building

Local Cathodic Protection

ground rod pipeline

for Compressor Stations and Industrial Plants

reinforced-concrete foundation & walls transformer rectifier unit ground rod

anode protective current

For further information on our cathodic protection services, please contact Ruhrgas AG Centre of Competence Corrosion Protection / TEEK Gladbecker Strasse 404 45 326 Essen Germany Tel. +49 / (0)201 / 184 - 8341 Fax +49 / (0)201 / 184 - 8444 E-mail: KKS@ruhrgas.com

Dr. Johannes Geiser Detlef Wessling First Published by Vulkan Publishing Company Pipeline Corrosion Protection 2001

Contents page 1. 2. 3. 3.1 3.2 4. 5. 6. Conditions for Cathodic Protection Risk of Corrosion at Compressor Stations or Industrial Plants Principle of Local Cathodic Protection Basic Protection Hot Spots Effects on Foreign Structures Effectiveness of Local Cathodic Protection System Start-Up 2 2 3 4 5 8 9 11

-2-

1.

Conditions for Cathodic Protection

Cathodic protection of pipelines is only feasible on economic terms if all line and branch line terminal points are fitted with isolating joints to isolating joint isolating joint electrically separate the pipeline to be protected from the connected low-resistance sections (Fig. 1). pipeline
transformer-rectifier

anode protective current

Fig. 1: Cathodic Protection for Pipelines

Isolating joints are not suitable for pipelines in large installations such as compressor stations or industrial plants (Fig. 2). Associated costs and cathodic

protection failure rates would be very high due to plant complexity and the large number of joints required. Also, explosion risks may exclude isolating joints as an option. Nor are isolating joints suitable for pipelines carrying conductive liquids (e.g. condensate) where they may involve the risk of internal corrosion.

Fig. 2: Compressor Station

2.

Risk of Corrosion at Compressor Stations or Industrial Plants

Reinforced concrete structures, earthing systems and piping at compressor stations or industrial plants are metallically interconnected for potential equalisation. The risk of corrosion is therefore higher for such piping than for other pipelines buried in soil due to the effects of the corrosion cell formed by steel in concrete and steel in soil (pipeline coating holidays; Fig. 3). The free corrosion potential of steel in concrete is approx. UCu/CuSO4 = -0.2 V, while the free corrosion potential of steel in soil is approx. UCu/CuSO4 = -0.5 V to UCu/CuSO4 = -0.7 V. As a result, equalising currents flow between pipeline coating holidays and reinforced concrete foundations. Current discharges from the coating holidays and the corrosion rate rises significantly.

-3Another detrimental factor is the small size of the coating defects, resulting in very high densities of the reinforced concrete structure currents discharged. There is a higher risk H+ 1/2O for coating holidays in 2 ground rod ++ pipeline Fe ++ Fe the immediate vicinity coating of reinforced concrete 2e coating holiday No. 2 coating holiday No. 1 foundations as they are located within the ground rod U Cu/CuSO4 foundation voltage casing potential at soil surface in V potential at pipe surface cones where the -0.2 driving voltage of the -0.4 corrosion cell is -0.6 particularly high.
distance from structure coating holiday No. 1

The two coating holidays shown in Fig. 3, for example, are located at different distances from the reinforced concrete structure. While the rest potential is the same for both defects, the driving voltage in the soil surrounding defect No. 1 (see potential along soil surface) is significantly higher than in the case of defect No. 2.
Fig. 3: Reinforced Concrete Structure / Pipeline Corrosion Cell (Potential Curves)

coating holiday No. 2

3.

Principle of Local Cathodic Protection

Local cathodic protection is an effective method to protect piping at compressor d (cm) stations or industrial plants 100.0 against corrosion and, in 50.0 particular, to prevent the 20.0 formation of corrosion cells. 10.0 Fig. 4 indicates a -2.0 V fundamental problem of 5.0 -1.5 V ON potential -1.2 V cathodic protection at 2.0 -1.0 V compressor stations: The 1.0 larger the diameter, the 0.5 more difficult it is to protect a coating defect, i.e. more 0.2 0.1 and more negative ON
10 20 50 100 200 500 1,000 r (W m)

Fig. 4:

Max. Controllable Holiday Size (IR Drop Free Potential, UCu/CuSO4 = -0.85 V) as a Function of ON Potential

-4potentials are required to ensure sufficient protection. Particularly non-coated building foundations at compressor stations act like coating holidays with extremely large diameters of several metres and therefore require much more negative ON potentials compared with conventional cathodic protection. Against this background there are basically two methods available to provide adequate corrosion protection for pipelines. Firstly, it is possible to provide cathodic polarisation of the entire station (basic protection). Secondly, soil potentials can be changed selectively to eliminate corrosion cells and polarise coating holidays in critical areas (hot spot protection).

3.1

Basic Protection

Figs. 5 and 6 illustrate the fundamental concept of basic protection at compressor stations. A corrosion protection system is installed to protect the relevant pipeline. It feeds current from one or more remote anode systems to the coating defects as well as to all components connected to the pipeline such as reinforced concrete structures and earthing systems. In soils with sufficiently low resistances, these anode systems are designed as deep groundbed systems for more homogeneous current distribution to the connected objects to be protected. If current levels are sufficiently high, all grounded plant components are polarised. In particular the OFF potentials for reinforced concrete structures will be sufficiently negative. Unfortunately, very high levels of protective current are required to polarise reinforced concrete structures and earthing systems.

building

ground rod pipeline

reinforced-concrete foundation & walls transformer rectifier unit ground rod

anode protective current

However, polarisation of reinforced concrete structures estimated to consume 5 to 20 mA/m is not required to preclude corrosion risks but to eliminate the steel in concrete / steel in soil corrosion cell.

Fig. 5: Concept of Basic Protection

-5Aside from reinforced concrete structures, compressor stations or industrial plants usually also include extensive earthing systems made of zinc-plated strap or high alloy steel or copper. These systems are also connected to the pipeline to be protected. Protective system design includes 5 mA protective current per metre of zinc-plated strap (30x3.5 mm cross section). Unlike zinc-plated strap, the rest potential of high alloy steel or copper is very positive compared with steel in soil. Therefore, high alloy steel or copper earthing systems further increase the risk of corrosion at coating holidays and should be avoided, if possible. Depending on plant size, basic protection may require several hundreds of amps of which only a negligible part reinforced concrete wall is consumed by the pipeline (protective current density < 0.1 mA/m2). Above all, the anode system must be designed to match the high protective current (e.g. current levels required. from deep anode) Groundbed resistance must V V be so low that the U <-0.85V U <-0.85V necessary current levels Fig. 6: Cathodic Polarisation of Reinforced Concrete Structure may be set for specified rectifier outputs. Also, high current levels and the associated increases in soil potential near the anode system or the decreases in soil potential near the reinforced concrete structures may lead to stray current interference with foreign structures.
Cu/CuSO4 Cu/CuSO4

pipeline

50 V/50 A protective current units have proved successful for use in basic protection. The output voltage must be limited to 40 V for metal oxide anodes (e.g. LIDA anodes) which are widely used on the west European market. Single deep anodes are usually designed for a maximum limit of 25 A per anode.

3.2

Hot Spots

Where basic protection is not adequate to provide complete protection of the pipeline, soil potentials can be increased selectively at specific points to eliminate corrosion cells formed by coating defects on the line and reinforced concrete structures. Fig. 7 shows schematically anodes installed at particularly critical points. Such points usually exist where pipelines are laid parallel to reinforced concrete

-6structures or in foundation entry areas. The anodes are always arranged in such a way that the pipeline runs within their voltage cones.
anode anode anode

pipeline transformer-rectifier unit

reinforced concrete wall

V UCu/CuSO4 =-0.4V

V UCu/CuSO4 <-0.85V

Fig. 7: Increase in Soil Potential

Figs. 8 and 9 show a single silicon-iron anode and a cable-type anode for pipelines laid parallel to reinforced concrete structures. When cable-type anodes are used, care must be taken not to exceed the max.

admissible amperage load per metre of anode length. Selective installation of single anodes makes it possible to provide adequate polarisation of pipeline holidays without significantly polarising other plant components at the same time. A negative aspect is the high number of anodes necessary for complex plants and the extensive excavation work involved. As basic protection and hot spot protection both have negative aspects, a combination of the two methods is mostly employed in practical operations. Often, a "basic current" is supplied from one or more deep anode Fig. 8: Single Silicon-Iron Anode systems (Figs. 5 and 6) and smaller anodes are installed additionally at points where coating holidays cannot be sufficiently protected (Fig. 9). The single anodes are connected to a separate protective current unit via single tappings allowing individual adjustment of anode output. 40 V / 20 A protective current units have proved to be a reasonable option in practical operations.

Fig. 9: Cable-Type Anode

-7L.No.439 = groundbed anode engine 4 TA 1 single anode vent PB 1 Raychem anode 1 TA 3 Raychem anode 3 PB 6 PB 7 TA 4 transformer rectifier PB 23 TA 2 single anode PB 16 Raychem anode 2 TA 5 3 x field lines L.No.39 single anode = single anode = Raychem anodes = coupon (PB)

TA 7 PB 26

TA 6

PB 20

TA 8 PB 29 TA 9 PB 28

L.No.53 PB 17 TA 10

water line

L.No.39/1

Fig. 10: Deep and Single Anode Positions

Fig. 10 shows one possible arrangement of 10 deep anodes for basic protection and different-length single anodes at a storage compressor station.
reinforced concrete wall

The problematic points are areas isolation where (underground) lines (Pohl collar) approach or enter reinforced concrete buildings, leading to the pipeline formation of differently polarised areas next to each other. Remedial action can be taken at such critical points by coating the concrete with protective current bituminous material for electrical Fig. 11: Pohl Collar at Wall Entries isolation against the surrounding soil (Pohl collar, Fig. 11). This extends in electrical terms the distance between the coating holidays and the bare reinforced concrete surfaces (the voltage cone of the reinforced concrete structure is removed from potential coating holidays).

-8Subsequent installation of Pohl collars is very difficult as the structures in the vicinity of the line must be uncovered over large areas. Pohl collars are therefore mostly used for new foundations or foundations to be uncovered for other construction work.

4.

Effects on Foreign Structures

Both the cathodic voltage cone of the station equipment (Fig. 13a) and the anodic voltage cone of the anode system (Fig. 13b) may interfere with the cathodic
V V Ux x

protection of incoming gas transmission and supply lines.

coating holiday outside cathodic voltage cone

potential of the surrounding soil generated by the anode pipeline affected Ux 0 system and the in V -0.2 resulting current flows -0.4 may lead to stray voltage cone of cathodically protected strap grounding rod current effects on U -0.1 incoming and outgoing in V -0.3 transmission lines. -0.5 Currents entering the x x pipe-to-soil potential of pipeline affected line in the station area Fig. 12: Interference of Earthing System with Transmission Line and again leaving the line through coating defects at some distance from the station may interfere with the cathodic protection of the line and cause corrosion.
Cu/CuSO4

cathodically protected strap grounding rod

The increase in the

However, the more serious risk is associated with the drop in soil potential in the vicinity of reinforced concrete structures and earthing systems (Fig. 12) as current discharging points on the pipelines affected tend to concentrate in these areas. To avoid interfering effects, the isolating joints on the pipelines affected should be installed outside the voltage cone of the entire system.

-9Ground rods in areas intersecting with transmission lines should be isolated over a length of 20 m or replaced by transmission line cables if possible. station
local CP isolating joint

anode

a
station local CP isolating joint transmission line

anode

A monitoring unit could be used, for example, to preclude detrimental effects on transmission lines by the station protection system if the protective system for the lines fails. Such a unit monitors the potentials on all incoming transmission lines and shuts down the protective systems for the station if the potential limit value determined for the lines is exceeded. The protective current systems and the monitoring unit should be installed at a central location to minimise the input required for simultaneous shutdown and startup of all units.

Fig. 13: Effects on Transmission Lines

To avoid any interference, local cathodic protection and cathodic protection of the transmission line should be balanced in such a way to ensure adequate protection for all coating holidays on the transmission line when the cathodic protection system for the station is in operation.

5.

Effectiveness of Local Cathodic Protection

Particularly in areas where pipelines enter buildings (e.g. compressor buildings) or are in close proximity to reinforced cast material plastic concrete structures, basic protection saturated sodiummay not provide an adequate sulfate solution calomel electrode decrease in ON potential and thus cast terminal strip material adequate polarisation. Therefore, cable connection steel plate protective system design should e.g.: 30 cm diaphragm plastic pipe include special test devices (test pipeline coupons or test probes; see Fig. 14) at these points. cable connection
test post test probe

Fig. 14: Test Probe

- 10 The test coupons or test probes are connected to the pipeline in an interruptible manner so that current input and potential can be measured. The test probe consists of a steel plate with a reference electrode at its centre. With this arrangement, it is possible to measure current input and IR-free potential of the probes. Steel probes as shown in Fig. 15 are another means to test current input and the effectiveness of the corrosion protection system. Such steel probes are usually installed together with permanent reference electrodes (at a distance of approx. 50 cm). While it is not possible to measure the IR-free potential of the steel probe due to the distance between the reference electrode and the steel probe as well as due the voltage cones existing in the reinforced concrete foundation area, the potentials measured at different times Fig. 15: Steel Probe can be compared as the distance between the steel probe and the electrode is constant. The large voltage cones in the area of the reinforced concrete structures are also the reason why displacement of the reference electrode at the surface by only a few centimetres may lead to significantly different potential values. In order to be able to detect changes in the effectiveness of cathodic protection over time, the test electrode must be positioned exactly at the same point for each test measurement. The test point must be identified, for example, by a plastic pipe installed in the soil at a depth of approx. 20 30 cm. The pipe must be large enough to accommodate the reference electrode and must be filled with soil. When the basic protection system has been set to a value ensuring adequate polarisation in large areas of the station, the ON and OFF potentials in the entire plant as well as the test probe currents are measured. Currents discharging from the test probes into the soil indicate corrosion risks at pipeline coating holidays. In these areas, additional anodes as shown in Figs. 7 to 9 must be

Fig. 16: Asbestos Cement Pipe for Reference Electrode

- 11 installed to protect hot spots. The effectiveness of cathodic protection in areas without test probes must be assessed by comparing the potentials measured with the potentials measured in areas with test probes where current (and the direction of current flow) can be determined.

6.

System Start-Up

To test the effectiveness of local cathodic protection, the following steps can, for example, be performed during start-up in the order listed: a. Prior to start-up of the protective systems, record rest potentials in a grid (e.g. specific test points) and measure test probe currents (focus on current flow direction). b. Set basic protection systems to approx. half of the calculated output current. Load cable-type anodes with max. current density and single anodes with 20 V output voltage. c. Record ON potentials at all test points as well as test probe currents. d. Adjust system output setpoints following data analysis. e. Make initial OFF potential measurement allowing for an adequate polarisation period of approx. one day and again adjust system output setpoints or install more single anodes, if required. f. Make a second OFF potential test after one year and again adjust system output setpoints, if required. Usually, the output setpoints set on the basic protection systems can be reduced.