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 
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”
12”to
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 (Columbia’s 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 = ICP
 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
 For current requirement calculations, we use a
higher number for higher soil resistivity for the
purpose of designing a higher amount of current
requirement.
New Steel Pipe Calculations –
Number of anodes
 Whatthe
Next calculate if the
totalsoil wasof
amount
very sandy
current requirement forand
CP of the
pipeline normally dry?
 Total bare area x current density = ICP
 104.1 x 1mA = 104.1 mA’s
Bare
BareArea
Areaof
of Current
Current Total
Totalamount
amountof
ofcurrent
current
pipeline
pipeline density
density requirement
requirement
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 = ICP
 104.1 x 3mA = 312.3 mA’s
Bare
BareArea
Areaof
of Current
Current Total
Totalamount
amountof
ofcurrent
current
pipeline
pipeline density
density requirement
requirement

Change
Changecurrent
currentdensity
density
to
toaahigher
highernumber,
number,
such
suchasas33mA’s
mA’s
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 mA’s
 How many anodes needed?
 Have to calculate anode output next???
120,000 • f • y
ρ
New Steel Pipe Calculations –
Number of anodes

The
Thetop
topthree
threenumbers
numbersare
aregiven
givenbased
basedanode
anodedesign,
design,
such
suchas
asshape
shapeand
andweight
weightof
ofanode.
anode.

120,000 • 1 • 1.21 = 22.3 mA

6,500 ohms cm

Anode
Anodeoutput
outputis
is
Input
Inputthe
thesoil
soilresistivity
resistivityto
tothe
the calculated
calculated
bottom
bottomofofthe
theequation
equation
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??????????

Need more anodes – Not the correct design

Sunde Theory
Single Anode Current
Used
Usedfor
for Reduction Factors (C)
banking
banking # of Anodes in
anodes
anodes Concentrated Bed Anode spacing
5 Feet 10 Feet 15 Feet 20 Feet
10 FT
2 1.84 1.92 1.95 1.96
spacing
3 2.45 2.70 2.79 2.85
4 3.04 3.45 3.62 3.71
5 anodes 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
5 anodes at
9 5.67 6.96 7.54 7.87
10ft apart =
4.19 anodes 10 6.16 7.64 8.38 8.68
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.
New Steel Pipe Calculations –
Number of anodes
 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%

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
 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 ft2 of surface area.
 A vertically installed 17# high potential magnesium anode in
5000 Ω-cm soil has a current output of 30 mA.
 A design current density of 2 mA/ft2 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/ft2 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 – Jeep Settings

(525) T = V o lta ge Fusion Bonded Epoxy

(1 2 5 )T = V o lta ge Powercrete

(1250) T = V o lta ge 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

10mils 1650 45mils 5625

20mils 2348 75mils 9375
30mils 2876
40mils 3320
50mils 3712
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
Coatings

 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 - 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

 10 mills of butyl rubber mastic

Coatings - Extruded

 Design for AC and/or DC interference

currents
 Use only Extruded – X-TECH II coating
systems
Coatings - FBE
 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
 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, 2nd choice for direct bury
Coatings – Powercrete

 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
 COH & CKY practice – a
minimum of 50 mils for
directional boring application
 COH & CKY practice – a
minimum of 70 mils for rocky
directional boring
applications
Coatings – Girth Welds
 Girth Welds
 FBE and Powercrete coating applications
 COH & CKY practice – two part liquid epoxy system
 Protal 7200 – temp’s at or above 50 degrees
 Protal 7125 – temp’s below 50 degrees
 R95 – temp’s 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
manufacture’s 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 – 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

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
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.
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

 Bond in the test station box,

 if rectified system
 If anode system and want to cathodically protect
as a single circuit
Insulators - Tying new and old
existing Coated Pipelines
 If not bonded in the test station box, then
create two facilities on WMS and two
test point sheets
Insulators - Tying new and old
existing Coated Pipelines
 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

Insulator – Weld - In COH
COH&&CKY
always
CKYpractice
alwaysuse
practice––
useweld-in
weld-in
insulators
insulatorsand
andonly
onlythe
the
Zunt
Zuntmonolithic
monolithicfor
forburied
buried
pipelines
pipelines
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.
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
Insulators – M&R Station

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.
Insulator – Casing and Carrier Pipe

 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.
Insulators – Casing & 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
Insulator – Casing & Carrier Pipe –
Casing Filling
 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
Casing
Casingfiller
fillercan
canbe
beinstalled
installed
hot
hotor
orcold.
cold.

There
Thereisistreatment
treatmentfor
forcasings
casings
already
alreadyfilled
filledwith
withwater.
water.

Pictures -Courtesy of Trenton co.

Insulator – Casing & Carrier Pipe -
Spacers
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.
Insulators – Casing and Carrier Pipe
– Link Seals & Rubber boots
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.
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
Insulator – FRP’s

FRP’s –
Fiberglass
Reinforced
Plastic
Insulator – FRP’s

 Primary function of FRP’s

 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 – FRP’s

There are a variety of

types of FRP’s.

Flat FRP’s are a practical way

of physically separating two
buried structures especially in
an excavation situation.
Insulator – FRP’s

Some FRP’s 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 – FRP’s

FRP’s are an excellent material to be used on

bridge crossings or other aboveground pipe
supports.

Courtesy of Glass mesh

IR Coupons
Two no. 12 stranded wires.

 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 in2

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.
 Test
IR Coupons Station
Bond or Switch

V The blue wires

identify the lead
Connect the wires used to
voltmeter to electrically bond the
the non- coupon to the pipe.
current
carrying lead
wire from the
coupon.

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
measurements of the coupon, current applied and
momentarily interrupted.
 The potential readings will be IR-drop free and will
represent the pipeline’s IR-drop free potential
readings.
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