CATHODIC PROTECTION

TALEGAON BOOSTER STATION

HARILAL NENAVATH
ASSISTANT MANAGER-OPERATIONS
 CP TRU/CPPSM details- MPSPL (Trombay to Pakni)

Sr. Description Chainage Sr. No. Description Chainage

No. (Kms) (Kms)
1 Trombay (WO & BO) 1.7 (IJ) 1 Loni Station 161.0 (IJ)
2 MANKHURD 7.1 2 SV-1 185.2
3 MOV-1 (WO & BO) 10 (IJ) 3 SV-2 222.1
4 VASHIGAON (WO & 13 (IJ) 4 SV-3 260.2
BO) 5 SV-4 287.6
5 VASHI (WO & BO) 21 (IJ) 6 SV-5 325.2
6 POYANJE 45.2 7 Hazarwadi RS 346 (IJ)
7 KHALAPUR 63.05
8 KHOPOLI 76 (IJ) 8 SV-6 372.3
9 TUNGARLI 82 10 SV-7 411.2
10 TALEGAON 112 (IJ) 11 SV-8 443
11 LOHEGAON 147.43 12 SV-9 476
12 Loni Station 161 (IJ) 13 Pakni RS 508.2 (IJ)
LIST OF CP EQUIPMETS/FACILITIES
1. TRU/CPPSM UNIT
2. TLPs
3. INSULATION JOINT
4. SPARK GAP ARRESTOR
5. GPS TIMER
6. ANODE BED
7. SACRIFICIAL ANODE
8. CORROSION PROBE
9. CORROSION COUPON
10. POLARISATION CELL
11. HOLIDAY DETECTOR
12. PDM
 BASIC CIRCUIT DIAGRAM

TR/CPPSM Current interrupter

Anode Bed Pipe

 TBS CP SYSTEM SCHEMATIC
IJ MOV IJ
TROMBAY
LONI
Ref.1 Ref.2

Cu BUSBAR
SHUNT
Variable resistor
TR UNIT
PSP
V
Fe. AJB
Ref.2 A
Ref.1
N P

HSCI ANODE BED

 TRU/CPPSM UNIT
 TBS is having M/s Kristron Systems make TRU Unit.
 Rating:50V,50A
 It has provision of AUTO/MANUAL System
 In case of any critical card failure, unit can be operated in Manual
mode.
How it works?
CRITICAL CARDS

104C 105D 106C

103A/B
REF.
AMPLIFIER FIRING SELECTOR
POWER CARD
CARD CARD CARD
 TLP
 There are various types of TLPs namely A,B,C,D,F,G,H,I&J
 Schematic Diagram of TLP connections:
TYPE- H

SGA

25 Sq.mm
4 Sq.mm

Ref.
 INSULATING JOINT

 IJs are used to separate the

pipeline electrically from terminal
facilities and pumping systems.
 They may be used also to divide
the line into sections so that
failure of CP systems or
development of contacts with
other structures or sections of the
pipeline will reduce the loss of
protection to an adjacent section.
 Rating of IJ:20kV,100M-Ohms.
 TESTING OF INSULATION JOINT

UGP IJ AGP

Normal Condition Failure of IJ

CP SYSTEM Protected Side Unprotected Side Protected Side Unprotected Side

ON -1.32 -0.456 -1.29 -1.20

OFF -1.15 -0.456 -1.12 -1.06
 SPARK GAP ARRESTOR
 Spark gap arrestor is used across
insulation joints for passage of Lightning
surges or any high voltages from
protected side to unprotected side of the
Pipeline or grounding through Sacrificial
anodes.
 It will maintain the isolation between
Protected and Unprotected side of the
pipeline so that CP current will not be
consumed/drained by unprotected
pipeline.
 The Spark Gap Arrestor shall be explosion
proof(Make:DEHN)
 Lightning impulse current (10/350 µs) (I-
imp):50 kA
 Rated impulse spark over voltage(1.2/50
µs) (Ur imp) <2.5 kV
TESTING OF SGA

100W Bulbs
SGA Ω Ω Ω Ω

500V

250V 800V

P N
0V 1100V

0 to101kV,500W
VARIAC 230V AC Source
 GPS TIMER
 Timer is designed for Time synchronization at multiple locations
 Real Time Clock (RTC) is synchronized within millisec. accuracy with the GPS clock
signal at regular intervals. This results in cancellation in any timing error due to drift
in the RTC of the timer unit.
 It can be programmed by user by setting date & time for ON/OFF survey.
 ON/OFF ratio preferred is 4:1.
CRITERIA FOR CATHODIC PROTECTION(OISD188,141)
 The minimum pipe to soil potential (PSP) shall be more negative than (-)0.85 volts
with respect to copper/copper sulphate half cell (Saturated Solution) and Max.
Value shall not be more negative than (-)1.2V.
 In areas where anaerobic bacteria are active minimum PSP shall be more
negative than (-)0.95 volts instead of( -) 0.85 volts.
OR
 A minimum negative (Cathodic) polarisation voltage decay of 100mV measured
between the pipeline surface and a reference electrode in contact with the
electrolyte.
 What is Polarised Potential?
Immediate OFF reading doesn’t represent the true Polarised
Potential of Pipeline as it is having inductive and capacitive
effects of Pipeline(Approx. time 0.3 Sec.)

NACE TM0497
 ANODE BED
• Anode Beds are mainly two types
– Deep well Anode Bed(Discrete Anodes and Continuous Anodes)
– Horizontal Anode Bed
• Anode material used are
– Graphite Anodes(2lbs/A-Y)
– High Silicon Cast Iron(1lb/A-Y)
– Ceramic Coated Titanium(Metal Oxide Coated)-1mg/A-Y
• Backfill material used are
– Petroleum coke(Calcinated):Increase effective area of anode and
reduces the resistance.
– Bentonite: (Absorbs water and retains moisture)
– Sodium sulphate: Act as catalyst for oxidation reaction.
• Anode Bed shall be located at Remote earth
• Anode Bed circuit resistance should be within 1Ω
• What is Remote Earth? Its significance.
 ANODE BED TESTNG
Deep well Continuous
Anode bed
Pipe

Cu BUSBAR
SHUNT TR

Variable resistor
AJB

HSCI ANODE BED Horizontal

Anode bed
 SACRIFICIAL ANODE
• Anode material used are
– Zn
– Mg
• Backfill material used:
– Zinc anodes shall be packaged in a
cotton bag and shall be surrounded by a
low resistivity chemical backfill of
following composition:
– Gypsum: 75 %(conductive environment
for anode dissolution).
– Bentonite: 20 %
– Sodium Sulphate: 5 %
• Anode shall be located min. Two
meters away from Pipeline
• OCV:-1.1V(wrt. Cu-Cuso4) for Zn. And
-1.65V for Mg.
 SACRIFICIAL ANODE TESTING
• Sacrificial anodes shall be tested for following
parameters at least once in Six months.
– Open Circuit Anode Potential
– Pipeline Potential (Anode‘OFF”)
– Pipeline Potential (Anode ‘ON’)
– Current Anode Output
 Testing of Casing Shorts
NORMAL CONDITION CASING SHORT
PSP CP SYSTEM CARRIER CASING CARRIER CASING

CP device ON -1.32 -0.456 -1.29 -1.29

OFF -1.15 -0.456 -1.12 -1.12

Vent Pipe

Casing

Anode Space
Pipe
rs

As per OISD 141 monitoring frequency :Quarterly

Internal Corrosion Coupon Monitoring
Calculations:
Test Coupon S.No. : XXXX
 Exposure in Days-"T" : 180
Initial Weight(g) : 16.8306
 Final Weight(g) : 16.75003
Weight Loss(g)-"W" : 0.08057
Exposed Area(mm2) -"A" : 1710
Density of Carbon Steel (g/cm2 )- “D”: 7.85
Corrosion Rate (CR) = 141.616 X 100000 X W/ (A X T X D)
= 0.469614335 MPY
39.4 MPY=1mmPY
Internal Corrosion Coupon Monitoring

Average corrosion rate

(MPY) Pitting rate (MPY)
<1.0 <5.0 Low
1.0-4.9 5.0 -7.9 Moderate
5.0-10 8.0 -15.0 High
>10.0 >15.0 Severe
 Corrosion Probe Monitoring

 R=ρL
A
 When the probe inserted in
the pipeline gets corroded, its
physical features like area of
cross section and the length
will vary.
 As cross section area and
length varies with corrosion,
resistance also varies. By
monitoring the resistance of
the probe, metal loss due to
the corrosion and the rate of
corrosion can be assessed by
current flowing through that
ER probe.
 Probe Monitoring-Internal Corrosion

Corrosion Rate (mpy) =0.365 x (Reading FINAL – Reading INITIAL) x Probe Span in MILS
Time in Days
 External Corrosion Monitoring

1,2,3-Ele.locations 4.Pipe 5.Soil 1.Pipe2.Backfill 3.Native Soil

4.Coupon(1cm2)
5.S.Resistor 6.Voltmeter
AC Current Density(Jac)=(8Vac/ρPi d)
Vac-Induced AC voltage
ρ –Soil resistivity(Ω-cm)
d –Holiday Diameter(cm)
*Ac current Density>30 A/m2-Chance of AC Corrosion(BS EN 15280)
 Polarisation Cell
• Polarisation Cell act as a electrochemical
switch blocking DC voltages in the CP
protection range
• It is having two no.s of metallic plates
immersed in 30% KOH solution
• Oil(Vaseline Oil) seal floating on the
electrolyte prevents evaporation,
absorption of atmospheric gases and
excessive foaming under high current
flow.
• Blocks voltages below 1.2V
• Solution Preparation:
– Remove the top cover and plates of
electrolyte cell
– Add KOH pellets and aprox.1.5 litres of
distilled water till solution level shows in
between max and min level.
– Mix slowly till pellets dissolve completely in
solution.
 Holiday Detector

• Holiday detector is used

to find the Holidays on
Pipeline coating.
• Holiday detector
operates on Battery
• It will develop a voltage
up to 20kV DC
• Generally Coating will
be tested at 15kV
• Use proper PPE
 PDM
• It has one transmitter and
receiver
• It can work on both 24V DC and
230V AC supply
• Connect Positive terminal to
Pipeline and negative to Anode
• Develops maximum current of
3Amps.
• Provision to select different
frequencies to avoid
interference from other sources
• All grounding systems shall be
isolated to have good signal
strength
• It also works on CP current.
S.No Equipment/Facility Frequency OISD Standard

1 TRU/ CPPSM UNIT Fortnightly 5.10.1(OISD-188)

2 PSP ON readings at feeding points(Should) Fortnightly 5.10.2(OISD-188)

14.4.8.1(OISD-141)

3 PSP ‘ON’ readings at the test lead points for entire pipeline Quarterly 5.10.3(OISD-188)
14.4.8.1(OISD-141)

4 Instant pipe to soil ‘OFF’ potential readings at the test lead points of Yearly 5.10.4(OISD-188)
entire pipeline.The PSP survey results shall be plotted graphically to
identify and locate cathodic holidays.

5 Current consumption data at test stations where current measurement Yearly 5.10.5(OISD-188)
facility exist.(Should) 14.4.8.3(OISD-141)

6 External coupons/ Probes at critical location Quarterly 5.10.6(OISD-188)

7 Internal Corrosion Coupon Half yearly 4.5.3(OISD-188)

8 Internal corrosion monitoring probe Quarterly 4.5.3(OISD-188)

9 Sacrificial anode Half yearly 5.10.7(OISD-188)

10 Continuous potential logging (CPL) survey once in 5 years or 5.11.1(OISD-188)

whenever inadequate CP is 14.4.9.1(OISD-141)
observed, whichever is
earlier
11 Coating survey i.e. Pearson / Current Attenuation Test (CAT) / Direct Current Voltage gradient once in 5 years. 5.11.2(OISD-188)
(DCVG) Survey shall be carried at probable coating defect location identified by CPL survey 14.4.9.2(OISD-141)

12 Rail bridge, Road bridge, suspended crossing and Road, River, Rail and Cannel crossings Quarterly 5.12.1&2(OISD-188)

13 Insulating joints and Couplings Yearly 5.13(OISD-188)

14.4.10(OISD-141)

14 Soil Testing (In addition, if any industrial effluents are flowing over the ROW soil sample shall be 10 Years 5.14(OISD-188)
tested for determining the efficacy of the existing coating and wrapping of the pipeline)

15 Pigging of Pipeline 6.0(OISD-188)&14.4.3(OISD-141)

Non ATF Half yearly
ATF Quarterly
Dedicated ATF Yearly
Crude Line Quarterly
Intelligent Pigging Once in 10 Years 14.4.3(OISD-141)

16 Cathodic protection rectifiers Quarterly 14.4.8.4(OISD-141)

17 Interference bonds Yearly 14.4.8.6(OISD-141)

18 All protective devices Quarterly 14.4.8.5(OISD-141)

19 Polarization cells [electrolytic type] shall be inspected and electrolyte level top up to be done after Quarterly 14.4.8.7(OISD-141)
every Inspection.

20 At the crossing location of one pipeline with other pipeline, current and PSP data Quartlely 14.4.8.8(OISD-141)