiency (n) 50%
Coating Impedance 25000/m
2

Maximum Groundbed
Resistance
2
Lifetime 15years
Impressed Current
Case Study
Step 1: surface area of pipeline

Step 2: total protection area

Step 3: total protection current

Step 4: determine type of anodes
Iron Silicon Chromium. Weight: 110 pon, cross section 4 sqft (0,371m2),
diameter 10 inch (0,833 feet = 2,54cm), length 84 inchi (7 feet = 20,32cm)





2
03 , 992 2072 1524 , 0 m dl Ap = = = t t
2 2
015 , 496 03 , 992 % 50 m m Ap n Ac = = =
A mA m sqm mA Ac Ip 88 , 14 45 , 14880 015 , 496 / 30
2
= = = =
Impressed Current
Case Study

Step 5: total number of anodes
Current limit (silicon: 10.76 A/m
2
)

Lifetime

Total anodes: 4.





anode
m
A
m
A
Ic Ai
Ip
N 72 , 3
76 , 10 371 , 0
88 , 14
2
2
=

=
anode
pon
mA
t AnodeWeigh
Ip Lifetime
N 02 , 2
110 1000
14880 15
1000
=

=
Impressed Current Case
Study
Step 6: groundbed resistance calculation
Resistance limit: 2 (to limit rectifiers spec)
Spacing: S = 30 feet , Anode Length: L = 7 feet
Anode Diameter: D = 0.8333 feet





Groundbed resistance is below limit.
If not, choose longer spacing.






O =
|
.
|

\
|

=
+

=
36 . 1
4 656 . 0 ln
30
7 2
1
833 . 0
7 8
ln
4 7
2000 00521 . 0

) 656 . 0 ln
2
1
8
(ln
00521 . 0
N
S
L
d
L
N L
Rg

Impressed Current -
Principle

Step 7: rectifier specification


Specification: 21VDC, 302W .

Final Results:
Anodes : Iron Silicon Chromium, 4 anodes.
Rectifier : 21VDC, 302W.





W Ip Vrec Srec
V Rg Ip Vrec
123 , 301
. 237 , 20 36 . 1 88 , 14
= =
= = =