Coating resistance pipelines protection

In analyzing the results on a cathodically protected pipeline, the protection current density and coating resistances should be calculated for individual sections of the pipeline in addition to the on and off potentials, the pipe current, and the resistances at insulating points and between the casing and the pipeline. The results should be shown by potential plots to give a good summary [15] (see Fig. 3-20). 

Fig. 3-13 Determination of the protection current density and coating resistance of a pipeline (explanation in the text).

The variation in the on and off potentials or the potential difference along the pipeline will usually indicate faults that prevent the attainment of complete cathodic protection. The protection current requirement of the pipeline may be estimated from experience if the age and type of pipeline is known (see Fig. 5-3). Figure 3-20 shows the variation in the on and off potentials of a 9-km pipeline section DN 800 with 10-mm wall thickness. At the end of the pipeline, at 31.84 km, an insulating unit is built in. The cathodic protection station is situated at 22.99 km. Between this and the end of the pipeline there are four pipe current measuring points. The applied protection current densities and coating resistances of individual pipeline sections are calculated from Eqs. (3-40) and (3-41). In the upper diagram the values of... 

Protection current density and coating resistance are important for the current distribution and for the range of the electrochemical protection. The coating resistance determines, as does the polarization resistance, the polarization parameter (see Sections 2.2.5 and 24.5). For pipelines the protection current density determines the length of the protection range (see Section 24.4.3). 

Galvanic anode systems are generally used in well-coated electrically isolated structures, offshore structures, ship hulls, hot-spot pipeline protection, heat exchanger water boxes and other environments of resistivity below 10000 Q cm. 

As shown in Fig. 15.6, external DC current is supplied from a power source such as a rectifier. The external DC current is used to cathodicaUy polarize the pipeHne. Impressed Current System (ICS) can be used to protect bare and poorly coated pipeHnes because of high current capacity. The anodes are made of durable materials that resist wear or dissolution. Iron with 14% silicon, carbon, and graphite are some commonly used anodes for pipeline protection [17,18]. All impressed current CPs require routine maintenance because they involve a power supply and more electrical connections than sacrificial systems. 

Successful application of cathodic protection depends upon the selection, design, installation, and maintenance of the system. Before designing the cathodic protection systems, adequate field data must be collected, analyzed, and evaluated. Nature and conditions of the soil are reflected by field measurements like soil resistance, hydrogen ion activity (pH), and the redox potential. To understand the nature of the pipeline, potential measurements, coating resistance, and meaningful design current requirement tests must be conducted. 

Cathodic protection is optimum within a specific potential range (see Section 13.7), so that the length of pipeline protected by one anode increases as the metallic pipe resistance, Rl, decreases, and coating resistance, z, increases. 

Guidetti, G.P., Locatelli, R., Marzola, R. and Rigosi, G.L. (1987) Heat resistant polypropylene coating for pipelines, in Proceedings of the 7th International Conference on the Internal and External Protection of Pipes, (ed. R. Galka), The Fluid Engineering Centre, Cranfield, pp.203-10. 

An acceptable life for undergound pipelines can sometimes be realized through the use of corrosion-resistant piping. Copper, aluminum, and stainless steel piping are sometimes used for this purpose. All three alloys can have greater corrosion resistance than carbon steel or cast iron. However, they are not immune to corrosion and are often more susceptible to localized corrosion such as pitting, crevice corrosion, and SCC than carbon steel or cast iron. Further, corrosion protection in the form of coatings and cathodic protection are frequently used. 

Soils will pit steels, which obviously affects buried pipelines. In one study of 10 carbon and low-alloy carbon steels containing Cr, Ni, Cu, and Mo and exposed to a variety of soils for 13 years, the conclusion was that factors such as soil pH, resistivity and degree of aeration have more influence on the severity of corrosion than the alloy content of the steel. In any case, protective coatings and cathodic protection are the best means of reducing corrosion in buried pipelines. 

Location of faults by the direct current method is based on the application of Ohm s Law. It is assumed that, because of the good pipe coating, virtually no current passes into the measured span and that the longitudinal resistance R is known. When the fault-locating current, I, is fed in and takes a direct path via the foreign line to the protected pipeline, the fault distance is determined from the voltage drop AU over the measured span ... 

The requirements derived in Eq. (10-5) are relevant in the cathodic protection of distribution networks for low and as uniform as possible values of resistance and leakage loading. The second requirement is often not fulfilled with old pipeline networks on account of their different ages and the type of pipe coating. When setting up cathodic protection, a distinction must be made between old and new steel distribution networks. 

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