A FINAL REPORT

ON
CATODIC CORROSION PROTECTION OF EARTH BURIED PIPELINES

BY
MOHAMMED ASHAR RIYAN KHAN

2013A8PS092U

AT
Automation & Power Solutions
Dubai Silicon Oasis, LIU #10
Dubai, U.A.E

A Practice School I Station of

BITS Pilani, Dubai Campus

Dubai International Academic City (DIAC)
Dubai, U.A.E

(JUNE 2016 - AUGUST 2016)

EIE

A FINAL REPORT

ON
CATODIC CORROSION PROTECTION OF EARTH BURIED PIPELINES

BY
MOHAMMED ASHAR RIYAN KHAN

2013A8PS092U

Prepared in Partial Fulfillment of the

Practice School I Course

AT
Automation & Power Solutions
Dubai Silicon Oasis, LIU #10
Dubai, U.A.E

A Practice School I Station of

BITS Pilani, Dubai Campus

Dubai International Academic City (DIAC)
Dubai, U.A.E

(JUNE 2016 - AUGUST 2016)

EIE

BITS Pilani, Dubai Campus

Dubai International Academic City (DIAC)
Dubai, U.A.E

Station: Automation & Power Solutions

Location: Dubai

Duration: 09-Jun-2016 to 03-Aug-2016

Date of Start: 09-Jun-2016

Date of Submission: 03-Jul-2016

Title of the Project: CATODIC CORROSION PROTECTION OF EARTH BURIED PIPELINES

Student Name: Mohammed Asher Riyan Khan

Student ID: 2013A8PS092U

Discipline of Student: Electronics And Communication Engineering

Name And Designation of Experts:

1.

Mr. Mohammad Inayatullah Khan

2. Mr. Mohammad Aamer F. Khan

Manager-Oil & Gas

Sales Engineer-Oil & Gas

Name of the Faculty:

Dr. Sunil Thomas

Assistant Professor,
Department of Electrical and Electronics Engineering

Key Words: APSPE, Saudi-Aramco, Benning

Project Areas:

Abstract:
The report contains an overview of the specification and Industry standards with regard to defining
the minimum requirements for design, manufacture and supply of CATODIC CORROSION
PROTECTION OF EARTH BURIED PIPELINES with detailed explanation.

Signature of the Student

Date:

Signature of PS Faculty

Date:

ACKNOWLEDGEMENTS

Firstly, I would like to express my heartfelt gratitude to Prof. R. N. Saha, Director BPD who has

given us an opportunity to apply and understand our engineering concepts in a practical

atmosphere.

I am grateful to Mr. Mohammad Inayatullah Khan- Manager (Oil& Gas), Automation & Power
Solutions, for guiding and helping me by giving his valuable time and required information about
the organization.

I would also like to thank Prof. B. Muralidharan, Dean - Placement & Practice School, for giving us

this opportunity to work and apply our knowledge in the technical field and gain firsthand

experience.

My sincere gratitude to Dr. Sunil Thomas, my PS Faculty, for providing me with all the assistance

required for successful completion of this report

Signature of the Student:

Date: 03-July-2016

Contents
Introduction_________________________________________________________6

1.1 Associated Companies: 7

1.1.1 Joint Ventures / Representation / Agency Agreements _______________________________ 7
1.2
Background and Activity 7
1.3
Quality Policy
7
2 Cathodic Protection System___________________________________________9

2.1 Summary 9
2.2 History 9
2.3 The Principles of Cathodic Protection_________________________________________________ 9
2.4
Advantages and Uses of Cathodc Protection
12
2.5
Two types of Cathodic Protection Systems:
13
a) A galvanic system requires ___________________________________________________ 13
b) An impressed-current system requires: __________________________________________ 14
2.6
Basic Requirements for Cathodic Protection
15
2.7
Design Aspects
16
2.7.1 Considerations that are initial _________________________________________________ 16
2.7.2 Potential Level and Distribution _______________________________________________ 17
2.7.3 Economics of decisions ______________________________________________________ 17
2.7.4 Problems to be avoided ______________________________________________________ 18
2.7.5 Kinds of Equipment _________________________________________________________ 19

Introduction
Automation & Power Solutions Projects Est. (APSPE), with its Diversified And Multi-Disciplinary
Contracting, Trading and Training Activities Ranging From Process Instrumentation and Control,
Power, Telecommunications, Electro-Mechanical to Civil Contracting.

APSPE is an established company and is rising steadily. We have been Successful in our
approach to various and Numerous Projects Serving Public and Private Sector Customers such as:

Saudi ARAMCO, Saudi Electric Company (SECO), Saudi Basic Industries Corporation (SABIC),
Royal Commission, Saudi Railways (SRO), and many other EPC/LSTK contractors.

APSPE represents different manufacturers for various products; details can be seen in section
Associated Companies.

APSPE is specialized in the Design, Supply, Installation, Testing And Commissioning including
Hands On Training for a wide range Of Power Systems (Substation, Transformers, Switchgears,
Battery Backup and UPS) Process Control Systems (DCS, SCADA, PLC, RTU, TMS and Field
Instrumentation), Telecommunications Systems (Fiber Optic OSP, Digital Communication, SDH,
Microwave, Radio, Ethernet Networks), Safety Systems (ESD, Fire & Gas Detection), Building
Management System and Security Systems.

Reflecting objectively the companys capabilities, expertise and reliability as a reputable Trading
and Contracting Company. Training also constitutes a Solid Part of Our Business.

1.1 Associated Companies:

By being part of Automation & Power Solutions Projects Est. is involved in wide and diversified number of

companies and industries:

1.1.1 Joint Ventures / Representation / Agency Agreements

A. BENNING Conversion De Energie.

France

B. Shore Waves

UAE

C. Automation & Power Solutions AJMAAN

1.2

UAE

Background and Activity

Automation and Power Solutions Projects was established during 2009 mainly to provide Process

Instrumentation and Control, Power, Telecommunications, Electro-Mechanical, City Contracting and

Trading services to the market that is Saudi stress on Customized and Standards Hands on Training.

The corporation has got the functions of managing projects on turnkey foundation in all technological &

financial aspects right from their very early on phases of conceptual design, thru to Design, purchase,

Staging, supply, Installation, start up, screening and commissioning, training, hand-over and exploitation

that is effective.

1.3

Quality Policy

It's the policy of Automation & Power Solutions Projects Reprsente. to always strive to supply the best

trading & Import services of Commercial and Electrical Equipments to maintain its leadership position in

this business.Devoted to comply with the requirement of absolutely free themes also to continually

increase the effectiveness of the Quality Management Program. It ought to be evidently understood that

this Quality Policy, Top quality Manual and associated Functioning Procedures and systems are

mandatory on all personnel.

2 Cathodic Protection System

2.1 Summary

This Report explains the fundamental principles of cathodic protection, the areas of use, and the
general things to be viewed in the choice and design of a system. It gives a standard introduction
and simple technical information on cathodic protection.

2.2

History

The first documented practical usage of cathodic protection is typically awarded to Sir Humphrey
Davy in the 1820s. Davys advice was wanted by the Royal Navy in researching the corrosion of
copper sheeting utilized for cladding the hulls of naval ships. Davy discovered that he could
preserve copper in seawater by the attachment of small levels of iron, zinc or tin. The copper
became, as Davy put it, catholically protected. It was conveniently abandoned because by
protecting the copper its antifouling properties became retarded, hence reducing the streamline of
the ships, as they began to collect marine growths.
Probably the fastest growth of cathodic-protection had been produced in America and by 1945, the
technique was more successful to meet up with the requirements regarding the oil that is quickly
expanding gas industry, which wished to enjoy the advantages of using thin-walled metal pipelines
for underground transmission.
In Britain, where low-pressure, thicker-walled cast iron pipes were used extensively, hardly any
cathodic security was used before the very early 1950s. The use that is increasing of protection in
our contemporary world has arisen, in component, from the initial success associated with method
as used from 1952 onwards to protect about 1000 kilometers of wartime fuel-line network. The
technique has become well established and is applied to a number that is wide of and hidden
facilities and infrastructure, also as strengthened concrete structures, to offer corrosion control.

2.3 The Principles of Cathodic Protection

Metal which has been extracted from its basic ore (metal oxides or other free radicals) has an allnatural tendency to revert to that state under the action of oxygen and water. This step is called
corrosion and the most common example is the rusting of steel.

Corrosion is an electro-chemical process that involves the passage of electrical currents on a micro
or macro scale. The transformation from the metallic to the combined form occurs by an anodic
reaction

M+
+
(metal)
(soluble salt)

e(electron)

A common example is:

Fe Fe++

2e-

This reaction produces free electrons, which pass within the metal to another site on the metal
surface (the cathode), where it is consumed by the cathodic reaction. In acid solutions the cathodic
reaction is:

2H+ +
(Hydrogen ions
in solution)

2e- H2
(gas)

In neutral solutions the cathodic reaction involves the consumption of oxygen dissolved in the
solution:

O2

2H2O +
4e- 4OH(Alkali)
Corrosion thus occurs at the anode but not at the cathode

( Unless the metal of the cathode is attacked by alkali).

2 M 2M++ + 4e

O 2 + 2H2 O + 4e 4 OH

(corro sion)

Electron (e -) flow in metal

Figure 1. Corrosion cell / bimetallic corrosion

The anode and cathode in a corrosion process might be on two various metals connected together
forming a bimetallic couple, or, as with rusting of steel, they might be close together on a similar
metallic surface.

This corrosion process is initially caused by:

Difference in natural potential in galvanic (bimetallic) couples. Metallurgical variations in the state of
the metal at various points on the surface.
Local variations in the environment, such as variations in the supply of oxygen at the surface
(oxygen rich areas become the cathode and oxygen depleted areas become the anode).
The concept of cathodic protection is in linking a anode that is outside the steel to be protected as
well as the passage through of a power dc current making sure that every area associated with
metal area be cathodic and so do not corrode.

The external anode can be a galvanic anode, where in fact the present is because the potential
difference between the 2 metals, or it might be an impressed current anode, where the current is
impressed from a dc power supply that is external.

The electrical potential between the steel and the electrolyte solution with which it really is in touch
is manufactured more negative, by the availability of negative charged electrons, to a value at which
the corroding (anodic) reactions are stifled and only cathodic responses can take destination in
electro-chemical terms. Into the discussion that follows the assumption is that the metal to be
protected is carbon metal, which is probably the most material that is common in construction. The
cathodic protection of reinforcing carbon steel in reinforced concrete structures are used in a
fashion that is comparable.

Cathodic protection can be achieved in 2 methods:

- By way of galvanic (sacrificial) anodes, or
- By impressed current.
Galvanic anode systems employ reactive metals as auxiliary anodes being directly electrically linked
to the steel become protected. The difference in natural potentials between the anodes therefore
the metal, as indicated by their relative jobs into the series that is electro-chemical causes a positive

current to flow within the electrolyte, from the anode to the metal. Hence, the top that is entire of
steel becomes more adversely charged and becomes the cathode. The metals commonly used, as
sacrificial anodes are aluminum, magnesium and zinc. These metals are alloyed to boost the
performance that is long-lasting dissolution traits.
Impressed-current systems employ inert (zero or dissolution that is low anodes and use an outside
way to obtain dc power (rectified ac) to impress a current from an external anode onto the cathode
area.
The connections are comparable for the application of cathodic protection to storage space that is
metallic, jetties, overseas structures and reinforced concrete structures.

2.4 Advantages and Uses of Cathodic Protection

The primary advantageous asset of cathodic protection over other forms of anti-corrosion treatment
is that it's used just by maintaining a dc circuit and its effectiveness may be monitored
continuously. Cathodic protection is commonly applied to a coated structure to provide corrosion
control to areas where the coating may be damaged. It may be used to existing structures to
prolong their life.
Indicating the use of cathodic protection in the beginning will avoid the need to provide a corrosion
allowance to thin parts of structures that may be expensive to fabricate. It may be used to afford
security in which even a small leak cannot be accepted for reasons of safety or surroundings.
Cathodic protection can, in principle, be applied to any metal structure in touch with a volume
electrolyte (including concrete). In practice, its primary usage is to protect metallic structures
covered up in soil or submerged in water. It cannot be used to prevent atmospheric corrosion on
metallic elements. However, it can be used to prote ct atmospherically exposed and buried
reinforced concrete from corrosion, as the concrete itself includes sufficient moisture to act as the
electrolyte.
Structures that are generally protected by cathodic protection would be the exterior areas of:
a) Pipelines
b) Ships hulls
c) Storage tank bases
d) Jetties and harbor structures
e) Steel sheet, tubular and foundation pilings
f) Offshore platforms, floating and subsea structures
Cathodic protection may also be used to protect the interior surfaces of:
a) Large diameter pipelines
b) Ships tanks (product and ballast) Storage tanks (oil and water) Water-circulating systems.

However, since an internal anode will hardly ever spread the protection for a distance of more than
two to five pipe diameters, the method is not commonly practical, or suitable, for the protection of
small-bore pipework.
Cathodic protection is applied to control the corrosion of steel enclosed in reinforced concrete
structures (bridges, buildings, port and harbor structures, etc.)

Cathodic protection can be applied to copper-based alloys in water systems, and, exceptionally, to
lead-sheathed cables and to aluminum alloys, where cathodic capacities have to be very cautiously
controlled.

2.5 Two types of Cathodic Protection Systems:

A galvanic system requires:

a)

i.
ii.

Sacrificial anodes
straight welding to the framework or a conductor connecting the anode to the
framework
Secure and minimum resistance connections in between conductor and structure, and
between conductor and anode.

iii.

b)

An impressed-current system requires:

i.

Inert anodes (groups of which, linked together often in a backfill, are called the ground
bed).
A dc power source.
Electrically well insulated, minimum resistance and secure conductors between anodes
and power source.
Secure and low resistance connectivity between power source and framework.

ii.
iii.

iv.

In both cases, important design decisions has to be made to select the type of system and the best
option of anode that's best for that system. Also required, is the determination of the dimensions
and number of the power sources, or sacrificial anodes, and their circulation on the structure.

2.6 Basic Requirements for Cathodic Protection

Requirements that must be met to ensure that cathodic protection is used in the most economic and
reliable manner are:

A. Electrical continuity

The opposition associated with conductor and framework is such as to minimize

the drop that is potential of return protective currents through the structure.

B. Coatings.
The supply of a protective/insulating coating to the framework will greatly reduce
the present demanded for cathodic protection associated with surface that is
metallic. The use of a well-applied and layer that is suitable advances the effective
spread of cathodic protection present. A combination of applying both a coating
and cathodic security will typically end in the absolute most practical and economic
protection system that is general. Ideal coatings are those that have a higher
opposition that is electric are continuous and certainly will adhere strongly to your
area to be protected. Other finish that is desirable include; stability within the
environment, abrasion opposition, and compatibility with all the alkaline
environment developed or enhanced by cathodic security.

C. Construction isolation.
It is often desirable to limit the spread of cathodic security. This might be achieved
by the insertion of monolithic electrical isolation joints in the structure for pipelines
and tanks. Insulating flange kits are sometimes utilized though they frequently
need regular upkeep. Polarization cells that limit low voltage cathodic protection dc
currents, but enable passing of high voltage ac currents, may be used to separate
low-resistance earthling systems from a well-coated framework that is protected.

D. Test facilities.

It's important to look at the location of test facilities, test channels, corrosion
monitoring discount coupons, permanent half cells (reference electrodes), plus the
manner that information is regularly collected or seen.

2.7 Design Aspects

2.7.1

Considerations that are initial

Modifications towards the dwelling to incorporate requirements are well made at the design that is
really early phase that is pre-construction with structure. The proposed course, to have information
that is additional low-resistivity areas, accessibility to energy, therefore the existence of stray dc
current or other feasible interaction for underground structures it could be essential to visit the
proposed site, or for pipelines.

It is practice that a common survey is made before design. This study can be combined with a
research to ascertain justification that is economic and recommended anti-corrosion proposal as the
principal data necessary for design (chemical and physical) are also collected.

If the structure currently exists, dimension of current structure-to-soil potentials is important to offer
information that is valuable to which areas are anodic and which are cathodic. In addition, with the
application towards the structure of temporary cathodic-protection current, utilizing any dc that is
convenient and a temporary anode system (ground bed), a more accurate assessment of present
need therefore the most likely spread of protection to the structure may be examined.

In the case of onshore pipelines and other structures, negotiation with landowners, public
authorities, or other interested events, for easements and way leaves for ground beds, cable routes,
transformer-rectifier sites, and electricity supplies should additionally be undertaken during the
design phase.

2.7.2 Potential Level and Distribution

Used, the structure-to-electrolyte potentials are measured utilizing a half-cell that is standard
reference electrode). As an example, a protection that is common used for steel in an aerobic
electrolyte of nearly neutral pH is a negative value of minus 850 mV. Whenever confronted with
sulphate-reducing bacteria, steel would need a more potential that is negative of 950 mV. Both
values are with respect to a copper/copper sulphate half-cell. Ideally, to achieve a degree that is
most of and in order to minimize measurement errors, the half-cell should really be very close to the
top at that your potential will be measured.
The potential values measured on a catholically protected structure is going to be influenced by the
anodic and cathodic reactions, structural geometry, and internal resistance that is electrical.
However, the provision of a protective coating has undoubtedly the effect that is greatest on the
potential for a given applied current. The potentials will generally be most negative at a point
nearest to the anode or ground bed and, for pipelines, will attenuate towards the corrosion that is
natural since the distance from the anode or ground bed increases.
A typical example of possible attenuation is that, in the event of a method that is power-impressed
an individual cathodic-protection installation may supply cathodic protection to around 150 km of
well coated pipeline, whereas for similar sizes of bare (uncoated) pipelines it might be necessary to
have installments at just 2 km periods.

2.7.3 Economics of decisions

A determination must be manufactured as to whether the scheme will be a galvanic or impressedcurrent system at the look stage of a cathodic-protection scheme. The employment of both forms of
systems could be appropriate, but care is required to avoid interaction between them in specific
circumstances.
Galvanic systems have actually the advantage of being

A.
B.
C.
D.

A simple that is install

Independent of a source of outside power that is electric
Suitable for localized protection
Less liable to cause interaction on neighboring structures.

Nonetheless, the present output available through the practical size and fat of galvanic anodes is
fairly small and depends principally on the electrical resistivity associated with electrolyte (local
environment if hidden / submerged / concrete). Hence, galvanic anodes of zinc and aluminum,
which have similar driving emfs to metal of approximately 0.5V, are restricted to utilize in
electrolytes of not as much as 5 Ohms resistivity. The anodes are usually self-regulating because
their production that is current is lower than their maximum output capability and it is managed by
the difference in potential between your two metals. The current from the anodes is not ordinarily
controllable; thus changes in the structure, such as the deterioration of a coating that causes a rise
in security demand that is current may necessitate the installing of further sacrificial anodes to
maintain protection.

Impressed-current installations have actually the benefit to be

Able to relatively supply a sizable current

Able to provide of high dc voltages that are driving to 50V).
Enables it to be utilized in most types of electrolytes
Able to provide a output that is flexible may accommodate changes in, and additions to,
the framework being protected

A.
B.
C.
D.

Generally, however, care must be used the style to minimize connection on other structures and, if
no ac supply is available, a power that is alternative (solar, diesel, etc.) is required. Impressed
systems that are present regular maintenance and monitoring.
Generally, galvanic systems have found favor for small well-coated, low need that is current
structures or for localized security. Impressed schemes which are current utilized for large complex
structures, which may be of bare steel or poorly coated. However, in North Sea work that is
offshore it offers been found cheap to provide galvanic protection to large uncoated platforms, and
comparable structures, where the initial cost of finish and the cost of maintenance are extremely
high. In addition, the anodes that are galvanic easy to install robust systems, which being separate
of a power source, provide protection straight away on float-out of the dwelling.

2.7.4 Problems to be avoided

There are certain limitations to the use of cathodic security. Exorbitant potentials being negative
because accelerated corrosion of lead and aluminum structures because of the alkaline
environments created during the cathode. These alkaline conditions are often harmful to coating
that is certain, and might cause loss of adhesion of this coating. Hydrogen evolution during the
cathode surface might, on high-strength steels, lead to hydrogen embrittlement associated with
steel, with subsequent loss of strength. This could cause catastrophic failures on some high energy
steels. It may additionally cause disbandment of coatings; the layer would then behave as an
insulating shield to the cathodic-protection currents.
Consideration should also get to spark hazards developed by the introduction of electric currents
into a structure located in a area that is hazardous. Generally anode that is sacrificial usually do
not cause problems, as they are self-regulating and are often regarded as systems which can be fit
and forget. They must, however, be inspected at regular intervals to make certain these are
typically with the capacity of supplying proceeded protection.
Any framework that is additional in the same electrolyte may receive and discharge the cathodic
protection direct current by acting as an alternative low-resistance path (interaction). Corrosion are
going to be accelerated in the framework that is secondary any point where current is discharged to
the electrolyte. This phenomenon is known as "stray current corrosion". Conversation may occur,
for example, on a ship that is moored alongside a catholically protected jetty, or on a pipeline or
cable that is metal-sheathed crosses a catholically protected pipeline.
Relationship may be minimized by careful design associated with protection system that is
cathodic. In specific, by design of a scheme to operate at the cheapest feasible current thickness
and by keeping good separation between the protected framework and the secondary structure, and
between the ground beds or anodes and the framework that is secondary.

It is an advantage of sacrificial-anode schemes they are popular for security in congested and
complex locations that they're perhaps not vulnerable to creating severe connection problems and
therefore.
Methods and procedures are around for overcoming interaction, and testing must be carried out in
the presence of interested parties, so the selection of remedial measures may be agreed, if and
when the limit that is acceptable of is exceeded.

2.7.5 Kinds of Equipment

Various galvanic anode alloys of magnesium, zinc or aluminum can be found in a number of block,
rod or wire forms. These alloys are cast around steel inserts to allow repairing of the anode and to
maintain continuity that is electric mechanical strength towards the finish of the anode life. The
insert can be directly welded or bolted to the structure to be protected, or anodes may be linked to
the dwelling by way of an lead that is insulated usually of copper, as for onshore and offshore
pipelines.
Impressed-current ground beds in soils have traditionally contained high-silicon cast iron.
Nevertheless, mixed metal oxide (MMO) anodes are becoming increasingly popular for all
environments for their good mechanical and electrical characteristics and size that is compact. For
seawater applications and areas where chlorides are current, MMO anodes work nicely as do highsilicon cast iron alloyed with chromium. Other anodes contain lead alloy and platinum formed in a
layer that is thin a titanium or niobium base
There are numerous possible sources of dc power; typically the most popular is the selenium dish
or silicon-diode rectifier with transformer unit in combination with an existing ac supply or diesel- or
alternator that is gas engine-driven. A constant dc voltage or constant present systems are used for
most applications.
In remote areas, power sources include thermo- electric generators, closed-cycle vapor turbines,
and solar or wind generators. The latter two are employed along with lead acid or storage that is
similar. The choice is dependent on energy needs, maintenance abilities, and conditions that are
environmental.