A MAJOR PROJECT REPORT

on

Experimental Study on Corrosion Behavior

Of Buried Pipeline
Under AC Interference

Submitted in partial fulfillment of the

requirements for the award of the degree

of

Master of Technology
in

PIPELINE ENGINEERING

Submitted By:
ANKIT PANWAR
Roll No.:R150217007
SAP ID:500063494

DEPARTMENT OF CHEMICAL ENGINEERING

UNIVERSITY OF PETROLEUM & ENERGY STUDIES, DEHRADUN
UTTARAKHAND-248007, INDIA

May -2019

1
 UNVIERSITY OF PETROLEUM AND ENERGY STUDIES
DEHRADUN-248007
CANDIDATE’S DECLARATION

I hereby declare that the work, which is being presented in this dissertation, Entitled “
Experimental Study on Corrosion Behavior Of Buried Pipeline Under AC
Interference’’, submitted in partial fulfilment of the requirement for award of the
degree of Master of Technology in Pipeline Engineering, is an authentic record of
my own work carried out under the supervision of Dr. Adarsh Kr. Arya, Assistant
Professor, Department of Chemical Engineering, University of Petroleum & Energy
Studies, Dehradun and Mr. Ajit Thakur from IOCL.

Date – 06 May, 2019

Place – Dehradun ANKIT PANWAR

This is to certify that the above statement made by the candidate is correct to the best of my
knowledge.

Dr. Adarsh Kr. Arya Mr. Ajit Thakur

Assistant Professor, General Manager,
Department of Chemical Engineering IOCL, Noida
University of Petroleum & Energy Studies
Dehradun, Uttarakhand-248007
INDIA

2
 .

PREFACE

This report documents the work done during the project work at UPES Bidholi, Dehradun. The

project was under supervision of Mr. Ajit Thakur (General Manager – IOCL, Noida) and Dr.

Adarsh Kr. Arya (Assistant Professor- UPES, Dehradun). The report first shall give an

overview of the tasks completed during the project work with technical details. The report also

contains the extensive study on cathodic protection for the pipeline and the effect of AC

induced current on the pipeline that increase the corrosion rate. The main content of the project

is to learn and analyse the data and produce my thoughts over them. This topic suited my major

in pipeline engineering, and also brought me to a very new and interesting approach by getting

to be directly involved in many operations. Through the assignment, I did not only gain a lot

of knowledge but more importantly, I also had a great chance to sharpen my skills in a

professional working environment. Throughout the project work, my colleagues Hemant

kumar singh and Syed Haider Hussain helped me in many aspects of the experiment.

The details of the project mentioned in the document are true to the best of my knowledge and

no confidential matters have been revealed. I have tried my best to keep report simple yet

technically correct. I hope I succeed in my attempt.

ANKIT PANWAR

3
 ACKNOWLEDGEMENT

With deep appreciation and gratitude, I would like to express my special thanks of gratitude to
my project guide “Dr. Adarsh kumar Arya who has given me the golden opportunity to do this
wonderful project on the topic “Experimental research on corrosion behavior of buried
pipeline under ac interfernce”, which also helped me in doing a lot of Research and I came
to know about so many new things .I am really thankful to them. Being a graduate in
Mechanical engineering, it was my wish to do something creative in this field and with the help
of my project guide Dr. Adarsh kumar Ayra and I also acknowledge the active cooperation by
Mr. Haider Hussain and Mr. Hemant kumar Simgh (M.Tech (Pipeline Engg.), UPES,
Dehradun) for helping me in the collection of information and data about the topic and for his
kind cooperation during the study. I express my regards to all UPES faculties for their co-
operation. No words can express my deep sense of gratitude for my beloved family members
and colleagues for their support. It is only because of their affection and motivation that I am
at this stage without them I could not have accomplished my goals. Overall, I would like to
thank almighty for showering blessing on me.

ANKIT PANWAR
M.Tech (Pipeline Engg.)
May 2019
 ABSTRACT

Stray current corrosion abide to be the argumentative subject and a full agreement on
influencing parameters and mechanism has not yet been achieved. The influence of AC
interference on the neighbouring corrosion resistance of passive metals is discussed on the
basis of laboratory test results called potentiodynamic and Galvanostatic test. Test were
performed in pipe sample coupon of API 5L X-80 with a chemical composition of Nacl (In soil
simulating environment) and on carbon steel on alkaline solution (under cathodic protection
of carbon steel with a pH at the soil-steel interface is higher than 10, so pipe coupon of carbon
steel of grade X-80is a passive metal. Potentiodynamic test were also carried out to analyse
the effect of AC stationary interference on passively current density. Applied AC was in the
range of 10 A/m2 to 30 A/m2. Results allows the effect of AC on AC Current density to
corrosion current. Time-to-corrosion

ii
 TABLE OF CONTENT

PREFACE…….………………………………………………………………........................ii

ACKNOWLEGEMENT……………………………………………………………………. iii

ABSTRACT………………………………………………………………………………… iv

LIST OF FIGURES………………………………………………………………………….v

ABBREVATIONS…………………………………………………………………………... vi

1. CHAPTER 1: INTRODUCTION
1.1 Research background………………………………………………………………1
1.2 Research objectives………………………………………………………………..2
1.3 Content of thesis…………… ……………………………………………………...2

2. CHAPTER 2 : LITERATURE REVIEW

2.1 AC Corrosion Mechanism…………………………………………………………4
2.2 Classification of Corrosion………………………………………………………...5
a) Wet Corrosion
b) Dry corrosion
2.3 Types of corrosion…………………………………………………………………7
2.4 Corrosion in prospects……………………………………………………………..8

3. CHAPTER 3 : MATERIAL AND METHODOLOGY

3.1 List of Materials……………………………………………………………..........12
3.2 Experimentation testing………………………………………………………......13
3.3 Experimentation Setup…………………………………………………………...15
3.4 Methodology……………………………………………………………………..18
3.4.1 Galvanostatic Test………………………………………………………..20
3.4.2 Procedure of gavanostatic test…………………………………………...24
3.4.3 Potentiostatic Test………………………………………………………..25
3.4.4 Procedure of potentiostatic test…………………………………………..30

iii
4. CHAPTER 4 : RESULT AND DISCUSSION……………………………………31

5. CHAPTER 5 : CONCLUSION……………………………………………………32

REFERENCES……………………………………………………………………33

iv
 List of Figures

Fig 1 Corrosion rate of pipe coupons………………………………………………………....2

Fig 2 Ac corrosion rate show a relationship between AC current density & potential………2

Fig 3 AC corrosion rusk diagram…………………………………………………………….3

Fig 4 leak site on underground natural gas transmission pipeline before and after cleaning…3

Fig 5 simplifies AC corrosion process……………………………………………………….4

Fig 6(A) Incidents in onshore and offshore liquid transmission pipeline………….………....5

Fig 6 (B) Natural gas distribution pipeline damage…………………………………………..6

Fig 6(C) Incident in gas distribution pipelines………………………………………………..6

Fig 7(a) Typical line diagram of experimental setup…………………………………………7

Fig 7(b) Real experiment setup model………………………………………………………..7

Fig 7(c) AC variac…………………………………………………………………………….8

Fig 7(d) Inductor……………………………………………………………………………...9

Fig 7(e) Rishbh Multimeter…………………………………………………………………..10

Fig 7(f) Salt for alkaline solution……………………………………………………………..11

Fig 7(g) Pipe coupon…………………………………………………………………………11

Fig 7(h) Tinker and razor 4 pin soil resistivity meter………………………………………...11

Fig 7(i) Resistor…………………………………………………………………………..…..11

Fig 7(j) Half cell (CU/CUSO4)…………………………….…………………………………11

Fig 7(k) PH Meter…………………………………………………………………………….12

Fig 7(l) HCL and Acetone…………………………………………………………………….12

Fig 7(m) Dc Galvanostat……………………………………………………………………..13

v
Fig 8 Galvanostat Readings (Sample) and observations of Pipe coupons………………….15

Fig 9 Graphical representation of pipe grade coupons API 5LX80…………………………18

Fig 10 Potentiostat Readings (Sample) and observations of Pipe coupons………………….20

Fig 11 Graphical representation of pipe grade coupons API 5LX80……………………….21

vi
 Abbrevations

Symbol Definition
A Exposed Area of Coating
AC Alternating Current
ASTM American Society for Testing and Materials
AV Alternating Voltage
C Capacitor
CD Cathodic Disbonding
CE Counter Electrode
CEPA Canadian Energy Pipeline Association
CP Cathodic Protection
CCS Cu/CuSO4 Electrode
DAQ Data Acquisition
DC Direct Current
DIN Deutsches Insitut Normung
EIS Electrochemical Impedance Spectroscopy
E01 Equilibrium Potential of Anodic Reaction
E02 Equilibrium Potential of Cathodic Reaction
FBE Fusion Bonded Epoxy
FT-IR Fourier Transform-Infrared Spectroscopy
GDP Gross Domestic Product
HDPE High Density Polyethylene
HVAC High Voltage Alternating Current
iAC Alternating Current Density
NACE National Association of Corrosion Engineers
Rs Spread Resistance
RE Reference Electrode
RMS Root Mean Square
SCE Saturated Calomel Electrode
SEM Scanning Electron Microscopy
VB1 Charge Transfer Resistance for Anodic
Reaction

vii
 Chapter 1
Introduction
1.1 Research background

Pipeline are considered one of the most safest and minimum expenditure transportation
system other than railroad, marine shipping and truck transport. According to Pipeline
and Gas Journal's survey about 1,90,900 km are planned and under process. Out of
these are in design phase 1,43,190 km and 47,710 are in different stages of construction.

In Pipelines we can transport liquids, gases and any low corrosive substance. Pipelines
are mostly used to transport natural gas and crude oil product. In hilly areas where water
cannot be transported through road transportation pipelines are used for transporting
water for drinking or irrigation for long distance.

Pipelines are buried deep underground so there is a wide variety of threats to pipeline
integrity including material and construction defects, mechanical damage from
construction, maintenance or third-party excavation, incorrect cathodic protection
operation, corrosion and coating degradation etc. With the increasing number of
pipelines the pipelines the interference between high voltage power line and alternating
current is considered as a threat to the safety of pipeline.

When a buried pipeline parallels or crosses through a high voltage tension line an
electromagnetic field is generated in the environment which then in turns generate an
inductive alternating current in the pipe. If the pipeline contains any microscopic or
macroscopic defect then steel at those area will be prone to AC induced corrosion. Ac
corrosion has been recognized in the beginning of the20th century. Although for many
year corrosion engineers did not considered ac corrosion as one of the important
corrosion because the percentage of corrosion is very less and the interference can be
controlled with the help of cathodic protection.

AC corrosion was first recognized in Germany 1986 a cathodically protected pipeline

got damaged by induced AC current. In the past 30 years, many pipeline failures in
North America and Europe have been ascribed to AC interference even when CP was
applied.
 1.2 Research objectives

The overall objective of this research is through experimental testing and fundamental
degradation in the presence of AC interference.

 To study the effect of different AC current density on different grade of pipeline.

 To study the behaviour of different kind of steel while it is cathodically
protected.
 Two type of test are conducted galvanostatic and potentiostatic.

1.3 Content of thesis

The thesis contains five chapters, with

 Chapter One giving an overall introduction of the research background and

objectives.

 Chapter Two reviews comprehensively the principle of AC interference on

pipeline integrity, including the fundamentals of AC induced corrosion and the
recognition of AC interferences on the applied CP as well as coating
performances.

 Chapter Three is devoted to the experimental setup and methodology of

experiment with the instrument used.

 Chapter Four investigates the AC induced corrosion with result and discussuion.

 Chapter five ends with the conclusion of the experiment.

2
 CHAPTER 2

LITERATURE REVIEW

For Many years corrosion engineers did not considered Ac induced corrosion as a major
phenomenon until an incident happen in Germany 1986 and the damage to pipeline was
done by ac induced corrosion. However ac can cause corrosion on steel but the
percentage is very less and can be mitigated by cathodic protection with the help of dc
current. It is not considered as a major problem because there is a problem in studying
the interference of ac and dc current. In the 20th century ac corrosion is considered as a
serious concern as there were cases of serious damage to the pipeline which are
cathodically protected. Recently ac corrosion is considered as a serious threat to the
metallic structures buried underground crossing a high voltage power line.

There is not enough data or study in the ac induced corrosion on metallic structure.
There is a simple understanding that a higher AC causes higher threat of induced
corrosion in pipelines. There was a case near a power plant of Rainier, Oregoin in 2001
a gas pipeline was located under a high voltage line. Four holes were seen after only
five months under the effect of AC voltage of 90v having a corrosion rate of 400mpy.

There are different methods for mitigation for ac corrosion but none of them reached a
conclusion due to improper understanding of the mechanism of corrosion.

Ragault in 1998 performed an experiment on coupon in field condition. In which

coupons are placed close were pipeline is defected. A polyethylene coated pipeline
which passes parallel to high voltage line and was protected by CP. There was no
relation between the value of ac current density and the corrosion rate after 18 months.
Further Song et al find out the linear relationship between corrosion rate and AC current
density. However Ac current density is not the only parameter responsible for AC
corrosion Rate.
Fig 1 corrosion rate of corrosion coupons

3
Fig 2 AC corrosion rate show a relationship between AC current density &
potential.

Fig 3 AC corrosion risk diagram.

Fig 4 leak site on underground natural gas transmission pipeline before and
after cleaning of deposit arrow indicate leak.

4
2.1 AC Corrosion mechanism

There are many theories and models which explain the mechanism of AC corrosion but
none of them explain the phenomenon behind that.

Yunovich and Thompson stated that the process during the anodic half cycle of AC is
completely reversed during anodic half cycle[5].during positive cycle the metal is
oxidized and forms an oxide film while during negative half cycle the film is reduced
to iron hydroxide. Hence a new film grows in the anodic cycle.

For every AC cycle there is a net increase in oxidation of metal and cause a metal loss
in long term of AC interference
Reaction involved are

The figure given below explains the AC corrosion mechanism although this is the case
when there is no Cathodic protection.

Fig 5 simplified AC Corrosion process

5
2.2 Classification of corrosion

There are different types of corrosion but the most preferred classification is

a) Wet Corrosion
b) Dry Corrosion

Wet by name defined itself when moisture content or water fully is present. It basically includes
aqueous solution or electrolyte for the higher part in the corrosion so far, A common example
is corrosion of steel rod or pipes or any steel slab by water, in this corrosion phenomena water
and gas these are two main components acts as corrodents. And associated with the high
temperature dry corrosion occurs, example is strike of hot fumes gas over furnances.

Why do metal corrode? The answer is that the significant amount of energy is put into a metal
when it is extracted from its ores, placing it in a high energy state. These ores are typically
oxides of the metal such as Ferric oxides (Fe2O3) for steel or bauxite (Al2O3) and (H2O) for
aluminium. One principle of thermodynamics is that a material always seeks the lowest energy
state, or in other words, most metals are thermodynamically unstable and will tend to seek a
lower energy state, which is an oxide or some other compound. The process by which metal
converts to the lower energy oxides is called corrosion.

Mechanism of Corrosion

Dissolution of Iron: Fe = Fe2+ + 2e- (Oxidation)

Reduction of oxygen to hydroxide: O2 + 2H2O + 4e- (Reduction)

Dissolved Iron and Hydroxides ions react to form Iron hydroxide layer: Fe2 + 2OH- = Fe(OH)2.

Ferrous hydroxide has low solubility and precipitations on the surface where it oxidised to
ferric hydroxide.

2Fe(OH)3 = Fe2O3 + 3H2O

Anodic and cathodic processes occurs at different sites, which are close together. Condition
required for the corrosion is an electrochemical process occurring at the interference between
metal and environment. Three conditions must be present for this to occur

1) Two areas on a structure or two structures must differ in electric potential.

2) Those areas called anodes and cathodes, must be electrically interconnected.

6
 3) Those areas must be exposed to a common electrolyte (Soil or Water)
4) The anode and cathode must be immersed in an electrically conductive electrolyte
which is ionised meaning that water molecules are broken down into positively charged
hydrogen ions (H+) & negativity charged hydroxyl ions (OH-).
5) The usual soil moisture or water, surrounding pipelines fulfil this condition
6) Corrosion cell elements
a) Anode
b) Cathode
c) Metallic path
d) Electrolyte
7) Corrosion takes place at anode only
Anode: the electrode from which current leaves to the electrolyte Anode gets corroded
Cathode: The electrode where current is collected No Corrosion takes place
8) Corrosion Cell – Dissimilar Metals i.e Steel pipe connected to copper ground rod
9) Half cells - Copper-copper, Sulphate (CSE) half cells are used for soil corrosion and
silver chloride are used for aqueous condition

2.3 Types of Corrosion

a) Uniform or general.
b) Galvanic
c) Pitting
d) Erosional Corrosion
e) Stress Corrosion
f) Stray Current Corrosion
g) Bacterial Corrosion
h) MIC

7
2.4 Corrosion in Prospect

A) Hazardous liquid pipeline significant incidents (1988 – August 2018) [4]

Damage

1.20%,
4.10%, 4%1%
19.90%, 20% 22.80%, 23%

6.90%, 7%
23.60%, 23%
21.70%, 22%

All other causes Corrosion Excavation Damage

Human Error Material failure Natural force damage
Other outside Force damage

Figure 6 a) Incidents in onshore and offshore liquid transmission pipeline

B) Gas Transmission lines accidents (1988 – August 2018) [5]

Damage

16% 24%
5%
12%
20%
21% 2%

Corrosion Excavation Damage Human Error Material Failure

Natural Force Damage Other outside damage All other causes

Figure 6 B) Natural gas distribution pipeline damage

8
C) Gas Distribution lines significant damages (1988 – August 2018) [6]

Damage
3.90%

25.40%
36.90%
8.30%

14.00%
5.10%
6.40%

Corrosion Excavation damage Human Error

Material failure Natural force Damage Other outside force Damage
All other causes

Figure 6 C) Incident in gas distribution pipeline

9
 Chapter 3
Material and Methodology

3.1 List of Materials

Sr.No Equipments Quantity

1 DC regulated power supply instrument 1

2 Variac (Variable Transformer) 1

3 Voltage Stabilizer 1

4 Load (To minimize the variable transformer output) 1

5 Ph meter 1

6 Soil resistivity meter and rod 1

7 Anodes 2

8 Cu/CuSO4 Half cell 4

9 Multi-plug Electricity Board 1

10 Pipe Sample (X46, 52 ,80) 15

11 Sand Paper 1

12 1 litre plastic jar 1

13 Wire Cutter 1

14 Screw Driver and plier 1

15 Hydrochloric Acid (1lit) 1

16 Hand gloves 2

17 Small water tank (25lit) 1

10
 18 Salt (1kg) 1

19 Instrument panel 1

20 Scale to measure level 1

21 Multi-meter (RISHB) 4

22 Resistors (10 Ohm) 3

23 Capacitors (470uF/50V) 2

24 Inductors (18w) 2

3.2 Experimentation Testing

1) Electrochemical setup
An environmental setup was created having 25 lit of water having variable PH
throughout the experiment procedure in order to act like soil surrounding buried pipe.
2) Potential
To measure Pipe to soil Potential (PSP) we have used Cu/CuSO4 Solution in a Half-cell
with a distance of at least 20mm with the submerged pipe samples and the readings
are measured with the help of multi-meter.
3) Resistivity
With every new soil environment there are different soil resistivity which can be
measured by wenner’s 4 pins method.
4) Cathodic Protection
With the help of DC regulated power supply we are protecting the pipe as well as
creating the pipe potential as 850mV, 950mV, 1050mV, 1150mV, 1250mV, 1350mV
by varying the voltage
5) AC interference
With the help of AC Variac we are varying the current density as 1mA, 3mA, 5mA,
10mA, 20mA to create AC interference in the environment.

11
 6) Pipe Coupons
We are using three different grade of pipe API 5L X
a) X-46
b) X-52
c) X-80
7) Anodes
We are using 2 sacrificial anodes (Magnesium)

3.3 Experiment Setup

Figure 7 a) Typical line diagram of Experimentation Setup

12
Figure 7 b) Real experiment setup model

Figure 7 c) AC Variac

Figure 8 d) Inductor 18w

13
Figure 8 e) RISHB Multi-meter Figure 8 f) Salt for alkaline Solution

Figure 8 g) Pipe Coupons Grade API 5L X-46

Figure 8 h) Tinker & Rasor 4 Pin Soil Resistivity Meter

14
Figure 8 i) 10Ω Resistors (3) Figure 8 j) Cu/CuSO4
Half cell

Figure 8 k) pH Meter Figure 8 l) HCL & Acetone

15
 Figure 8 m) DC Galavnostat

3.4 Methodology

3.4.1 Gavanostat

Galvanostatic refers to an experimental technique whereby an electrode is maintained at a

constant current in an electrolyte. This technique is used to measure corrosion rate and
electrochemical reactions.

Galvanostatic, like potentiostatic and potentiodynamic, is a polarization technique that allows

for the controlled polarization of metal surfaces in electrolytes, in order to directly observe
cathodic and anodic behaviours.

In galvanostatic tests, the change is plotted in potential verses time at constant current. A
constant DC current is applied to the metal of interest while it is immersed in the electrolyte.

Galvanostatic polarization is an alternative to potentiostatic polarization. In galvanostatic

polarization measurements, the current between working and counter electrodes is controlled,
and the potential between working and reference electrodes is automatically adjusted to the
value required to maintain the current. The potentiostatic polarization curve provides
considerably more information about passivity than does the galvanostatic curve.

In the galvanostatic approach to measure linear polarization resistance:

1. A small current is applied.

2. The electrode potential changes.

3. The potential change is measured.

16
3.4.2 Procedure of Galvanostat Experiment

 First clean all the instruments.

 Specially clean the pipe coupon with hcl and acetone carefully.

 Note down the grade of pipe coupon.

 Check whole circuit for any loose connection with the help of circuit diagram.

 Make salt solution in a container, emerge two anodes, pipe coupon and half cell in the

solution.

 The distance between coupon and half cell is minimum 10mm.

 Measure the ph with the help of ph meter and soil resistivity with the help of 2 pin

method. Note down the readings.

 Apply dc current 0.01mA with the help of galvanostat and take psp readings on

application.

 Leave the whole apparatus with running dc and without any other interruption for 24hrs.

 After 24hrs note down the psp reading again.

 Now apply ac current and start taking readings of psp in intervals of 5 mins with the

help of AC variac as per the given format.

 Measure the readings carefully with the help of multimeter and note down it carefully.

 Again measure the ph and soil resistivity after finishing whole experiment.

 Stir the salt solution after every 30 minutes for different dc current readings.

 Change the salt solution for every new experiment.

 Tighten and check each and every connection weekly.

 Check the fuse.

 Repeat the same experiment for different grade of pipe coupon.

17
Figure 9 Galvanostat Readings (Sample) and observations of Pipe coupons

18
19
Fig 10 Graphical representation of observations of pipe coupons grades API 5L X 80

API 5L X80
0

-0.5
DC Current (mA)

-1

-1.5

-2
1 3 5 10 20
0.01 -0.846714286 -0.853285714 -0.867571429 -0.914142857 -0.995
0.03 -0.845571429 -0.851714286 -0.867714286 -0.914428571 -0.999428571
0.05 -0.906428571 -0.909428571 -0.923285714 -0.963857143 -1.043285714
0.1 -1.081 -1.079571429 -1.081857143 -1.107714286 -1.175
0.2 -1.216571429 -1.214428571 -1.21 -1.219 -1.270714286
1 -1.522714286 -1.518571429 -1.513714286 -1.505 -1.528285714
AC Current (mA)

0
1 3 5 10 20
-0.2
Galvanostat API 5LX 80
-0.4

-0.6
DC Current (mA)

0.01
-0.8
0.03
-1 0.05
0.1
-1.2
0.2

-1.4 1

-1.6

-1.8
AC Curretnt (mA)

20
3.4.3 Potentiostat
Potentiostatic, like galvanostatic and potentiodynamic, is a polarization technique that allows
for the controlled polarization of metal surfaces in electrolytes, in order to observe cathodic
and anodic behaviors. Corrosion reactions are monitored on a sample of the desired metal. A
number of characteristics of the metal/environment pairing can be determined through this
technique.

Potentiostatic techniques can be used in:

 Corrosion product identification and analysis

 Industrial and chemical plant corrosion and chemical attack
 Alloy selection
 Crevice corrosion analysis
 Electronics corrosion
 Local corrosion analysis

The potentiostatic technique is used to observe anodic and cathodic behaviors of a metal
surface in electrolytes. Polarization experiments are performed with a computer-controlled
potentiostat.

The metal sample is known as the working electrode (WE), which can be either bare metal or
coated. The reference electrode (RE) should typically be a material that is very stable under
the test conditions. The RE is used to monitor and maintain potential at the WE surface. A
potentiostat monitors ionic current passing through the electrolyte between the counter
electrode (CE) and the WE, and electron current passing between the CE and WE. Evaluation
of behavior and reactions can help determine a material's:

 Open circuit or corrosion potential

 Instantaneous corrosion rate
 Passivation behavior
 Pitting potential and susceptibility
 Crevice corrosion susceptibility
 Sensitization of heat affected zones
 Galvanic corrosion behavior of dissimilar metal pairs

21
For determining critical pitting potentials, the most reliable approach is to use a potentiostatic
technique in which a constant potential is applied, and the current is recorded as a function of
time. At electrode potentials below the pitting potential, the current decays to a constant value.
But at the pitting potential and above, the current increases with time as corrosion pits initiate
and grow.

3.4.4 Procedure of Potentiostatic Experiment

 First clean all the instruments.

 Specially clean the pipe coupon with hcl and acetone carefully.
 Note down the grade of pipe coupon.
 Check whole circuit for any loose connection with the help of circuit diagram.
 Make salt solution in a container, emerge two anodes, pipe coupon and half cell in the
solution.
 The distance between coupon and half cell is minimum 10mm.
 Measure the ph with the help of ph meter and soil resistivity with the help of 2 pin
method. Note down the readings.
 Maintaine the psp -850 mV with the help of galvanostat and measure the DC current
on application.
 Leave the whole apparatus with running dc and constant psp without any other
interruption for 24hrs.
 After 24hrs note down the dc current reading again.
 Now apply ac current and start taking readings of dc current in intervals of 30 minutes
with the help of AC variac as per the given format.
 Measure the readings carefully with the help of multimeter and note down it carefully.
 Again measure the ph and soil resistivity after finishing whole experiment.
 Stir the salt solution after every 30 minutes for different dc current readings.
 Change the salt solution for every new experiment.
 Repeat the same experiment for different grade of pipe coupon.

22
Fig 11 Potentiostat Readings (Sample) and observations of Pipe coupons

23
Figure Potentiostatic Readings (sample) for pipe coupons.

24
 Figure 12 Graphical representation of observation of pipe coupon API 5LX 80

API 5L X-80 Potentiostat

0.5

0.4

0.3
DC Current (mA)

0.2

0.1

-0.1

-0.2
0 1 3 5 10 20
850 0.031 0.03 0.029 0.024 -0.042 -0.094
950 0.065 0.06 0.066 0.052 0.04 0.012
1050 0.111 0.078 0.07 0.074 0.08 0.065
1150 0.111 0.105 0.102 0.103 0.11 0.157
1250 0.159 0.155 0.16 0.169 0.208 0.254
1350 0.291 0.288 0.297 0.307 0.363 0.424
AC Current (mA)

0.06
API 5L X-80 Potentiostat
0.05

0.04
DC Current (mA)

0.03

0.02

0.01 AC Current (mA)

0
0 1 3 5 10 20
850 0.016 0.012 0.01 0.008 0.011 0.007
950 0.019 0.018 0.017 0.017 0.018 0.02
1050 0.022 0.023 0.024 0.026 0.028 0.034
1150 0.029 0.03 0.027 0.027 0.036 0.043
1250 0.034 0.033 0.031 0.033 0.04 0.053
1350 0.052 0.051 0.044 0.044 0.045 0.055

25
 CHAPTER 4
Results & Discussion
The cathodic protection applied on pipe for corrosion protection cannot be maintained under
ac interference. The increase in CP potential do not depend only one factor that is current
density it is also a factor of soil resistivity and ph of soil.
We may observe that different materials will behave differently for a particular protection level.
There may be some protection levels, where AC interference may not affect the corrosion
current severely up to certain magnitude beyond which affect may be appreciable.
As we can see from figure the Graphical representation of potentiostatic experiment at CP
potential of -0.850V(CU/CUSO4) the CP could not protect the steel in the presence of AC
interference even at 5A/m2 AC current density from the graph. When the CP potential is change
to 950mv it can protect the pipe from small AC corrosion at 5A/m2 (AC current density) but
with the increase in current density between 10 and 20 A/m2 the corrosion in the pipe increases.
At more negative CP potential as 1150mv, 1250mv, 1350mv there is a different variations in
the graph at 10A/m2 and 20A/m2 we can conclude that at such a high potential it may provide
overprotection to the pipeline.
As we can see from figure the graphical representation of galvanostatic experiment a constant
current of 0.01, 0.03, 0.05, 0.1, 0.2 &1mA is used to measure corrosion rate at different AC
current density.
A very small dc current of 0.01mA we can observe there is a more negative potential at ac
current density of 10 A/m2 hence same observation is observed for 0.03,0.05,0.1. while for
1mA dc current there is a negligible variation in potential at different AC current density.

26
 CONCLUSION
 In this experiment it is concluded that different pipe grade will behave differently for
each protection level (say 0.85, 0.95 etc).
 There may be some protection levels, where AC interference may not affect the
corrosion current severely upto certain magnitude beyond which affect may be
appreciable.
 It is seen that there is a decrease in pipe to soil potential with the increase in AC current
density by AC variac.
 The presence of AC interference could affect the CP even at small AC current density.
 The CP potential of -0.85V(CU/CUSO4) is not able to protect the pipeline from
corrosion even at small ac current density but a CP of more negative potential does not
have the same affect at same AC current density.

27
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