PRESENTATION AT

O I S D WORKSHOP
HPCL AJMER
APRIL 27,2018

MOUNDED BULK LPG

STORAGE VESSELS
CATHODIC PROTECTION
SYSTEM
By

Dr M B Mishra
Corrosion Consultant
Nace Corrosion 2004
3
 REF. ELECTRODE
SAND MOUND

INLINE
SPLICE

LPG BULLET
TO
TR UNIT
CONNECTING
CABLES

ANODEFLEX -1500 MOUNDED BULLETS POLYMERIC ANODE

 ANODEFLEX -1500 MOUNDED BULLETS
ISOLATING JOINT
POLARIZATON
CELL
EARTHING

INLINE
AJB SPLICE

LPG BULLET
TR
UNIT CJB

- ve + ve

REJB Ref Cell

CONNECTING
POLYMERIC ANODE
CABLES
 SAND MOUND REF. ELECTRODE

BULLET-1 BULLET-2

POLYMERIC ANODE
ANODEFLEX -1500 MOUNDED BULLETS
7
8
9
 CORROSION PROTECTION

PRIMARY PROTECTION : COATINGS

SECONDARY PROTECTION : CATHODIC PROTECTION

Nace Corrosion 2004

COATINGS

PRIMARY PROTECTION

COAL TAR EPOXY

TAR POYLURETHANE
POLYURETHANE

Nace Corrosion 2004

 Corrosion Protection

COATING
(PRIMARY PROTECTION)

PROTECTIVE CURRENT

CATHODIC PROTECTION
BULLET
BULLET (SECONDARY PROTECTION)

COATING

METAL SURFACE

Nace Corrosion 2004

MOUNDED BULLET TANKS

Nace Corrosion 2004

 REASONS FOR CATHODIC
PROTECTION

 HEAT OF WELDING DESTROYS SOIL SIDE BOTTOM PLATE TANK

COATING, WHICH IS UNREPAIRABLE.

 WELDING OF STEEL PLATES RESULTS IN MICRO STRUCTURE

CHANGES IN STEEL RESULTING IN FORMATION OF CORROSION
CELLS AND SIGNIFICANT METAL LOSS.

 COATINGS ALONE CAN NOT BE RELIED TO PROTECT THE

TANKS / MOUNDED BULLETS FROM EXTERNAL CORROSION FOR
DESIGN LIFE.

 ENVIRONMENTAL HAZARDS SHOULD LEAK ARISE.

Nace Corrosion 2004

TANK BOTTOM PLATE PITTING
CORROSION

Nace Corrosion 2004

 TYPE OF ANODES
 DEEP WELL GROUND BED ANODES

 DISCRETE ANODES

 ANGLE DRILLED ANODES

 MMO RIBBON TYPE

 MMO PIGGY BACKED

 LONG LINE POLYMERIC ANODES

Nace Corrosion 2004

 KEY DESIGN CRITERIA FOR CP
OF TANKS / BULLETS
 -0.85V TO -1.2V “OFF” (Ref Cu/CuSO4)

 MINIMIZE STRAY CURRENTS, TO OTHER STRUCTURES, PIPE

SUPPORTS, EARTHING GRID ETC.

 ELECTRICAL REMOTENESS TO BE ACHIEVED IN THE

IMMEDIATE VICINITY OF THE ANODE.

 COMPLETE CIRCUIT RESISTANCE TO BE LESS THAN 1 OHM.

 NO JOINTS / SPLICES BELOW THE TANK PLATE OR IN THE

MOUND.

Nace Corrosion 2004

 The Cathodic Protection system
comprises of :
 Power Source Transformer Rectifier
Unit [TRU] or Grid/DG power feed
 Anodes Long Line Polymeric Cables or
Mixed Metal Oxide [MMO]
 Reference Electrodes CuCuSO4 & Zn
 Junction Box
Reference,Anode,Cathode and
Electrolytic Polarization Cells
 Cables
 Surge Divertor
 Earthing for TRU and Electrolytic
Polarization cells
SUITABLE ANODE TO MEET KEY
DESIGN CRITERIA

LONG LINE POLYMERIC ANODES PROVIDE DESIRED

FEATURES TO CATHODIC PROTECTION DESIGN
ENGINEERS TO MEET -
KEY DESIGN CRITERIA FOR CP ON TANKS / BULLETS

Nace Corrosion 2004

TANK CP – POLYMERIC ANODE
CONSTRUCTION

Nace Corrosion 2004

COPPER CONDUCTOR
 LOW RESISTANCE BUS BAR TO DELIVER REQUIRED
CURRENT.

 NEGLIGIBLE LONGITUDINAL VOLTAGE DROPS.

 LOW VOLTAGE AT THE START OF CIRCUIT HELPS IN

ACHIEVING ELECTRICAL REMOTENESS IN THE
IMMEDIATE VICINITY OF THE ANODE.

Nace Corrosion 2004

CONDUCTIVE POLYMER JACKET

 LIMITS CURRENT OUTPUT PER UNIT LENGTH.

 PREVENTS EXCESSIVE CURRENT DELIVERY AT THE

BEGINNING OF THE ANODE.

 LONG CIRCUIT LENGTH HENCE NO SPLICES /

JOINTS.

Nace Corrosion 2004

HIGH PERFORMANCE COKE BREEZE

 INCREASED SURFACE AREA.

 LOWER OVERALL CONTACT RESISTANCE HELPS IN

REDUCING OVERALL CURRENT RESISTANCE BELOW
1 OHM.

 PREVENTS EXCESSIVE VOLTAGE TO BE APPLIED TO

THE ANODE.

Nace Corrosion 2004

 CONTINUOUS POLYMERIC ANODE

Tyco Nace Corrosion 2004 Anodeflex

 CONCEPTUAL DESIGN OF CP FOR
BULLET TANKS

REF. ELECTRODE
SAND MOUND

INLINE
SPLICE

LPG BULLET
TO
TR UNIT
CONNECTING
CABLES

POLYMERIC ANODE

Nace Corrosion 2004

 CONCEPTUAL DESIGN OF CP FOR
BULLET TANKS

ISOLATING JOINT
POLARIZATON
CELL
EARTHING

INLINE
AJB SPLICE

LPG BULLET
TR
UNIT CJB

- ve + ve

REJB Ref Cell

CONNECTING
POLYMERIC ANODE
CABLES

Nace Corrosion 2004

CONCEPTUAL DESIGN OF CP FOR BULLET
TANKS

SAND MOUND REF. ELECTRODE

BULLET-1 BULLET-2

POLYMERIC ANODE

Nace Corrosion 2004

LONG LINE POLYMERIC ANODE SYSTEM
FOR MOUNDED BULLET

Nace Corrosion 2004

 Power Source TRU
 AC single phase or three phase Input
 DC Output maximum 50V and 75 A
 Enclosure with specified IP [ingress
protection such as IP55]
 Earthing for TRU
 Location duitable for routine and
emergency repair etc. as well as per
Area Clasiification
 Refrenec Elecctrodes for each Bullet at
least Twelve numbers CuCuSO4
permanent type electrodes are installed
for routine monitoring adequacy of
ptotection [P-S-P] also at least one Zn
anode is installed to monitor [P-S-P] in
case all CuCuSO4 Ref Electrodes
become defunct
 Junction Boxes are installed for Block
Termination of each of Reference
electrodes duly Tagged, and for each
Cathode (bullet),and for each Anode
termination in block,also one box is
installed for Electrolytic Polarization
cells and all these boxes have to
conform to area classification
requirement and usually FLP boxes are
required
 Electrolytic Polarization cells are
installed at least one for each Bullet for
the purpose of Dissipating any AC
buildup on vessels due to lightning etc.
The levels of liquid should not fall below
minimum specified and not go over
Maximum levels specified as it will
overflow out
 All Cable terminations should have
appropriate Tags,Ferrules and it should
be ensured that all FLP box Nuts are
totally tightened and no ingress be
ensured from outside by doing this

 All TRU to be Earthed through Earth

Pits and All Electrolytic Polarization cells
should only be Earthed through 20Kg
Zn anodes individually
 Across each Insulation Flange/Mono-
Block a Surge divertor is installed and
the coaxial cable should have no
intermediate coneection as caxial cable
of exact length between pup to pup only
should be used
 At each Cathodically Protected Metal
part in touch with unprotected utilities
(air and fire water pipelines etc a
isolating Neoprene sheet or Teflon
should be inserted
 MIXED METAL OXIDE (MMO) TYPE ANODES

POWER FED THRU

CONNECTING CABLE

NO POWER INCASE
OF FAILURE

MMO ANODE

ANODE TO CABLE JOINT

(AT EVERY 6 M LENGTH)

WEAK POINT

tyco Nace Corrosion 2004 Anodeflex

 MIXED METAL OXIDE (MMO) TYPE ANODES

MMO ANODE

NO CURRENT FLOW IN
THIS ZONE

tyco Nace Corrosion 2004 Anodeflex

 MAJOR COMPONENTS OF CP SYSTEM

 LONG LINE POLYMERIC ANODES

- ANODEFLEX
 TRANSFORMER / RECTIFIER UNIT
 JUNCTION BOXES
 REFERENCE ELECTRODES
 POLARIZATION CELLS
 ISOLATING JOINTS
 ISOLATING SPARK GAP
 CONNECTING CABLES

Nace Corrosion 2004

 DESIGN PARAMETERS

CURRENT DENSITY : 3mA/sq.meter

BARE STEEL : 25mA/sq.meter
SURFACE AREA / BULLET : 3000 sq.meter

Nace Corrosion 2004

CONCEPTUAL CP DESIGN FOR NEW
TANK

Nace Corrosion 2004

LONG LINE POLYMERIC ANODESYSTEM FOR
ABOVE GROUND STORAGE TANKS

Nace Corrosion 2004

CONCEPTUAL DESIGN OF CP FOR
EXISTING TANKS

Nace Corrosion 2004

 Cathodic Protection of Pipelines
with Continuous Polymeric Anodes

Rectifier
AC power
input

- +
Current return
path Anodeflex laid next to pipe

Pipe

Failed coating- exposed

steel

Tyco Nace Corrosion 2004 Raychem

 Pakistan State Oil Fuel Oil Pipeline CP
System
Anodeflex Cathodic Protection
System Layout
5550

3.6V, 16" dia. pipeline

2.3 A PARCO
Termin al
Anodeflex
TR 700 900 1000 1300 1500 150

JIMCO
Terminal

Anodeflex
8.6V, TR
3.2A (Lalp ir)

LEGEND

Anodeflex 1500

RESULT: Power Lead Wir e Power Lead Wir e #6AWG Power Lead Wir e - 1.32 ohms/k m
(Raychem Type Permarad-6)
Off Potential along Tunin g
entire line: -882mv to Resito r Junctio n Box
-1210mV after 1 week

End Begin All numbers are lengths in Meters except where

Anodeflex
otherwise stated

Typical Junction Box Pakistan State Oil, PSO-JIMCO

lay out 16" dia.x 5.55km pipeline
Drawing Title : Filename Is sue / Rev. Date Drawn
Raychem Chemelex Division Drawing Number: PSO -01 12 Aug.96 SAM

Tyco Nace Corrosion 2004 Raychem

 PIPELINE COATING AND CATHODIC
PROTECTION SYSTEM ASSESSMENT

Installation of the Anodeflex System. It provides Cathodic Protection on every point

without causing any under or overprotection
Tyco Nace Corrosion 2004 Raychem
POLYMERIC ANODE LONG TERM
PERFORMANCE

 MAXIMUM OUTPUT OF ANODE 52 mA / meter.

 DESIGN LIFE TIME -- 20 YEARS AT 52 mA / meter

OUTPUT

 GROUND PERFORMANCE -- MORE THAN 30 YEARS

Nace Corrosion 2004

 MAJOR PROJECTS WITH LONG LINE POLYMERIC
ANODE FOR ABOVE GROUND STORAGE TANKS
NO. OF TANKS DIAMETER CUSTOMER COUNTRY

69 NOS. 3 - 68 MTRS PETRONAS MALAYSIA

MELACCA
REFINERY
8 NOS. 77 MTRS ESSO MALAYSIA
PRODUCTION
24 NOS. 79 MTRS INDIAN OIL INDIA
CORPORATION
LTD.
26 NOS. 10 - 54 MTRS HYUNDAI KOREA
REFINERY
8 NOS. 80 MTRS SINOPEC CHINA

Nace Corrosion 2004

 MAJOR PROJECTS WITH LONG LINE POLYMERIC
ANODE FOR MOUNDED BULLETS
DIAMETER LENGTH NO OF CUSTOMER COUNTRY
BULLETS

7.5 MTRS 39 MTRS 3 SHELL MALAYSIA

7.5 MTRS 90 MTRS 9 GAIL INDIA INDIA

LTD.

8 MTRS 70 MTRS 18 INDIAN OIL INDIA

CORPN.
LTD.

7 MTRS 63 MTRS 9 HINDUSTAN INDIA

PETROLEUM
LTD.

Nace Corrosion 2004

 TRACK RECORD

Nace Corrosion 2004

OPERATING DATA FOR LONG LINE POLYMERIC ANODE SYSTEM
FOR ABOVE GROUND STORAGE TANK – 6 YEARS IN OPERATION

Nace Corrosion 2004

OPERATING DATA FOR LONG LINE POLYMERIC ANODE SYSTEM
FOR BURMED BULLET TANKS – 6 YEARS IN OPERATION

Nace Corrosion 2004

 CP SYSTEM INSTALLED COST
AVERAGE COST AVERAGE COST PERCENTAGE
OF 80 METERS DIA OF SUITABLY COST OF CP
ABOVE GROUND DESIGNED AND SYSTEM VS TOTAL
STORAGE TANK INSTALLED CP TANK COST
SYSTEM FOR A
LIFE TIME OF 35
US $
YEARS
US $
AVERAGE COST AVERAGE COST PERCENTAGE
OF 8 METERS DIA, OF SUITABLE COST OF CP
80 METERS LONG DESIGNED AND SYSTEM VS TOTAL
MOUNDED INSTALLED CP BULLET TANK
STORAGE TANK SYSTEM FOR LIFE COST
US $ TIME OF 35 YEARS
US $
Nace Corrosion 2004
 CONCLUSIONS
 TO EXTERNALLY PROTECT THE BOTTOM PLATES OF AGSTS AND
BURMED BULLET TANKS FROM CORROSION IT IS NECESSARY TO
INSTALL A SUITABLE IMPRESSED CURRENT CATHODIC
PROTECTION SYSTEM.

 POLYMERIC ANODE CABLES CAN EFFECTIVELY PROTECT THESE

STRUCTURES BY ENSURING THAT THE UNIVERSALLY ACCEPTED
CRITERIA OF -0.85 V TO -1.2 V “INSTANT OFF: (CU/CUSO 4
REFERENCE ELECTRODES) IS ACHIEVED THE 100 MV SHIFT
CRIETARIA SHOULD NOT BE USED.

 IT IS RECOMMENDED THAT ALL ANODE SYSTEMS USED FOR THE

PROTECTION OF THESE STRUCTURES BE INSTALLED WITHIN A
LAYER OF HIGH CONDUCTIVITYCOKE BREEZE TO KEEP THE
TOTAL CIRCUIT RESISTANCE BELOW 1 OHM.

 FACTORY OR FIELD WELDS AND CONNECTIONS TO THE ACTIVE

ANODE SHALL ONLY BE ALLOWED IN REGIONS OUTSIDE THE
TANK WALLS OR BURMS, WHERE ACCESS CAN BE GAINED FOR
REPAIR.

Nace Corrosion 2004