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

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

RISK = PROBABILITY x SEVERITY

Risks on Pipeline
PRESSURE
DROP

LEAKAGE

CORROSION

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

Copper (Cu/Cu2+)

+0.34

Water (O2+H20+4e- = 4OH-)

+0.401

Hydrogen (H2)

Iron (Fe/Fe2+)

-0.44

Zinc (Zn/Zn2+)

-0.76

Magnesium (Mg2+)

-2.36

(cathodic)

(reference)

(anodic)

Galvanic Sacrificial
Anode-Installation

(Source: Peabodys Control of Pipeline Corrosion)

Galvanic Sacrificial
Anode-Installation

(Source: Peabodys Control of Pipeline Corrosion)

Galvanic Sacrificial
Anode-Installation

(Source: Peabodys Control of Pipeline Corrosion)

Minimum potential: -0.85V

Reference electrode: Copper Sulfate

Galvanic Sacrificial
Anode-Design
Calculate total area to be protected (Ap)
Determine the current density ()
Calculate total protection current (I tot = .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 (> 104
cm)

Impressed CurrentInstallation
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
Peabodys
Control od Pipeline Corrosion
A.W Peabody
NACE Press

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

Ap Ap2inch Ap1inch dl2inch dl1inch

0,0508 300 0,0254 1300 151,613m 2
Step 2: total protection area

Ac n Ap 50% 151,613m 2 75,806m 2

Step 3: total protection current
Ip Ac 9mA / sqm 75,806m 2 682,254mA 0,682 A

Galvanic Sacrificial Anode

Case Study
Step 4: Anode resistance (Dwights Equation)
0,159 4 L
0,159 4 53,54
R
ln
1 4500
ln
1 29,15

L
r
53,54
8,89

Step 5: Current per Anode

Ia

DrivingVol tage PolarisedsteelVoltag e E 1,55 0,85

0,024 A
Re sis tan ceAnodeElectrolyte
Rae
29,15

Galvanic Sacrificial Anode

Case Study
Step 6: Total Number of Anode
Initial N Ip 0,682 A 28.41anodes
Ia 0,024 A
Lifetime
N

Lifetime Ip
20 682,254

30.75anodes
49,3 AnodeWeigh t
49,3 9

Selected number of anodes: 31.

Galvanic Sacrificial Anode

Case Study
Step 7: Distribution and Layout
Distribution

Ac 75.806
A

2.445m 2
N
31
Layout
Type of Pipe

Effective Surface (Ac)

Number of Anode
(Ac/A)

Diameter 2inch
(0.0508m)

0.5 0,0508 300 23.935m 2

23,93 : 2,445 10

Diameter 1inch
(0.0254m)

0,5 0,0254 1300 51.87 m 2

51.87 : 2,445 21

Total

31

ICCP & Sacrificial Anode

Installation

ICCP-INSTALLATION

ICCP-INSTALLATION

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/m2

Maximum Groundbed
Resistance

Lifetime

15years

Impressed Current
Case Study
Step 1: surface area of pipeline

Ap dl 0,1524 2072 992,03m

Step 2: total protection area

Ac n Ap 50% 992,03m 2 496,015m 2

Step 3: total protection current

Ip Ac 30mA / sqm 496,015m 2 14880,45mA 14,88 A

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)

Impressed Current
Case Study
Step 5: total number of anodes

Current limit (silicon: 10.76 A/m2)

N

Ip
14,88 A

Ai Ic 0,371m 2 10,76 A

Lifetime
N

3,72anode
m2

Lifetime Ip
15 14880mA

2,02anode
1000 AnodeWeigh t 1000 110 pon

Total anodes: 4.

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

0.00521
8L
2L
(ln
1
ln 0.656 N )
LN
d
S
0.00521 2000
87
27

ln

ln
0
.
656

74
30
0.833

Groundbed resistance is below limit.

1.36
If not, choose longer spacing.
Rg

Impressed Current Principle

Step 7: rectifier specification

Vrec Ip Rg 14,88 1.36 20,237V .

Srec Vrec Ip 301,123W

Specification: 21VDC, 302W .

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