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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
Coatings (types)
Test stations
IR Coupons
Galvanic Anodes Types?
Length
Coating Effectiveness
Current Density
Soil Resistivity
New Steel Pipe Calculations
Number of anodes
For an example
Firstcalculate 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
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?
Keep
Keepin
inmind,
mind,aa66inch
inchdiameter
diameterpipe
pipeis
istruly
truly6.625
6.625inches
inches
R Length Area
3.14 (6.625) = 1.735 12,000 = 20,820 sq ft
12
Need
Needto
todivide
dividethe
thediameter
diameterby
by12
12to
to
convert
convertto
tofeet
feet
New Steel Pipe Calculations
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
98.5% to 99.5% - Good
95% - Fair
Less than 95% - Poor
New Steel Pipe Calculations
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
New Steel Pipe Calculations
Number of anodes
What is the total surface area?
New Steel Pipe Calculations
Number of anodes
What is the total surface area?
20,820 sq ft
What is the total bare area of the
pipeline?
New Steel Pipe Calculations
Number of anodes
What is the total surface area?
20,820 sq ft
What is the total bare area of the
pipeline?
104.1 sq ft
New Steel Pipe Calculations
Number of anodes
Next calculate the total amount of
current requirement for CP of the
pipeline
Total bare area x current density = I CP
What is the bare area?
104.1 sqft
What is the current density?
New Steel Pipe Calculations
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
Change
Changecurrent
currentdensity
density
to
toaahigher
highernumber,
number,
such
suchasas33mAs
mAs
New Steel Pipe Calculations
Number of anodes
Number of anodes = Icp/Ia
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???
120,000 f y
New Steel Pipe Calculations
Number of anodes
The
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andweight
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New Steel Pipe Calculations
Number of anodes
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?
Number of anodes = Icp/Ia
104.1 mA / 22.3 mA = 4.6 (round to highest number = 5 anodes)
5 anodes
Correct or not??????????
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
Carrier pipe
Two wires No. 12 White
Old/bare
Casing
Test Stations
(1 2 5 )T = V o lta g e Powercrete
( 1 2 5 0 ) T = V o lta g e Extruded
Reference
Reference
NaceRPO274-98
Nace RPO274-98==Extruded
Extrudedcoating
coating
NaceRPO490-95
Nace RPO490-95==Epoxy
Epoxycoating
coating
PowercreteManual
Powercrete Manual
Coatings Jeep Settings
Extruded
Thickness Voltage Some common
10mils 3953
Jeep voltage
20mils 5590 settings for
30mils
40mils
6847
7906
common coatings
50mils 8839
60mils 9682
70mils 10458
Epoxy Powercrete
Thickness Voltage Thickness Voltage
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 - Extruded
Coatings - Extruded
Direct Bury -
X-Tech II COH & CKY practice for direct
bury design, 1st choice
70 mill application
Two layers of 30 mills of polyethylene coating
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 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
Coatings - Rock shield
Kero-TestMonolithic 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.
Insulators - Tying new and old
existing Coated Pipelines
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
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
Insulators M&R Station
There
Thereisistreatment
treatmentfor
forcasings
casings
already
alreadyfilled
filledwith
withwater.
water.
FRPs
Fiberglass
Reinforced
Plastic
Insulator FRPs
Coated
pipeline
Coupon
IR Coupon - Measurements
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
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