Corrosion Training Design Part 11

Corrosion Training
CP Designed Part 1
Galvanic Anodes (current requirement
testing), Insulators, Test stations,
Coatings
Learning Over View
Part One
Current requirement design
Galvanic anode design
Insulators
Coatings
Test stations
Coupons
Part Two
Rectified Systems, Solar panels
Part Three
AC Design
Objective of Class
Understanding of design for COH and
CKY with Corrosion
Anodes (Galvanic)
Insulators (types)
Coatings (types)
Test stations
IR Coupons

Galvanic Anodes Types?
Magnesium anodes are used for
galvanic anodes in our system
17lb anode - remediation of WT pipelines
17lb anode - new steel coated pipe
9lb anode - bare main or service
3lb anode - bare customer service
1.5lb drive in anode company or customer
metallic coated risers
1.0lb zinc serv-a-node
Galvanic Anodes When?
Any time a metallic pipeline is exposed and
the surface of the pipeline is disturbed and the
pipe to soil readings are below -1.000 V CSE.
Any time corrosion technician has indicated on
corrosion recommendations
CP mains reading below -.850 V CSE on a
2512 J.O. (annual monitoring)
Cost and application evaluation performed for
comparison of anodes vs. solar vs. rectified
systems
Galvanic Anodes Connected?
Thermite welded to the pipeline
Thermite welds shall be 4 apart from each
other
Thermite welds shall be 6 away from an
adjacent weld
At any test station locations, connected
by mechanical means by junction of the
test station terminal
Galvanic Anodes Design?
Current Requirement test
Soil resistivity test
Determine the output of a 17lb HP anode
Number of anodes = Icp/Ia
Sunde theory

Galvanic Anode Design
(new Coated Steel Main)
Surface Area of pipeline
Diameter
Length
Coating Effectiveness
Current Density
Soil Resistivity

New Steel Pipe Calculations
Number of anodes
For an example
First calculate the total surface area of 6
WT MP pipe at a length of 12,000 feet?
Use the formula
Total surface area = Diameter x Length x

Number of anodes
For an example
First calculate the total surface area of 6
WT MP pipe at a length of 12,000 feet?

R Length Area
3.14 (6.625) = 1.735 12,000 = 20,820 sq ft
12
Need to divide the diameter by 12 to
convert to feet
Keep in mind, a 6 inch diameter pipe is truly 6.625 inches
Next Calculate the total coating effectiveness
The coating effectiveness will decide the total
bare area that the CP current will be needed
Keep in mind, the CP current protects only the
holiday areas of the pipeline
Calculate Coating Effectiveness %
99.5 % - Great
98.5% to 99.5% - Good
95% - Fair
Less than 95% - Poor

Number of anodes
Next Calculate the total coating effectiveness
The coating effectiveness will decide the total
bare area that the CP current will be needed
Keep in mind, the CP current protects only the
holiday areas of the pipeline
Calculate Coating Effectiveness %
99.5 % - Great (Columbias Standard used)
98.5% to 99.5% - Good
95% - Fair
Less than 95% - Poor

Number of anodes
What is the total surface area?
Number of anodes
20,820 sq ft
What is the total bare area of the
pipeline?
Number of anodes
20,820 sq ft
What is the total bare area of the
pipeline?
104.1 sq ft
Number of anodes
Next calculate the total amount of current
requirement for CP of the pipeline
Total bare area x current density = ICP
What is the bare area?
104.1 sqft
What is the current density?

Number of anodes
Number of anodes
Current Density
Is considered the square of the pipeline in which
will conduct current
Normally in the range 1 to 3 mA
Sandy or Dry soil 3 mA
Semi-dry soil 2 mA
Wet soil 1 mA
For current requirement calculations, we use a
higher number for higher soil resistivity for the
purpose of designing a higher amount of current
requirement.
104.1 x 1mA = 104.1 mAs

Number of anodes
Current
density
Bare Area of
pipeline
Total amount of current
requirement
What if the soil was
very sandy and
normally dry?
104.1 x 3mA = 312.3 mAs

Number of anodes
Current
density
Bare Area of
pipeline
Total amount of current
requirement
Change current density
to a higher number,
such as 3 mAs
What is the total requirement for wet
soil?
Based on our calculations = 104.1 mAs
How many anodes needed?
Have to calculate anode output next???

Number of anodes
120,000 f y

Number of anodes
120,000 1 1.21
6,500 ohms cm
= 22.3 mA
The top three numbers are given based anode design,
such as shape and weight of anode.
Input the soil resistivity to the
bottom of the equation
Anode output is
calculated
Now with the anode output and the total
amount of current requirement is calculated,
What is the total amount of anodes needed, if
we decide to bank the anodes 10 feet apart?
104.1 mA / 22.3 mA = 4.6 (round to highest number = 5 anodes)
5 anodes
Correct or not??????????

Number of anodes
Need more anodes Not the correct design
Single Anode Current
Reduction Factors (C)
# of Anodes in
Concentrated Bed
Anode spacing
5 Feet 10 Feet 15 Feet 20 Feet
2 1.84 1.92 1.95 1.96
3 2.45 2.70 2.79 2.85
4 3.04 3.45 3.62 3.71
5 3.59 4.19 4.43 4.56
6 4.12 4.90 5.22 5.41
7 4.65 5.60 6.00 6.22
8 5.15 6.28 6.77 7.04
9 5.67 6.96 7.54 7.87
10 6.16 7.64 8.38 8.68
Sunde Theory
Used for
banking
anodes
5 anodes at
10ft apart =
4.19 anodes
10 FT
spacing
5 anodes
Sunde Theory Calculation
5 anodes to be banked at 15 feet spacing.
4.43 22.3mA = 98.8 mA
The current requirement was at 104mA therefore 5 anodes
would not be enough.
6 anodes to be banked at 15 feet spacing.
5.22 22.3mA = 116.4mA
The current requirement was at 104mA therefore 6 anodes
would have enough output to meet cathodic protection.

Summary
6 WT Pipe @ 12,000 length =
5 anodes, if distributed along the line
6 anodes, if banked at 10 feet apart
Soil resistivity of 6500 ohms cm
Current density of 1 mA
Coating effectiveness of 99.5%

Number of anodes
Test Stations
Above Ground
Cott
Large Fink
Small Fink
Gerome
Tri-view flex
B-T
Curb box type
COH and CKY Recommended use is the Tri-
view flex for above ground use
Gerome box for any continuity or interference
bonds

Test Stations
Two wires No. 12 Black
New
Carrier pipe
Two wires No. 12 White
Old/bare
Casing

Test Stations
Interference test station (bond)
Two No. 8 wires (1-Company & 1-Foreign)
Two No. 12 wires black (company)
Two No. 12 wires white (foreign)

Test Station - Spacing's
Business 750 Feet
Residential 1500 Feet
Rural 6000 Feet
P/P - 653-3
Coatings are our first line of defense against
corrosion.
Coatings are a high resistance barrier between
the metallic structure and the surrounding
electrolyte.
A quality dielectric coating material can reduce
costs in additional corrosion control materials
such as sacrificial anodes or impressed
current type cathodic protection systems.
Coatings
Cathodic protection system design is
based upon protecting the bare surface
area of the buried/submerged metallic
structure.
Typically a well coated pipeline will be
protected over 90% of its surface.
In this case, only 10% of the pipeline
surface will require cathodic protection
current.
Coatings
As an example:
100 feet of 12 diameter pipe has 314 ft
2
of surface area.
A vertically installed 17# high potential magnesium anode in
5000 -cm soil has a current output of 30 mA.
A design current density of 2 mA/ft
2
results in a current
requirement for the pipe of 628 mA.
With 30 mA per anode, 21 anodes are required.
However, if the pipe is 90% coated, then only 10% or 31.4 ft
2

is bare.
At 2 mA/ft
2
the current requirement is 62.8 mA.
With 30 mA per anode, only 3 anodes are required!
This shows the importance of having a quality coating.
Coatings
Holiday Testing (Jeeping)
Test process which the operator can identify
holidays (imperfections) in the coating
Involves a high voltage power source
Instruments can be adjusted to apply the proper voltage
across the coating
Different thickness of coating requires different settings
Electrode is passed over the coating surface
If the coating resistance is low or a holiday is present, an
audio signal is heard due to an electrical discharge from
the electrode onto the pipe surface
Repair of the coating is made
Coatings
(525)
T= Voltage
(125)T
=
Voltage
(1250)
T= Voltage
Powercrete
Fusion Bonded Epoxy
Extruded
Reference
Nace RPO274-98 = Extruded coating
Nace RPO490-95 = Epoxy coating
Powercrete Manual
Coatings Jeep Settings
Extruded
Thickness
10mils
20mils
30mils
40mils
50mils
60mils
70mils
Voltage
8839
9682
10458
3953
5590
6847
7906
Epoxy
Thickness
10mils
20mils
30mils
40mils
50mils
1650
2348
2876
3320
3712
Voltage
Powercrete
Thickness
45mils
75mils
Voltage
5625
9375
Some common
Jeep voltage
settings for
common coatings
Coatings Jeep Settings
Coatings Jeep settings
You maybe asked to QA or verify the
coating thickness base on the jeep
process
Check the coating thickness
DFT
Check the voltage setting of the Jeep
Verify, the contractor or crew is creating a
holiday to verify the setting
Coatings Jeep Process
Coatings Jeep Process
Three common types mostly used in the
gas industry
Extruded
Fusion bonded epoxy (FBE)
Powercrete
Coatings
Extruded
High density polyethylene
Can be supplied in different thickness up to 60
mils
Asphalt or rubber butyl adhesive
Normal thickness is in the range of 10 to 15 mils
Used primarily for direct bury application
Girth welds normally coated with cold-
applied tapes

Coatings
Coatings - Extruded
Coatings - Extruded
Direct Bury -
X-Tech II COH & CKY practice for direct
bury design, 1
st
choice
70 mill application
Two layers of 30 mills of polyethylene coating
10 mills of butyl rubber mastic
Coatings - Extruded
Design for AC and/or DC interference
currents
Use only Extruded X-TECH II coating
systems
Fusion Bonded Epoxy
Surface preparation includes sand blasting
To clean the surface and form anchor patterns for the coating to
adhere or bond to the pipe surface
Surface is acid washed to remove salt deposits
Surface is washed with dionized water
Pipe surface is heated to 500 degrees or hotter
Epoxy powders are electro statically charged and sprayed
onto the hot surface
The powders melt to a liquid form and fuse to the pipe surface
forming a hard shell
The applied coating normally cures within 90 seconds and
then is blasted with cool water in order to facilitate handling
Coatings - FBE
Coatings - FBE
FBE
12 15 mills of FBE first layer
20 mills of FBE second layer
Total of 32 to 35 mills coating
COH & CKY practice only use dual coats, never
single layer systems, 2
nd
choice for direct bury
Epoxy base Polymer Concrete
The pipe is coated with an FBE normally
with a thickness of 12 to 15 mils
The FBE is then coated with the polymer
concrete coating (Powercrete) 20 mills
Coatings Powercrete
Can be applied in the field
Each pass applies approx.
20 mils thickness
Max 125 mils
Perfect for directional boring
COH and CKY
recommendation for
directional boring design
Use for above ground design
with a polyurethane outer coat

Coatings - Powercrete
COH & CKY practice a
minimum of 50 mils for
above ground application
minimum of 50 mils for
directional boring application
minimum of 70 mils for rocky
directional boring
applications

Coatings - Powercrete
Girth Welds
FBE and Powercrete coating applications
COH & CKY practice two part liquid epoxy system
Protal 7200 temps at or above 50 degrees
Protal 7125 temps below 50 degrees
R95 temps at or above 50 degrees back up coating
Surface will need to be sand blasted to a Nace 1 anchor
pattern
The two parts are mixed
Epoxy resin
Epoxy hardener
Coat the surface of the girth weld according to
manufactures recommended wet film thickness
Use the same material on the holiday areas as well
Coatings Girth Welds
Girth Welds
Extruded Coatings X-Tech II
Acceptable methods
Polyken 936
Tape coat H35
Petrolatum Tape
Utility tape (PVC) on new steel applications to be
used
S105 paste recommended, especially in cold
climates

Coatings Girth Welds
Coatings Thermite welds
No mastic..
Preference especially for vacuum
systems
Acceptable methods
Petrolatum products
Profile mastic petrolatum Denso product (bird seed)
Top coat with the Denso Color Tape petrolatum
Denso product
Protal 7200 cartridge
Mix product on cardboard
Dip brush and paint onto surface
Cover with Trenton wax paper to prevent any damage
due to debri of dirt
Trenton patch kits (watch cost higher dollar)
Coatings Transmission and/or
Directional boring Applications
Corrosion FLL shall be contacted
Corrosion department will inspect the
pipeline at the coating Mill using the
recommended Hold points
In a rocky back filled situation, one
should apply an outer protected
shield for your pipeline coatings.
Note: On CP systems, use the mesh
rock shield only.. As to not cause
cathodic shielding with the solids
Coatings - Rock shield
Insulators - Types
Kero-Test Monolithic Weld-in
Bangs Flanged Weld-in
Dresser bolted coupling
Compression
Unions
Flanges
Insulators When?
Tying new pipe to old pipe (coated)
Tying coated pipe to bare pipe
Domestic, large volume and GM settings
Separate house lines from company lines
Casing from carrier pipe
Pipe from supports
Bridges
M&R settings
Break a large circuit to smaller units for easier
troubleshooting and management
Separate shorts with foreign lines
River crossings
Insulators - Tying new and old
existing Coated Pipelines
Recommended for use in galvanic systems due to
limited driving potential of the magnesium anodes
Cost comparison
Evaluate the cost for an insulator to be installed
For example, if one insulator to separate a 100 section of new
coated metallic pipe from an existing CP coated metallic
anode system (older), will cost in the range 4,800.00 x 2 =
9,600.00; then it may not be cost effective to make this
recommendation.
Purpose to prevent a galvanic cell to be created due
to the potential difference with the new coated pipeline
and the old coated systems
For an example, the new coated system can have a high
negative potential in reference to the old coated bare main.
Test station installed at location
Two black wires - #12 (New)
Two white wires - #12 (old)
Two no. 8 wires
One wire connected to the New
One wire connected to the old
Bond in the test station box,
if rectified system
If anode system and want to cathodically protect
as a single circuit

If not bonded in the test station box, then
create two facilities on WMS and two
test point sheets

Recommended spacing's of insulators
Business 1500 feet
Residential 3000 feet
Rural 12000 feet
Insulators - Tying to Bare Pipe
All coated systems tying to bare systems
are to be insulated off
Test station installed at location
Verification to be made on annual
monitoring
Trouble shooting purpose
Two white wires on the bare pipe
Two black wires on the coated pipe

Monolithic weld end
insulators are an
excellent choice for
high pressure
systems where pull
out may be an issue
with other insulated
coupling devices.
No field assembly required or
bolts,washers or sleeves that
could cause an electrical short.
Insulator Weld - In
COH & CKY practice
always use weld-in
insulators and only the
Zunt monolithic for buried
pipelines
Insulators - Meter settings - Types
Insulated valves
Insulated Unions
Insulated Meter bars
Insulated Swivels
Insulated Flanges
Design purpose
Domestic size meters
Insulated Valves
Large volume, or GMB accounts
Insulated Unions
Insulated flanges
Insulators M&R Station
Insulated in a structure
Must have a zinc grounding cell installed (DOT and
procedure requirement)
Insulated at flange @ outlet of valves
Outlet valve
If need to replace flange insulators, on lower pressure end
Bypass valve
All control lines need to have insulated unions
A high dielectric strength material is used
fiber glass or a plastic material to
prevent a metallic connection between
the two flange faces.
The bolt acts
as a bypass if
not insulated
properly.
Insulators M&R Station
Casing isolation two primary functions
Prevent an electrolyte from entering the
casing and creating a galvanic corrosion
cell.
Prevent metallic contact between the carrier
pipe and casing pipe.
Casing isolation may remove up to two of
the four parts of a corrosion cell.
Insulator Casing and Carrier Pipe
Casing isolation Three primary tools used
Casing filler
High dielectric material (high resistance) to displace the
electrolyte within the casing
Casing spacers
Insulating material to prevent metallic contact between the
casing pipe and the carrier pipe
Casing seals
Physical seal used to seal the ends of the casing in order
to prevent an electrolyte from entering the casing
Insulators Casing & Carrier Pipe
Petrolatum based material that has a
high dielectric strength.
Displaces the surrounding electrolyte in
the casing around the carrier pipe.
Prevents water from entering the casing
and displaces the existing water.
Environmentally safe non-hazardous.
Insulator Casing & Carrier Pipe
Casing Filling
Pictures -Courtesy of Trenton co.
Casing filler can be installed
hot or cold.
There is treatment for casings
already filled with water.
Insulator Casing & Carrier Pipe
Casing Filling
Spacers are made from a dielectric
material, hard polymer (plastic). A
spacers primary function is to
prevent the metallic contact
between the casing pipe and the
carrier pipe.

Insulator Casing & Carrier Pipe -
Spacers
Seals the ends of the
casing around the carrier
pipe.
Keeps the casing filler
inside the casing.
Prevents water or other
elements from entering
the casing and creating a
galvanic cell.
Insulators Casing and Carrier Pipe
Link Seals & Rubber boots
Pipe Supports
Coated metallic pipe shall be isolated
from any bridge structure
Fiber board
Glass mesh insulated bridge supports

Pipe Supports
Coated metallic pipelines shall be
insulated from any supports at M&R
settings
Existing pipe may need to be lifted off the
support area to be insulated properly

FRPs
Fiberglass
Reinforced
Plastic
Insulator FRPs
Primary function of FRPs
To prevent an electrical connection between
the structure intended for cathodic
protection and foreign metallic structures.
Separates the anode from the cathode by
electrically isolating the two structures.
Reduces the required amount of corrosion
materials to be used.
Insulator FRPs
There are a variety of
types of FRPs.
Flat FRPs are a practical way
of physically separating two
buried structures especially in
an excavation situation.
Insulator FRPs
Some FRPs are attached to the structure with
an epoxy adhesive sealant, this helps mitigate
crevice corrosion from taking place between
the FRP and the pipeline.
Another type of installation involves applying
a petrolatum tape material between the FRP
and the pipeline to mitigate crevice corrosion.
Insulator FRPs
FRPs are an excellent material to be used on
bridge crossings or other aboveground pipe
supports.
Courtesy of Glass mesh
Insulator FRPs
Benefits of using coupons
Obtain IR drop free potentials
Especially on systems that the
current source can not be
interrupted.
AC measurements such as
AC current density
calculations.
Surface area = 1.34 in
2
Two no. 12 stranded wires.
IR Coupons
The coupon needs to be of the
same material as the pipeline in
order to represent it accurately.
IR Coupons
Need to have the coupon close to
the pipeline (normally within 4
to 12, buried in the same native
soil as the pipeline.
IR Coupons
Best practice is to place the
coupon about mid way of the
pipeline on the side.
IR Coupons
Connect the coupon in the
test station by bonding to the
pipeline. The coupon will
receive the same cathodic
protection current as the
pipeline.
IR Coupons
The coupon represents a holiday area of the pipeline. The cathodic
protection system (CP) protects the holiday areas of the pipeline, by
bonding the coupon to the pipeline, the CP will polarize the coupon as
well. We can remove the IR drop and find the true polarization on the
pipeline by separating the connections and taking an instant-off
structure-to-electrolyte potential measurement.
IR Coupons
V
Bond or Switch
The blue wires
identify the lead
wires used to
electrically bond the
coupon to the pipe.
Connect the
voltmeter to
the non-
current
carrying lead
wire from the
coupon.
Coated
pipeline
Coupon
Test
Station
IR Coupons
Coupon measurements:
Allow the coupon to polarize by electrically bonding
the coupon to the structure in the test station.
Disconnect or interrupt the coupon from the
structure.
Obtain structure-to-electrolyte potential
measurements of the coupon, current applied and
momentarily interrupted.
The potential readings will be IR-drop free and will
represent the pipelines IR-drop free potential
readings.
IR Coupon - Measurements
Material Summary
Test stations
Above ground
Tri-view Flex
Gerome for multiple wire connections such as bonds
Anodes
Connected in the test station box
Get soil resistivity in designing
Use anode calculation spread sheet
17lb CP remediation and new coated steel pipeline
9lb Bare pipe leak repairs
3lb customer service lines
1.5lb drive in anodes isolated metallic coated risers

Material Summary
Insulators
Below ground Zunt Monolithic Weld-in
Above ground M&R flange insulated kits
Insulation made inside a building (M&R)
Zinc grounding cell installed
Always place a test station at insulation
Always insulate casings and fill

Material Summary
Coatings
Powercrete 50 mil directional boring
Powercrete 70 mil rocky directional boring
Powercrete 50 mil bridge crossings and/or any
exposures
10 mils of polyurethane top coat
FBE only use dual coat applications of 32 to 35
mils
Extruded used primarily as direct bury applications
Use for stray current surroundings
AC or DC
All coating applications transmission class
Inspected at the coating mill

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