Handout - Cathodic Protection - AC DC Interference and Mitigation

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NIGIS EDUCATIONAL ONLINE TRAINING PROGRAMME ON

CATHODIC PROTECTION
AC/DC Interference and Mitigation
21 - 22 May 2021
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CORRESPONDENCE
NACE Interna,onal Gateway India Sec,on
305-A, Galleria, Hiranandani Gardens, Powai, Mumbai – 400076, India
Tel: 022-25797354/ 930 Email: rishikesh@naceindia.org | info@naceindia.org
Website : www.naceindia.org. | www.corcon.org
Virtual Educational Training Programme
CATHODIC PROTECTION – AC/DC Interference and Mitigation
21st – 22nd May 2021
Technical Programme
DAY - 1
08:45 - 09:00 Registration & Briefing to participants Mr. Rishikesh Mishra
Manager - Technical Services
09:00 - 09:15 Welcome Address & Inauguration Mr. N Manohar Rao
Trustee, NIGIS
09:15 - 11:15 AC Interference
1. Basics of AC Interference Mr. Prashanth BG
2. AC Corrosion Jef Techno Solutions Pvt. Ltd.
3. AC for Safety of People
4. AC Corrosion Modeling
11:15 - 11:30 Break
11:30 - 01:30 AC Interference
1. The advance in AC Interference
2. AC Interference Survey & Data Collection
3. Selection of AC Interference Model Software Mr. Craig Botha
4. Assumptions in Modeling Reignite, South Africa
5. Mitigation Materials
6. Polarisation Cell & SSD
7. Why Mitigation Fails
8. Robust and Practical Design of AC Mitigation
DAY- 2 :
09:00 - 11:00 DC Interference
1. Basics of DC Interference Mr. Pankaj Panchal
2. Static and Dynamic Interface Details. Corrosion Protection Specialist
3. Common Corridor Pipeline Design and Results. Pvt Ltd
4. Mitigation of DC Interference
11:00 - 11:15 Break
11:15 - 01:15 Interference and Coatings
1. Coating Effects on Interefrance
2. Mounded Bullets Mutual Interefarnce Mr. K B Singh
3. IJs on plant and DC Interference issues. K B Associates
4. IJs on Water Pipelines and DC Interference
effect on internal corrosion
5. Suggestions for Batter Design to avoid AC/DC
interference
01:15 - 01:30 Open Forum, Discussions & Conclusions Mr. N Manohar Rao
Vote of Thanks & Group Photograph Trustee, NIGIS
Correspondence Address
NACE International Gateway India Section
305-A, Galleria, Hiranandani Gardens, Powai, Mumbai – 400076, India
Tel: 022-25797354 Email: info@naceindia.org Website: www.naceindia.org / www.corcon.org
Contact Person : Mr. Rishikesh Mishra : 9820459356 / Mr. Manoj Mishra 9820631320
PRASHANTH B G
Managing Director and CEO
Present Affiliation
JEF Techno Solutions Private Ltd.
Academic
B.E (Electrical & Electronics)
Qualification
Area of AC Interference of pipelines, Earthing & Lightning

Specialization Protection and EMI/EMC consultancy.
Papers published in many journals and magazines.

Guest Speaker in CBIP, CEA, CPRI, FICCI,
International Copper Association, Institution of
Engineers and presented various papers in these
Achievements /
Awards Forums
With Patents and several “firsts” to his credit, he has
been active with innovations in grounding and
electrical safety domains.
Presentation on : AC Interference Study of CGD Network

AC INTERFERENCE STUDY
OF
CROSS COUNTRY PIPELINES
BY
PRASHANTH BG
MANAGING DIRECTOR AND CEO
List of AC Interference Projects – JEF Techno
Total length of
Client No of Projects
Pipeline (KM)
GAIL 4 3823
HPCL 5 2289
BPCL 4 1322
IOCL 4 769
Reliance 1 120
8323
Agenda
• Basics of AC Interference
• Standards, Regulations and Guidelines
• Factors affecting AC Interference
• Comparison – Conventional Vs Software Modelling
• Inputs & Data Collection
• Importance of SOIL RESISTIVITY
• Selection of AC Interference Modelling Software
• Typical AC Interference Software Model and Validation
• Conclusion and Recap
• Q&A
Basics ofAC Interference - Genesis
 Space constraints causing laying of gas pipeline, HT
cable, overhead HVAC transmission line and Metro
rails running in close proximity.
Clearance between Gas Pipeline and Footing of
Transmission Line can be up to 3 m.
 High dielectric coating on pipeline.
 Significant increase in the load and short –circuit

current levels as a result of growing energy demand.
 Rapid expansion of power transmission systems and

pipelines in the Country.
Basics ofAC Interference Inductive Coupling
Basics ofAC Interference Conductive Coupling
Basics ofAC Interference Capacitive Coupling
Steady State Interference
 Steady state effect occurring all the time
 Steady state effect occurring all the time
 Induced AC voltage on pipeline creates safety hazard for
personnel.
 Induced AC voltage on pipeline creates safety hazard for
 Current induced in the pipeline belongs to the Transmission line.
personnel.
Will go back to the transmission line.
At location of discharge AC corrosion takes pla
 Current induced in the pipeline belongs to the power
system. Will go back to the transmission line.
At location of discharge AC corrosion takes place.
Fault State Interference
 Damages pipelines causing, perforations / melting of

pipe wall.
 Damages Coating
 CP equipment damage due to high transient voltages

and GPR.
 Endangers operating personnel due to high touch

voltages.
AC Interference
Steady State Fault State
Inductive coupling
Yes Yes
Conductive / Resistive
Yes Yes
Coupling
Capacitive coupling Only for aboveground sections of pipeline

Induced AC Voltage on Pipeline
Safety
Hazard
Leakage AC Current density
791 A/m2
Corrosion of Pipeine
DC Interference AC Interference
AC Corrosion
Reference Standards
•ISO 15589 Part I - Cathodic protection of pipeline/structure transportation systems - Part I-Onland
pipeline/structure, issued by the International Organization for Standardization (ISO)
•NACE SP 0177–2014, Mitigation of Alternating Current and Lightning Effects on Metallic Structures and
Corrosion Control Systems.
•IS 8062 – Part II - Code of Practice for Cathodic Protection of Steel Structures – Underground Pipelines
•Canadian Standard C22.3 No.6M 91 (2003) – Principles and practices of Electrical Coordination between
pipe lines and Electric Power Lines.
•BS EN 15280 – 2013 – Evaluation of AC. corrosion likelihood of buried pipelines applicable to cathodically
protected pipelines.
•ISO 18086 – Corrosion of Metals and Alloys – Determination of AC Corrosion – Protection Criteria
•IEEE 80 standard (latest revision), “Guide for Safety in AC Substation Grounding”.
•Criteria for Pipelines Co-Existing with Electric Power Lines, prepared for The INGAA Foundation by DNV
GL.
•CEPA – A/C Interference Guideline Final Report – June 2014 and INGAA or CEPA for mitigation
measures.
•IEEE81-2012 IEEE Guide for Measuring Earth Resistivity, Ground Impedance, and Earth Surface
Potentials of a Grounding System
•EN50443:2012 “Effects of Electromagnetic Interference on Pipelines Caused by High Voltage”
Criteria of AC Interference – Steady State
 Steady state AC Touch Voltage Less than15 Volts
 Effective AC corrosion mitigation can be achieved by meeting the cathodic
protection potentials and
 maintaining the AC current density (rms) over a representative period of
time (e.g. 24 h) to be lower than 30 A/m2 on a 1 cm2 coupon or probe,
Or
 maintaining the average cathodic current density over a representative
period of time (e.g. 24 h) lower than 1 A/m2 on a 1 cm2 coupon or probe
if AC Current density is more than 30 A/m2,
Or
 maintaining the ratio between AC current density ( Ja.c.) and DC current
density (Jd.c.) less than 5 over a representative period of time (e.g. 24
h).
Criteria of AC Interference – Fault State
 Coating Stress Voltage depending coating type

For 3LPE < 5 KV
For FBE < 5 KV
For CTE < 3 KV
 During short-circuit/fault conditions, the permissible AC touch-and-step

voltages at above grade portions of the structure and appurtenances should be
determined in accordance with IEEE Standard 80 2013
NACE SP 0177 “Pipeline Section Selection”
In reference to clause 3.4.2. of NACE SP 0177 which states "Grounding is usually

present to some degree...................... ".
• Hazardous induced potential can easily extend over distances of many
kilometers (miles), both within a power line corridor and beyond the extremities
of the corridor.
• Installing grounding at one location can make matters significantly worse

elsewhere; therefore, the whole system should be carefully considered when
designing mitigation.
Interpretation
•Induced voltage on pipeline due to interference with HVAC transmission line(s)
can even be seen at locations out of collocation of pipeline and powerline.
•Furtherwhile designing mitigation measures, the pipeline from IJ to IJ shall be

considered; so that shifting of the potential to other locations is also taken care.
OISD 188: 2019 “When and What to perform”
• Clause 5.12 Coating Survey
Initial AC and DC interference survey shall be carried out at the time of pipeline commissioning
along with CIPL and coating survey for providing the mitigation measures at the interference
locations. Subsequent survey should be carried out based on the indications in the quarterly
potential monitoring cycle however not later than 05 years, survey shall be conducted to check the
efficacy of measures taken.
• Clause 6.2. AC Interference
Effects of possible induced AC current and voltage on the pipeline from overhead electrical
transmission lines shall be evaluated including the effect on safety of personnel during pipeline
construction. Appropriate mitigation measures shall be designed and implemented to limit such
influence both from personnel safety point of view and corrosion of pipelines.
During short-circuit/fault conditions, the permissible AC touch-and-step voltages at above grade

portions of the structure and appurtenances should be determined in accordance with IEEE
Standard 80 and should be maintained below the Ground Potential Rise (GPR) for human safety.
PNGRB Regulations, 2008 for T4S
PNGRB Regulations, 2008 for T4S .... Contd.
Main areas of concern
 Transmission line convergence / divergence / Crossing
 Parallel sections of pipeline
 HT cable crossing and parallelism
 Method of Cable Laying and construction
 AC or DC Traction
 Special design transformers located near pipeline

Factors affecting AC Interference
Factors influencing AC Interference
Factors influencing AC Interference
3. Parallelism length
Factors Influencing AC Interference
5. Soil Resistivity
Comparison
Conventional Vs Software Modelling

AC Interference Study
Conventional versus Computer modeling
AC Interference with Computer

S No Parameter Conventional way
Modeling
•Steady state
Conditions of
1 interference •Fault state •Steady state only
covered
•Lightning
•Current in normal, peak and design
Site measurements are
condition is considered for study.
Powerline not correlated with
2 •For cables flat or trefoil formation
parameters powerline operating
•Collocation is studied using GIS
parameters.
platform.
Conductor type and size, tower
Details These details are not
3 location and type, number of circuits,
considered paid attention to.
shield wires etc. are considered
Conventional versus Computer Modeling
AC Corrosion Risk
AC Coupons
Distribution of AC Mitigation Measures
Mitigation Design: AC Corrosion
Improper Design of Mitigation
Shifting of voltage elsewhere

Mitigation Required at New Locations
Fault State: Coating Stress Voltage
Zinc Ribbon
Fault State: Touch & Step Potential
Inputs and Data Collection
Pipeline Input Data
 TLP List and its Chainage numbers.
 Route drawings in GIS (KML file).
 IJ Details.
 Catholic protection system types and its details (drawings).
 General arrangement drawings for earth grids installed at SV Stations,
IP Stations, cathodic protection anode beds, etc.
 Pipeline material information including pipeline diameter, wall
thickness, coating type, coating thickness, coating resistance, depth,
Earthing types and GPS locations.
 The location and the characteristics of the Existing grounding details
(i.e: Polarisation cell or Solid State decoupler details)
Soil Resistivity Measurement
The All Important Soil Resistivity Meter
• High power delivery capability suitable for measurements at
large spacing (greater depth).
• Operating at a fraction of Hz (quasi-dc) is recommended to
avoid coupling between measurement leads at large spacing.
• The meter must indicate how much current it is injecting, how
much voltage it is measuring, apply a low frequency square
wave of alternating polarity, and indicate the % variation in
apparent resistance measured throughout a series of wave
train readings (minimum of five pulses).
• The contractor shall report apparent resistance, apparent
resistivity, injection current, measured voltage, and percent
error, for every reading taken, at each pin spacing.
Transmission line voltage & frequency
 Counting the no of
Insulators Disk, we
can find out the
voltage rating.
 1 Insulator Disk =
11KV.
Voltage Rating
Powerline: Number of circuits
Double Circuit/400 KV
Single Circuit/400 KV Double Circuit/400 KV
Powerline: Number of circuits
Shield Wire Configuration
Transposition
Transposition Tower Structure
Phase conductors size and material
Phase Conductors configurations
400 KV D/C Line with center point symmetry (Line 1)
400 KV line 1 shield wire current flow
400 KV D/C Line with centre line symmetry
400 KV line 2 shield wire current flow
Summary
TL1 with centre TL2 with centre

point & symmetry line symmetry
Phase current 680A 560A
Peak Shield wire

14A 46A
current
Leakage current
density 300 A/M2 900 A/M2
1 cm2 holiday
AC/DC Data Logging
DC-PSP Reading AC-PSP Reading AC/DC-DATA-LOGGING

AC Coupon Installation
Coupon Coupon fixed Coupon Circuit

Current Density Measurement
Actual Magnitude of Longitudinal current
 Acceptable limit of current density - 30 A/M2
 Size of holiday - 1 cm2
 Limit of Longitudinal current exiting from a 1cm2 holiday

= 30/ 10000 = 3mA
 For current density of 900 A/M2
 Longitudinal current exiting from a 1 cm2 holiday =

900/10000 = 90 mA
Measuring AC Current density
Selection of Software
• Multilayer soil resistivity modelling. As many
layers (typically three or more) of soil as
necessary to represent accurately the electric
structure of the soil as determined from the
measured resistivity traverses.
• Ability to model any number of regions with
different soil structures along the right of user.
Soil Resistivity Measurment & Interpretation
Soil Modeling
Soil Modeling
Soil Modeling
Soil Model Definition
• AC Interference accounting for capacitive,
magnetic field inductive coupling and through-
earth coupling between all segments of all power
transmission lines and grounding systems
(including pipeline mitigation systems) and
pipelines both in steady state normal operating
condition as well as in fault state conditions, no
matter their relative angles or distances apart.
Model Validation : Inductive Modelling
Validation Graph Inductive Results

25.0000
20.0000
15.0000
Voltage
10.0000
5.0000
0.0000
Chainage in KM
24 hrs average of logged data Computer modelling: Inductive
Model Validation : Total Interference
Validation Graph with Total Interference

30.0000
25.0000
20.0000
Voltage
15.0000
10.0000
5.0000
0.0000
Chainage in KM
24 hrs average of logged data Computer modelling: Total Interference
• This should be able to accommodate multiple
pipelines, electric transmission lines, electrified
railways and nearby DC or AC grounding
systems coexisting simultaneously.
• Ability for modelling and simulation of HVDC
networks and other DC sources during load and
fault conditions.
• Ability to model single phase to ground, two
phase to ground and cross-country faults (faults
at two locations simultaneously), if necessary.
Profiling on GIS Platform
Transmission Line Definition
Modeling Existing Ground Points
Monitoring Faults
Defining the Fault between ‘R’ phase of circuit 2 and Shield wire of
Meramundali to Vedanta 400kV line at Ten Towers - ROW software
screenshot
TW 2
TW 1
TW 2
Pipe Line Details for Computer Modeling
TL Input Data for Computer Modeling
Importing Polyline
Pipeline Characteristics
Touch Voltage - Before Mitigation
Model Validation
Leakage Current Density before Mitigation
Typical Mitigation for Normal Load
Zinc Ribbon
Typical Mitigation for Normal Load
Bare Copper conductor prepacked with carbon backfill
Mitigation Recommendations
Touch Voltage after Mitigation
Leakage Current Density after Mitigation
Summary
DC Decoupler
Zinc Ribbon Installation
Fault Condition
Touch Potential
Step Potential
Creating Faults for Study
Defining the Fault between ‘R’ phase of circuit 2 and Shield wire
Monitoring Faults
Defining the Fault between ‘R’ phase of circuit 2 and Shield wire of
Meramundali to Vedanta 400kV line at Ten Towers - ROW software
screenshot
TW 2
TW 1
TW 2
Fault Current
Defining current source in both ends Terminals.
ROW software screenshot.
Pipeline Coating Stress Voltage before Mitigation
Safety Evaluation of SV / IP Station
Results with Surface Layer SV / IP Station
Designing Mitigation for SV / IP station
Proposed Grounding System Modelled

Results with Mitigation Measures
TLP Locations - Touch Voltage
TLP Locations - Step Voltage
Model Validation : Voltage - 1
Model Validation : Voltage - 2
Model Validation : AC Current Density - 1
Model Validation : AC Current Density - 2
Conclusion & Recap
• Vulnerable locations are not necessarily the crossing locations.
• Vulnerable locations for AC Corrosion can be entirely different from

vulnerable locations of AC Voltage.
• To make pipeline free from AC Corrosion, detailed study is required where

AC voltage and AC current density on full length of pipeline is studied not
only at TLP locations and exposed appurtenances.
• Pipeline section from IJ to IJ shall only be considered for AC Interference

study.
• Study performed by skilled and experienced professionals with Computer

modelling and simulation provides satisfactory results.
Q&A
Thank you
Present Affiliation Reignite (Pty) Ltd - CEO
Academic Bachelor of Science in Metallurgical Engineering
Qualification
Area of Professional Engineer
Specialization
AC Mitigation - Investigation, Modelling, Design,
Implementation, Commissioning
ECDA, Cathodic Protection, Corrosion

Investigation, Coatings, Training
Achievements / NACE Instructor - CP, Interference and DA
Awards NACE CP Specialist
Subject Matter Expert
Consulting Engineer of the Year 2013, CORRISA
Published numerous technical papers
CEO of Reignite (Pty) Ltd

AC INTERFERENCE
1. Advances in AC Interference
2. AC Interference Survey and Data Collection
3. Selection of AC Interference Model Software
4. Assumptions in Modelling
6. Polarisation Cell and Solid-State DC Decouplers

• A review of some standards …
• NACE SP0169
• IAC > 30A.m-2 AC corrosion may be significant
• IAC > 100A.m-2 AC corrosion may be expected even if CP criteria is satisfied
• Under some soil conditions increasing CP polarization can increase AC
corrosion significantly
• BS EN 15280 / ISO18086
• AC voltage on the structure
• ON Potential
• IR-free potential
• AC current density
• DC current density
• AC/DC current density ratio
• Soil resistivity
• Corrosion rate

• NACE INTERNATIONAL TECHNICAL REPORT 35110
• “Considering that the primary factor in determining the possibility for the
presence of AC corrosion is the AC density, monitoring the current density
rather than the AC voltage is used to assess the AC-related hazards to a
buried pipeline.” Page 7, last paragraph.
• BS EN 15280 replaced by ISO18086 circa 2017
• ISO 22426 Assessment of the effectiveness of cathodic protection
based on coupon measurements. Released February 2020
• The determination of the effectiveness of CP under AC interference is only
possible based on a current density measurement on coupons. The validity
and accuracy of data obtained on coupons depend on a number of factors,
such as location, geometry and bedding conditions.

• ISO 22426 Assessment of the effectiveness of cathodic protection
based on coupon measurements.
• ISO 22426 Application Principles:
• IR-free potential measurements
• DC and AC currents and current densities
• Spread resistance
• Corrosion rate measurements
• ISO 22426 Coupon Design Considerations:
• General – Purpose of coupon use to assess CP Effectiveness
• Geometry of the defect
• Dimensions of the coupon base plate
• Surface area of the coupon
• Other types of coupon geometries

• ISO 22426 Coupon Design Considerations:

• Critical Factors
• Pipeline route – GPS co-ordinates
• Powerline route – GPS co-ordinates
• Pipeline geometry: diameter, length, steel wall thickness
• Powerline tower geometry: tower design / types, conductor height above
ground, position and spacing
• Pipeline coating properties, sol resistivity, deep soil resistivity
• Powerline information: phase arrangement, conductor details, conductor
loading, steady state and emergency loads, fault current information
• High Risk Areas:
• Minimum separation between tower foot and pipeline
• Highest induced AC voltage areas
• Lowest soil resistivity areas
• Exposed steel structures
• Parallelisms

• Pipeline and Powerline Route
POWERLINES
PIPELINE

• Pipeline and Powerline Geometry – Google Earth View

• Powerline Geometry

• Powerline Operating Information Example
Powerline Normal Full Conductor Maximum Shield Wire Type /

Type Operating Operating Type Expected Equivalent
Phase Phase Tower Fault
Current (A) Current (A) Current (kA)
TIGER, first 7.5 km

1AVN/MSY
426 1112 2 x ZEBRA 12.44 19/2.65 steel wire for
275kV
the balance
TIGER, first 7.5 km
1AVN/MSY
425 1085 2 x ZEBRA 12.44 19/2.65 steel wire for
275kV
the balance

• Electromagnetic Field (EMF) Testing
Milligauss
Meter

• Longitudinal Electric Field (LEF) Testing

• Several AC Interference Modelling Software Options
• Select based on the following:
• Ease of data input
• Pipeline Geometry – Graphical User Interface
• Powerline Geometry – Graphical User Interface
• Use of external data formats permitted ie. CSV files
• Pipeline properties may be defined ie. 3LPE, Coal Tar, Wrapping and so on
• Powerline geometry and tower types may be defined
• Fault current simulation at one or all towers on iterative basis
• Steady state simulation (Normal and Emergency)
• Gradient mat / grounding mat design possible
• Model output data of all key variables in CSV format
• Model output into Google Earth Format including mitigation materials
• Note: Emphasis on multi-layer soil resistivity modelling for fault current
assessment should be weighed in the context of safety while balancing the
corrosion risk.

• GUI Inputs

• Outputs

• Gradient / Grounding Mat Assessment

• Model Exported to Google Earth

• Model Exported to Google Earth – Showing Mitigation Materials
Mitigation
Material
Pipeline
Powerlines

• Establish Baseline
• Quality of Input Data Determines Output Quality
• Powerline operating parameters
• Powerline tower information
• Pipeline coating properties, connections and cross-connections to other
pipelines
• Field Data
• Powerline tower coordinates
• Cross Bonds
• Existing AC Mitigation
• Existing CP installations
• 3RD Party Data – Power / Gas / Oil / Water
• Powerline Geometry - Accuracy
• Pipeline Geometry - Accuracy
• Questionable Baseline / Unreliable Data
• Validate Information in the Field
• Photograph powerline tower types
• LEF and EMF to assess actual operating conditions of powerlines
• Use established pipeline coating information
• Field Data – Measure
• Powerline tower coordinates
• Cross Bonds
• Existing AC Mitigation
• Existing CP installations
• During Model Development
• Use recognised standards and references for assumed data
• Use recognised powerline tower geometry
• Note: State clearly what has been assumed with references and basis

• Key Materials
• Cables
• Keep these as short as possible
• Size cross sectional area correctly NACE SP0177
• Keep the cable path as straight as possible
• Avoid inductive loops

• Key Materials
• Pipe connections
• Select appropriate attachment method
• Test cable attachment to pipe
• Make sure the cable attachment is properly sealed / wrapped

• Key Materials
• Earthing / grounding
• Select appropriately designed grounding earthing method and material
• May use Zinc, Copper, Magnesium Anodes and so on. NACE SP0177 Ampacity
• Geometry and orientation of earthing important

• Key Materials
• Voltage limiting / surge protection devices - Example
• Select appropriately designed devices for use at test station gradient / grounding mats
• Typically have a higher conduction voltage than a standard DC decoupler
• Conduct AC from approximately 60V to gradient / grounding mats to create an
equipotential plain

• Key Materials
• DC decoupler devices
• Select appropriately rated device
• Continuous operation to allow AC to pass to earth / ground
• Must block DC pick up due to CP systems, foreign operator CP and stray current
DC Decoupler

• Key Materials
• Test stations
• Design for the environment
• Consider human settlements
• Theft and vandalism
• Electrical safety

• Key Materials
• Method statements for construction
• Clearly defined works
• Drawings
• Wiring diagrams
• Safety components
• Dead front design OR “Authorised Personnel Only
• QA and QC of construction works
• Company policy
• Factory Acceptance Testing
• Site Acceptance Testing
• Functionality Testing and sign off

6. Polarisation Cell and Solid-State
DC Decouplers
• Polarisation Cell
• Most commonly known is the Kirk Cell – Kirk Engineering
• The Kirk Cell acts as an “electrochemical switch,” blocking DC voltages in the
cathodic protection range while instantaneously shunting hazardous voltages
to ground. The Kirk Cell consists of multiple pairs of stainless-steel plates
immersed in a potassium hydroxide electrolyte solution.

DC Decouplers
• Solid State DC Decouplers
• Commonly known as the polarization cell replacement (PCR)
• No electrolyte
• Solid state elements comprise capacitors, diodes and electronic circuits
• Set DC blocking voltage POSITIVE
• Set DC earthing / grounding voltage SPIKE
ADJUSTMENT
• Stray current environment

• Positive pipeline spikes - HVDC
Solid State DC
NEGATIVE Decoupler with Blocking
BLOCKING
VOLTAGE Voltage adjustment
ADJUSTMENT

DC Decouplers
• Key Differences between Polarization Cells and Solid State DC
Decouplers
• Polarization cell chemicals, gases, over voltage
• Polarization cell replenishment of potassium hydroxide electrolyte solution
• Polarization cell size and arrangement required in series and parallel to
achieve certain voltages
• Solid State Decouplers significant DC voltage management options
• Solid State Decoupler maintenance significantly less if rated correctly
• Solid State Decouplers can be used in parallel with surge protection devices

• Incorrect Installation
• Cabling incorrectly wired / reverse wiring between pipe and earthing /
grounding
• Cable terminations loose / dry joint
• Connections left “open circuit”
• Incorrect engineering and design
• Incorrect modelling and estimation
• Incorrect specification of DC Decoupler for environment
• Incorrect rating of cables, terminals, nuts bolts
• Excessive cable lengths
• Fault current under / over estimation
• Ignoring DC stray current and HVDC “positive”spikes

• Incorrect rating
• Device, cabling, terminals overheat or are critically damaged
• Pipe corrosion
• Safety hazard to humans and animals
• Earthing / Grounding resistance too high
• Soil resistivity measurements inaccurate / inadequate
• Earthing / grounding design of mitigation insufficient
• Generally earthing / grounding resistance should be << 5 Ohm
• Ideally earthing / grounding systems resistance should be < 1 Ohm
• High earthing / grounding resistance = NO AC MITIGATION

• Detailed Drawings
• Device, cabling, terminals
• Cable route
• Test station enclosure
• Minimise cable lengths
• Detailed Technical Specification
• Clearly define equipment rating
• Clearly define cable rating
• Clearly define connections and terminations
• Clearly define Factory Acceptance Test (FAT) procedures
• Clearly define Site Acceptance Test (SAT) procedures
• Clearly define functionality testing of installation
• Clearly define commissioning procedure
• Clearly define compliance criteria for acceptance and hand over

• Detailed Bill of Quantities
• Number, unit, rates
• Connect line items with the drawings and technical specification
• Set out measurement / criteria

• Detailed Drawings - Examples



• Detailed Technical Specification – Examples
• Vandal proof Test Stations
• Specify Concrete MPa rating
• Specify reinforcing steel
• Specify foundation and base
• All other critical equipment

• Detailed Bill of Quantities - Examples

20/05/2021
PIPELINE CATHODIC PROTECTION

SYSTEM
Presented by
Pankaj Panchal
NACE, Corrosion Specialist
NACE, Cathodic Protection Specialist
Mobile : +91 94092 54131
E-mail : : cpspanchal@gmail.com
Corrosion Cures Pvt. Ltd.

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PIPELINE CORROSION Corrosion Protection Specialist Pvt. Ltd
DIRECT ASSESMENT OF CORROSION
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FAILURE OF DESIGN & PROJECT END
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SOME OF THE SPECIFICATIONS
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THINKING OF DESIGNER IN OFFICE FROM DRAWINGS
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I am CP Current and not following Owner, Project’s Paths.

I always take shortest path.
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THINKING OF DESIGNER IN OFFICE FROM DRAWINGS
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ACTUAL SITE CONDITIONS
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STRAY CURRENT
 Stray currents are defined as currents through electrical
paths other than the intended circuit.
 Stray current is not the galvanic corrosion current between
anodes and cathodes on the same structure.
 Stray currents, or interference currents, can be classified as
being either:
 Static
 Dynamic
 Stray current can be either DC and AC
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CORROSION ASSESMENT
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CORROSION ASSESMENT
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INTERFERENCE CURRENT CORROSION
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FACTORS OF SEVERITY OF INTERFRERENCE

CORROSION
 Separation and routing of structures

 Location of current source
 Magnitude and density of interference current
 Coatings
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DYNAMIC STRAY CURRENT
 Dynamic stray current changes in amplitude and/or

direction.
 Dynamic stray currents are either man-made or of

geomagnetic origin (telluric current).
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 DC transit systems
 Welding
 Mining operations
 Electrical power transmission
 Industrial plants
 Telluric
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TELLURIC CURRENT
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POTENTIAL FLCUTUATION DUE TO DYNAMIC

STRAY CURRENT
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EARTH CURRENT (POTENTIAL) MEASUREMENT

BETWEEN TWO REFERENCE ELECTRODES
+ Reading
Voltmeter with
Reference + Reading
_
Electrode +
Reference
Electrode
Current
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EARTH CURRENT (POTENTIAL) MEASUREMENT

BETWEEN TWO REFERENCE ELECTRODES
(+) (+) (–)

V V V
V V V
(+) (–) (–)
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STATIC (STEADY STATE)
Static or steady-state interference currents are defined as

those that maintain constant amplitude and constant
geographical paths.
Examples are:
 HVDC ground electrodes
 Cathodic protection systems
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DC POWERLINE
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DC POWERLINE
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STRAY CURRENT INTERFERENCE FROM CP

SYSTEM
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TYPES OF INTERFERENCE
 Cathodic Interference
 Anodic Interference
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CATHODIC INTERFERENCE
 When a voltage gradient overlaps a foreign structure

and is negative with respect to remote earth, it
promotes current discharge from the foreign
structure in the area of influence.
 If current discharges from a structure, then it must

pickup current outside the area of influence.
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CATHODIC INTERFERENCE
Interference Interference Current Interference
Current Foreign Discharge Current
Pickup Pipe Pickup
Voltage Gradients
Around the
+ -
Protected Pipe
Rectifier
Protected
Impressed Current
Groundbed Remote from Pipe
Foreign Pipe PROFILE VIEW
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ANODIC INTERFERENCE
 When a voltage gradient overlaps a foreign structure

and is negative with respect to remote earth, it
promotes current discharge from the foreign
structure in the area of influence.
 If current discharges from a structure, then it must

pickup current outside the area of influence.
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ANODIC INTERFERENCE
Interference
Interference Interference
Foreign Current Pickup
Current Current
Discharge Pipe Discharge
Protected Voltage Gradients

Pipeline Around the
Remote from - +
Groundbed
Foreign Pipe Rectifier
Impressed
Current
TOP VIEW Groundbed
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DETECTION OF STRAY CURRENT MEASUREMNTS
Structure-to-electrolyte potential changes

Changes in the line current magnitude or direction
Localized pitting in areas near or immediately adjacent to a
foreign structure
Breakdown of protective coatings in a localized area near
a source of stray current.
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DETECTION OF STRAY CURRENT

MEASUREMNTS
Current discharge is indicated by an electropositive

change in potentials.
Note that in a galvanic system, the most electronegative
metal is discharging current and corroding.
In the first case the source of energy is external while in
the last case the source of energy is between the two
metals.
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CP INTERFERENCE
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CP INTERFERENCE
-900
25’ Off Pipe Current Discharge
-800 Anodic Area
Pipe-to-Soil Potential (mV)
-700
-600
Over Pipe
-500
-400 Current Pick-Up

Cathodic Area
-300
Current Pick-Up
-200
Cathodic Area
-100
0 100 200 300 400 500 600 700 800 900 1000
Distance (Feet)
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EFFECT OF STATIC STRAY CURRENT ON

POTENTIALS FOR COATED CP STRUCTURE
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COMBINED ANODIC AND CATHODIC

INTERFERENCE
Potential Profile On Foreign Pipeline
–
Near Anode Bed
At Crossing
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INTERFERENCE MITIGATION ELECTRICAL

BONDING
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DC INTERFERENCE
I's
P1 P2
Bond Variable Bond
Cable Resistor Cable
(Rb) Test Station
interferred-with
P1
structure I's
I's
Is
bond cable and

I''s test station
interferring buried reference

P2 structure electrode
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GALVANIC ANODE MITIGATION

Test Station
Interferring
Is,t Structure
 Is
Is
Is
I's' Is Icp
Icp
Icp
Is
Is
Is Icp
Icp
Icp
Is,t = I's' + Is Interferred-with Structure
where:  Icp > I's'

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INTERFERENCE MITIGATION OF GALVANIC

ANODES
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INTERFERENCE MITIGATION FORCED

DRAINAGE BOND
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PIPELINE ATTENUATION MODEL FOR SINGLE

PIPELINE
rs = unit linear resistance of structure (ohms)

rL = unit leakage resistance (ohms)
g = 1/ rL = unit leakage conductance (S)
α = propagation of attenuation constant
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Pipeline Attenuation Model for Multiple

Pipelines after Bonding
rsx = unit linear resistance of structure (ohms)

rLx = unit leakage resistance (ohms)
x = pipeline number / name 50
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ATTENUATION
 The attenuation constant is dependent on unit linear
resistance of pipeline, coating resistance and
homogenous soil resistivity.
 A general practice for the attenuation considerations

in CP design of the pipelines to take an ideal
equivalent circuit for the calculations, but with the
use of bonding for interference mitigation, the
equivalent circuit considered for remote earth to
pipeline gets altered, hence formulas for attenuation
calculations do not provide the realistic attenuation
value for common buried pipeline corridor.
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CHOICE OF ANODE BED LOCATION

 The current per unit cross-sectional area of earth
(current density) flowing away from an anode bed is
found highest at a point close to the anode bed and
decreases with distance away from it.
 The potential gradient depends on soil resistivity in
vicinity of the anode bed, distance from anode bed and
current delivery from anode bed.
 We must realize that the increase in pipe-to-soil potential
caused by the voltage gradient due to the anode bed will
increase the accumulation of current on the structure at
coating defects subject to the greater potentials in
vicinity as compared to remote earth.
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VOLTAGE GRADIENT OF ANODEBED
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ICICP SYSTEM
2.500
0.5  I    L2  X 2  L 
Vx  ln
  L  X 

2.000
I = Current 1 Amp.
L = Length of Anode 3 mtr.
Potential Rise in Volt
X = Distance in Mtr. - X Axis

20 ohm-cm
P = Soil Resistivity
1.500 50 ohm-cm
100 ohm-cm
200 ohm-cm
300 ohm-cm
500 ohm-cm
1.000
1000 ohm-cm
1500 ohm-cm
2000 ohm-cm
0.500
Assumed -500mV CSE Steel
0.000
0 2 4 6 8 10 12 14 16 18 20
Distance in Mtr.
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ANODEBED REMOTENESS
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80% DESIGNS ARE
Cathodic
Protection
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DESIGNER
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WE ARE GRATEFUL TO
Sir Humphrey
Michael Faraday
Davy
55
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THANK YOU
Pankaj Panchal
Mobile : +91 94092 54131
E-mail : cpspanchal@gmail.com
www.corrosionps.com
Corrosion Cures Pvt. Ltd.
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INTERFERENCE & COATINGS
CATHODIC PROTECTION- AC/DC INTERFERENCE & MITIGATION

VIRTUAL EDUCATIONAL TRAINING PROGRAM
CONTENTS
COATING EFFECTS ON INTERFERENCE
MOUNDED BULLETS MUTUAL INTERFERENCE
MIJ’s ON PLANT AND DC INTERFRENCE ISSUES
MIJ’s ON WATER PIPELINES AND DC INTERFRENCE EFFECT ON CORROSION
SUGGESTIONS FOR BETTER DESIGN TO AVOID AC/DC INTERFRENCE
2
COATINGS EFFECTS ON INTERFERENCE
BURIED
INFRASTRUCTURE
PREVENT CORROSION
COATINGS
(3LPE/3LPP/FBE/DFBE/ CATHODIC
CTE/CAT/PU/VISCO PROTECTION
ELASTIC)
AC INTERFERENCE DC INTERFERENCE
3
COATINGS EFFECTS ON INTERFERENCE
Coatings are universally applied to buried High performance coatings which have
pipelines to provide the primary corrosion high coating resistivity considerably
protection with cathodic protection to reduce the overall cathodic protection
protect areas of coating damage. Coatings current requirement but as a
reduce the overall cathodic protection consequence increase the risk of AC
current requirement and, as a consequence, corrosion on the pipeline on which the
the risk of interference to adjacent buried coating is applied.
structures ( from DC Corrosion)
Application of DC CP potentials that are too negative can result in cathodic over-
protection leading to coating disbondment and blistering and hydrogen
embrittlement of some metals.
4
EXTERNAL / INTERNAL
INTERFERENCE & COATINGS CORROSION
DC STRAY CURRENT
INTERFERENCE CAUSES AC STRAY CURRENT
ACCELERATED CORROSION INTERFERENCE CAUSES
/ COATING DAMAGE ACCELERATED CORROSION /
COATING DAMAGE /
SOURCES SOIL SIDE PERSONNEL SHOCK / PIPE STEEL
CORROSION DAMAGE
FOREIGN PIPELINES
CROSSINGS / ANODE DC TRACTION
BEDS IN COMMON SOURCES
ROW DIRECTLY
BURIED HV AC
HV AC
DC-SOLAR PLANTS / HVDC TRANSMISSION CABLES
TELECOM
HDD
WRONGLY DESIGNED AC FAULT
AC INDUCED
ELECTRICAL TELLEURIC CURRENTS
ISOLATION- WATER CASED CURRENTS
CURRENTS
PIPELINES CROSSINGS
WITH IJ’S
5
COATINGS EFFECT ON INTERFRENCE
COATINGS
INTERFERENCE
EFFECT EFFECT
ON ON
INTERFRENCE COATINGS
6
COATINGS EFFECT ON INTERFERENCE
DIFFERENT TYPE OF EXTERNAL COATINGS– INFLUENCE DC / AC INTEREFRENCE
COATINGS
(3LPE/3LPP/FBE/DFBE/
CTE/CAT/PU/VISCO
ELASTIC)
DC INTERFERENCE AC INTERFERENCE
LEVEL OF CP CURRENT DENSITY LEVEL OF AC INDUCED VOLTAGE
SIZE OF HOLIDAY SIZE OF HOLIDAY
LEVEL OF ANODIC STRAY CURRENT DENSITY DISCHARGING INTO SOIL AC STRAY CURRENT DENSITY
RATE OF STRAY CURRENT DC CORROSION DC CP CURRENT DENSITY
RATE OF STRAY CURRENT AC CORROSION
GROUND POTENTIAL RISE WITHSTAND VOLTAGE

7
INTERFERENCE EFFECT ON COATINGS
INFLUENCE DC / AC INTERFERENCE – ON COATINGS
COATINGS
CTE/CAT/PU/VISCO
ELASTIC)
LOSS OF COATING ADHESION AC INDUCED COATING DEGRADATION
HIGH RATE OF WATER ABSORPTION – REDUCED DIELECTRIC STRENGTH COATING BREAKDOWN
CATHODIC BLISTERING OF THIN FILM COATINGS – FBE / DFBE
8
CORROSION RATES – WITHOUT CP / WITH CP /
WITH CP & AC OR DC INTERFRENCE
ASME B31.8S-2010 gives the following guidance on By applying CP and maintaining
corrosion rates in the absence of CP: IR free potential of steel
Corrosion rate Soil Resistivity (ohm cm) between (-) 0.85 to (-) 1.1V CSE
0.075mm/yr >15,000 Corrosion rate < 0.01mm / year
0.15mm/yr 1000-15,000 By applying CP IR free potential
0.3mm/yr <1000 (worst case) of steel more negative than
(-) 1.2V CSE causes coating
damage
The effects of stray direct current (D-C) on pipelines AC corrosion caused due to induced A-C voltages on
is severe due to the significant metal removal power pipeline with 3LPE coating in common right-of-ways
of D-C currents. has been reported.
Corrosion rates of 10mm/yr have been reported Corrosion rates of 2.4mm/yr have been reported
9
AC & DC INTERFERENCE & COATINGS
SOIL BASED CORROSION
Differential Corrosion Cell

Varying soil properties
Varying 02 concentration
in soil
DC STRAY CURRENT CORROSION
Varying temperatures of
AC INDUCED CURRENT CORROSION
pipeline
COATINGS & AC / DC INTERFERENCE
COATINGS
INTERFERENCE EFFECT
EFFECT ON
ON COATINGS
INTERFERENCE
PROPERTIES OF COATINGS
THICKNESS OF COATING
COATING RESISTIVITY
SIZE OF HOLIDAYS
CP CURRENT DENSITY
CP CURRENT DENSITY AT HOLIDAY
RESISTANCE TO WATER PERMEABILTY
RESISTANCE TO CATHODIC BLISTERING
RESISTANCE TO CATHODIC DISBONDMENT
DIELECTRIC STRENGTH
11
Current STEADY
discharge to soil STATE
INDUCED
AC
CURRENT
AC STRAY CURRENT INTERFRENCE BY INDUCTIVE COUPLING

CORROSION
12
AC INTERFERENCE- FAULTS & COATINGS
"Short-Circuit" HVAC Conditions or
• Occurs when line to ground shorts or faults take place
Lightning
• On High Voltage power lines faults normally occur during
lighting strikes
• Fault currents in soil cause “GROUND POTENTIAL RISE”

• EXCESSIVE GROUND POTENTIAL CAUSE “BREAK DOWN OF
COATING & DAMAGE TO STEEL
GPR
DC CP CURRENT DC STRAY CURRENT
AT STRAY CURRENT “PICK UP” – HIGH “ON” PSP
AT STRAY CURRENT “DISCHARGE”– LOW “ON” PSP
AT STRAY CURRENT “PICK UP” pH is HIGH
AT STRAY CURRENT “DISCHARGE” pH is LOW
MITIGATION OF DC STRAY CURRENT IS DETERMINED BY

DC STRAY CURRENT CORROSION MEASURING “ON PSP” SHIFT SWITCHING ON/OFF
NTERFERING CP SOURCE
DC CP CURRENT
AC INDUCED CURRENT
AC INDUCED CURRENT HALF WAVE (CATHODIC)
HALF WAVE (ANODIC)
MITIGATION OF AC STRAY CURRENT INTERFERENCE IS

DETERMINED BY MEASURING “AC / DC CURRENT DENSITY”
AC CURRENT CORROSION
AT COUPONS & “ CP ON / OFF POTENTIALS” & AC VOLTAGE
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AC INTERFERENE & COATINGS
15
AC INTERFERENCE PROBLEMS ON COATED PIPELINES
10
High Voltage AC Power Lines Can Cause: kV
Ouch!!!
•AC Corrosion of the Steel Potential
• Personnel Shock Hazard Due To Induced AC Touch
voltage =
Voltages 2kV
9 kV
•Coating damage
8 kV
7 kV
EFFECTS OF PIPELINE DUE TO AC INTERFERENCE
Steady State Interference

• Induced AC voltage on pipeline creates safety hazard for personnel
• Risk of AC corrosion on the pipeline
• Risk of Degradation of coating
Fault state Interference
• Risk of damaging pipeline causing perforation / melting of pipewall
• Risk of damaging coating
• Risk of CP equipment damage due to high transient voltages and GPR
• Endangers operating personnel due to high touch and step voltage
17
COATINGS EFFECT ON AC INTERFERENCE
Long term AC interference on a buried pipeline can cause corrosion due to an exchange of
AC current between the exposed metal of the pipeline and the surrounding electrolyte.
This exchange of current depends on an AC voltage whose amplitude is related to various
parameters such as the following:
Configuration of AC power line phase conductors;

Presence and configuration of the earthing conductor;
Distance between the AC power line/traction system and the pipeline;
Current flowing in the AC power line/traction system phase conductors;
Type of coating
Average coating resistance of the pipeline;
Thickness of the coating;
Soil resistivity;
Presence of earthing systems;
Voltage of the AC railway system or the AC power line system
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TYPE OF COATINGS - NEWCONSTRUCTION
DUAL LAYER FUSION BOND EPOXY THREE PAYER POLYETHYLENE
THREE PAYER POLYPROPYLENE COALTAR ENAMEL
Thursday, May 20, 2021 19

TYPE OF COATINGS – FIELD JOINTS THREE LAYER HSS PE OR PP
THREE LAYER HEAT SHRINK SLEEVES
Thursday, May 20, 2021 20

TYPE OF COATINGS – 5D BENDS
THREE LAYER PE + THREE LAYER HSS THREE LAYER PE + PU COATING

SAME COATING CONSTRUCTION DIFFERENT COATING CONSTRUCTION
THREE LAYER HEAT SHRINK SLEEVES

PU COATINGS
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TYPE OF COATINGS –REHABILITATION
VISCO ELASTIC TAPE COATINGS
3PLY / 2PLY TAPE COLD APPLIED TAPE
HIGH BUILD EPOXY COATING

POLYURETHANCE COATING
22
COATINGS EFFECT ON AC INTERFERENCE – TYPE OF COATING
3LPE
3LPP
FBE
DFBE
CTE
PU
COLD APPLIED TAPE
VISCO ELASTIC
23
COATINGS EFFECT ON AC INTERFERENCE – COATING RESISTIVITY
3LPE >108
3LPP >108
VISCO ELASTIC >108
COLD APPLIED
TAPE
>108
FBE >106
DFBE >106
PU >106
CTE >104
24
COATINGS EFFECT ON AC INTERFERENCE – COATING THICKNESS
3LPE 2.5 to 4 mm
3LPP 2.5 to 4mm
FBE 0.4mm
DFBE 0.8mm
CTE 4 to 5mm
PU 1 to 1.5mm
COLD TAPE 2 to 2.5mm
VISCO 2 to 2.5mm
ELASTIC
25
AC INTERFERENCE VOLTAGE INDUCED IN PIPELINE IS DEPENDENT
ON AVERAGE COATING RESISTIVITY & COATING THICKNESS
RL LL
CS RS
108 Ω-m2
106
103 or 4
AC CORROSION ON CATHODICALLY PROTECTED
BURIED PIPELINE- STEADY STATE INDUCTION
TYPE OF COATING (COATING
RESISTIVITY PARAMETER)
DECIDES CP CURRENT DENSITY
FOR COATED PIPELINE
3LPE or 3LPP: 0.001 to 0.2mA/m2

FBE: 0.02 to 0.7mA/m2
CTE: 0.2 to 0.8mA/m2
PU : 0.2 to 0.8mA/m2
SIZE OF HOLIDAY IN COATING &

COATING THICKNESS
DECIDES CP CURRENT DENSITY
FOR COATED PIPELINE AT
HOLIDAY
CAN VARY FROM
1mA/m2 to 10000mA/m2
27
COATING BREAK DOWN FACTOR & SIZE / TYPE OF DAMAGES
Pipeline coating Fi % Δf % Design Life Ff % CP current density Type & Size of damages
years µA/m2
3LPE 0.1 0.03 25 0.85 1 to 200 Pin holes / Disbondment
3LPP 0.1 0.03 25 0.85 1 to 200 Pin holes/cracks / disbondment
FBE / DFBE 0.5 0.3 25 8 20 to 700 Pin holes / Blistering and
disbondment
CTE 0.8 0.5 25 13 200 to 800 Cracks & large scale disbondment
CAT 0.5 0.3 25 7.6 20 to 300 Wrinkling / pin holes
disbondment
VISCO ELASTIC 0.5 0.3 25 7.6 1 to 200 Wrinkling / No pinholes
LIQUID EPOXY 0.8 0.5 25 13 200 to 800 Pin holes / Blistering and
URETHANE 0.8 0.5 25 13 200 to 800 disbondment
The final coating breakdown factor, ff, is given by
f f = fi + (D f ´t dl )
where
fi is the initial coating breakdown factor at the start of pipeline operation;
Δf is the average yearly increase in the coating breakdown factor;
tdl is the design life time expressed in years
28
DAMAGES TO COATINGS – 3LPE DURING LAYING
29
DAMAGES TO COATINGS – 3LPE DURING LAYING
30
DAMAGES TO COATINGS – 3LPP DURING LAYING
31
DAMAGES TO FBE COATING – DURING LAYING
32
DAMAGES TO 3LPE COATING – DURING OPERATION
DAMAGES TO FBE COATING – DURING OPERATION BLISTERING
34
35
36
37
38
DAMAGES TO 3LPP COATING – DURING OPERATION
39
DAMAGES TO CTE COATING – DURING OPERATION
40
DAMAGES TO PU COATING – DURING LAYING
41
PU BEND COATING – BLISTERING
42
AC INTERFRENCE & COATINGS- AC CORROSION – FBE
Hard mound of carbonate Coating
Hemispherical Pit Pipe
Corrosion product
43
AC INTERFRENCE & COATINGS- AC CORROSION – 3LPE
44
BLISTERING OF FBE COATING
Diffusion Diffusion
O2 H2O
POLYETHYLNE
DFBE ADHESIVE
FBE
STEEL STEEL
DFBE High Permeability

LEADING TO BLISTERING
46
AC INTERFRENCE & COATINGS- EVALUATION /
MITIGATION & CONTROL
• Basically, there are three different approaches to prevent AC corrosion: to limit
the AC current flowing through a defect, to control cathodic protection level, and
to ensure that any coating remains defect free. These approaches are not
mutually exclusive.
• The evaluation of AC corrosion likelihood should be performed by evaluation of

some or all of the following parameters:
– AC voltage on the structure;
– on-potential;
– IR-free potential;
– AC current density;
– DC current density;
– AC/DC current density ratio;
– soil resistivity;
– corrosion rate.
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48
1 cm2
49
pH at soil interface changes
DC Current flowing
from soil into coating
dfeect
1 cm2
50
COATINGs & AC INTERFRENCE – STEADY STATE
Pipeline coating CP current density Type & Size of damages Risk of AC corrosion Risk of coating damage
µA/m2
3LPE 1 to 200 Pin holes / Disbondment High Less
3LPP 1 to 200 Pin holes/cracks / High Less
disbondment
FBE / DFBE 20 to 700 Pin holes / Blistering and High High
disbondment
CTE 200 to 800 Cracks & large scale Less -
disbondment
CAT 20 to 700 Wrinkling / pin holes High Medium
disbondment
VISCO ELASTIC 20 to 700 Wrinkling / No pinholes High Low
LIQUID EPOXY 200 to 800 Pin holes / Blistering and High High
disbondment
URETHANE 200 to 800
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Conversely, a well coated pipeline with high
Resistance of pipeline coating to ground is a
coating resistivity / higher thickness and
significant factor controlling the level of induced
excellent coating condition, the resistance to
potential that may build up on a pipeline.
earth along the length of the pipeline is relatively
high allowing for greater induction build up over
Coating resistance to ground is a function of the
longer distances.
coating type, condition, thickness, and local soil
resistivity, all of which may vary along a typical
Due to high resistance to ground, and relatively
collocation length.
few ground paths, the induced AC potential can
build along the collocation length.
In general, a poorly coated pipeline, or deteriorated
coating with low resistance to ground allows multiple
This generates elevated AC potentials, which are
paths to ground for AC potential to dissipate. This
hazardous from a safety standpoint, but also
reduces the buildup of induction, resulting in lower
create a possible corrosion risk, as AC current
AC potential and lower current density discharge at
discharge’s from a relatively few holidays after a
any individual holiday
physical or electromagnetic discontinuity, such
as the pipeline diverging from the collocation.
52
Based on the type of coating, CP current density

is decided which decides the DC current density
thru coating holiday to provide necessary
polarization to prevent soil based corrosion.
However, the CP current thru the coating holidays

also controls AC current density discharging into
the soil by changing the spread resistance at the
coating holiday.
DC current density > 1A/m2 thru coating defect is

classified as excessive cathodic protection and
can lower the spread resistance increasing the AC
corrosion and also damaging the coating.
53
CRITERIA AS PER ISO 18086 2015
EFFECTIVE CONTROL OF AC CORROSION ON PIPELINES
0.025 mm / year
or
>3mA
<0.1mA
or CP CRITERIA FOR BURIED PIPELINES WITH
NO INDUCED AC VOLTAGE
TIME WEIGHTED AVERAGE – 24 HOURS

54
CRITERIA AS PER NACE SP-21424 2018 FOR
EFFECTIVE CONTROL OF AC CORROSION
55
1 Less negative cathodic protection level
2. High negative cathodic protection level COATING DAMAGE
3. AC corrosion
X DC current density A/m2

Y AC current density A/m2
56
COATINGS EFFECT ON INTERFERENCE
COATINGS
CTE/CAT/PU/VISCO
ELASTIC)
LEVEL OF CP CURRENT DENSITY LEVEL OF AC INDUCED VOLTAGE
SIZE OF HOLIDAY SIZE OF HOLIDAY
LEVEL OF ANODIC STRAY CURRENT DENSITY DISCHARGING INTO SOIL AC STRAY CURRENT DENSITY
RATE OF STRAY CURRENT DC CORROSION DC CP CURRENT DENSITY
RATE OF STRAY CURRENT AC CORROSION
DURING AC FAULT CONDITIONS: GROUND POTENTIAL RISE WITHSTAND VOLTAGE

57
INTERFERENCE EFFECT ON COATINGS
INFLUENCE DC / AC INTERFERENCE – ON COATINGS
COATINGS
CTE/CAT/PU/VISCO
ELASTIC)
LOSS OF COATING ADHESION AC INDUCED COATING DEGRADATION
HIGH RATE OF WATER ABSORPTION – REDUCED DIELECTRIC STRENGTH COATING BREAKDOWN
DURING AC FAULT & LIGHTNING CONDITIONS:
58
AC INTERFERENCE ON PIPELINE FROM POWER LINE FAULT:
MAINLY SAFETY CONCERNS, ALSO COATING & PIPE DAMAGE
Shield (“Sky”) Wire To

Adjacent Towers
Fault Current – 5,000 -15,000 Amperes total not
uncommon, <0.1 time
Fault clearance second duration
10-20 milli sec
Counterpoise Cable To
Adjacent Towers
Pipeline
AC FAULTS AND EFFECT ON PIPELINE COATINGS
60
AC FAULTS AND EFFECT ON PIPELINES
61
62
63
64
65
COATING STRESS VOLTAGE DUE TO GPR
66
COATING STRESS VOLTAGE DUE TO GPR – WiTH STAND
Pipeline Coatin Dielectric Thickness Breakdown voltage COATING STRESS

coating g Strength VOLTAGE AS PER
Resistiv @ 1000V/sec NACE SP 0177
ity in
Ω-m2
3LPE >108 > 30KV/mm 3mm 90 KV 5 KV
3LPP >108 > 30 KV/mm 3mm 90 KV 5KV
FBE / DFBE >106 > 45 KV/mm 0.4 / 0.8mm 18KV / 36 KV 3KV
CTE >104 > 10 KV/mm 4mm 40 KV 2 KV
CAT >108 > 30 KV/mm 2.5mm 75 KV 3KV
VISCO >108 > 30 KV/mm 2.5mm 75KV 3KV
ELASTIC
LIQUID >106 > 30 KV/mm 1mm 30KV 3 KV
EPOXY
URETHANE >106 > 30 KV /mm 1mm 30KV 3KV
The ability of the coating to stand voltage stress is also dependent on the duration of the fault
67
AC INTERFERENCE PROBLEMS ON COATED PIPELINES
COATING
DAMAGES
STEADY STATE
INDUCED AC FAULT CURRENT
CURRENT
INCREASE pH Value of SOIL DUE TO GROUND POTENTIAL

CAUSES INCREASE OF RISE INCREASING BEYOND THE
ALKALINITY CAUSING LOSS OF DIELECTRIC STRENGTH OF THE
ADHESION OF COATING COATING
INCREASED BLISTERING
IN THIN FILM COATINGS
68
THANK YOU
69
DC INTERFERENCE & COATINGS
COATINGS
CTE/CAT/PU/VISCO
ELASTIC)
COATINGS EFFECT ON DC INTERFERENCE DC NTERFERENCE EFFCT ON COATINGS
LEVEL OF CP CURRENT DENSITY LOSS OF COATING ADHESION
SIZE OF HOLIDAY HIGH RATE OF WATER ABSORPTION – REDUCED DIELECTRIC

STRENGTH & COATING RESISTIVITY WITH TIME
LEVEL OF ANODIC STRAY CURRENT DENSITY DISCHARGING INTO SOIL
RATE OF STRAY CURRENT DC CORROSION
70
Pipeline CP current Type & Size of Pipe Dia 24” / 50 Kms – CP Current Density AMPS/m2
coating density µA/m2 damages
Start 15 Years 25 Years
3LPE 1 to 200 Pin holes / 20 35 50
Disbondment
3LPP 1 to 200 Pin holes/cracks / 20 55 75
disbondment
FBE / DFBE 20 to 700 Pin holes / Blistering 20 100 300
and disbondment
CTE 200 to 800 Cracks & large scale 75 150 700
disbondment
CAT 20 to 700 Wrinkling / pin holes 20 50 150
disbondment
VISCO 20 to 700 Wrinkling / No 20 35 50
ELASTIC pinholes
LIQUID 200 to 800 Pin holes / Blistering 20 150 300
EPOXY and disbondment
URETHANE 200 to 800 20 200 700
71
Pipeline coating CP current density
Coatings are universally applied to µA/m2
3LPE 1 to 200
buried pipelines to provide the
primary corrosion protection with 3LPP 1 to 200
cathodic protection to protect areas FBE / DFBE 20 to 700
of coating damage.
CTE 200 to 800
CAT 20 to 300
Coatings reduce the overall cathodic
protection current requirement and, VISCO ELASTIC 20 to 200
as a consequence, the risk of LIQUID EPOXY 200 to 800
interference to adjacent buried
URETHANE 200 to 800
structures - from DC Corrosion
72
Pipeline CP current Type & Size of Pipe Dia 24” / 50 Kms – CP Current Amps
coating density µA/m2 damages
Start 15 Years 25 Years
3LPE 1 to 200 Pin holes / 2 3.5 5
Disbondment
3LPP 1 to 200 Pin holes/cracks / 2 5 7
disbondment
FBE / DFBE 20 to 700 Pin holes / Blistering 2 10 29
and disbondment
CTE 200 to 800 Cracks & large scale 7 14 67
disbondment
CAT 20 to 700 Wrinkling / pin holes 2 5 14
disbondment
VISCO 20 to 700 Wrinkling / No 2 3.5 5
ELASTIC pinholes
LIQUID 200 to 800 Pin holes / Blistering 2 14 29
EPOXY and disbondment
URETHANE 200 to 800 2 19 67
73
HIGH CP CURRENT
DENSITY OF
COATING
HIGH CURRENT OUTPUT

OF ANODE BED
CTE COATING
HIGH ANODIC GRADIENTS

CAUSING STRAY CURRENT PICK
UP BY ADJACENT BURIED 3LPE COATING
STRUCTURES TYPICAL STR AY CU R R E NT
SYSTE M. HIGH “ON / Instant OFF PSP”
COATING DAMAGE
74
LOW CP CURRENT
DENSITY OF
COATING
LOW CURRENT OUTPUT

OF ANODE BED
3LPE COATING
ANODIC GRADIENT RADIUS IS

LIMITED ANO NOT
INTERFERING WITH OTHER 3LPE COATING
BURIED PIPELINES TYPICAL STR AY CU R R E NT
SYSTE M.
75
Cathodic protection current entering the pipeline causes several chemical reactions to occur on
the interface of the steel and soil. Due to DC Stray Current interference at pick up points – the
current entering the pipeline is CP current + Stray Current . These chemical reactions cause the
following:
Formation of hydrogen gas bubbles (H2) under the edge of the coating causing lifting of the
coating. (CATHODIC DISBONDMENT)
Formation of hydroxyl-ions (4OH-) causing cathodically generated alkalinity which reacts with
organic polymer causing leaching of the coating and / or adhesive of the coating there-by
changing properties of the coating that are essential for proper adhesion to steel.
The electrical field across the coating thickness generated due to cathodic protection accelerates
the migration / transmission of metal cations and polar water molecules to epoxy / steel interface
leading possible large scale disbondment of the coating from the pipe surface. (ELECTRO
OSMOSIS – CATHODIC DELAMINATION)
76
CP CURRENT
POLARIZATION
FBE COATING 0H-0H- ON PSP - 1.1V

INSTANT OFF – 0.9V
API X70
77
DC STRAY CURRENT CP CURRENT
POLARIZATION
FBE COATING 0H-0H- ON PSP - 2.2V

INSTANT OFF – 1.3V
API X70
78
DC INTERFERENCE & COATINGS - PICK UP POINT
DC STRAY CURRENT CP CURRENT
BLISTERING DUE TO EXCESS IVE ANODIC GRADIENT DISBONDMENT DUE TO EXCESS IVE CP
CURENT AT PICK UP POINT
+2V
POLARIZATION
0H-0H- 0H- ON PSP - 2.2V

H2 H2 INSTANT OFF – 1.3V
-1.3V
API X70
HIGH pH - 13
LOSS OF ADHESON
79
DC INTERFERENCE & COATINGS - PICK UP POINT
80
DC INTERFERENCE & COATINGS - MAX ON / OFF PSP
Pipeline CP current MAX “ON MAX “INSTANT OFF

coating density µA/m2 POTENTIAL” POTENTIAL”
3LPE 1 to 200 (-)1.5V (-)1.18V
3LPP 1 to 200 (-) 1.5V (-1.18V
FBE / DFBE 20 to 700 (-) 1.5V (-).15V
CTE 200 to 800 (-) 2V (-)1.2V
CAT 20 to 300 (-)1.5V (-)1.2V
VISCO ELASTIC 20 to 200 (-) 1.5V (-)1.2V
LIQUID EPOXY 200 to 800 (-) 1.5V (-)1.15V
URETHANE 200 to 800 (-)1.5V (-)1.15V
Potentials are relative to CSE

81
DIRECT STRAY CURRENT CORROSION –
ANODIC / CATHODIC INTERFERENCE
• In the current pickup region, the
potential of the pipeline will shift in
the negative region.
• It receives a boost of cathodic

protection current locally.
• This local current boost will not

necessarily be beneficial, because
a state of overprotection could be
created. Excess of alkaline species
generated can be harmful to
pipeline coating
82
DC INTERFERENCE & COATINGS - DISCHARGE POINT
AT THE DISCHARGE POINT – RATE OF CORROSION WILL DEPEND ON THE SIZE OF COATING DAMAGE & MAGINTUDE
OF THE STRAY CURRENT
COATINGS – LIKE 3LPE / 3LPP / FBE HAVE PIN HOLE DAMAGES AS SUCH RATE OF CORROSION SHALL BE HIGH
AS COMPARED TO OTHER COATINGS.
83
RATE OF METAL LOSS DUE TO DC CORROSION THRU COATING
HOLIDAYS
Pipe dia: 12.75”
WT: 6.4mm
Damage in 3LPE coating 1 sq.cm
DC Stray Current Weight of Steel Days to leak

A mA gms Kg
1 1000 50 0.05 2
0.1 100 50 0.05 20
0.01 10 50 0.05 200
0.001 1 50 0.05 2000
0.0001 0.1 50 0.05 20000
84
INTERFERENCE – FOREIGN PIPELINE DAMAGED BY CP INSTALLATION
AREA OF INFLUENCE
SURROUNDING THE GROUND BED
CURRENT FLOW FROM FOREIGN

STRUCTURE TO PROTECTED
FOREIGN PIPELINE PIPELINE IN CROSSING AREA
REMOTE
GROUND RECTIFIER
BED
o. +
o. -
CTE COATED PIPE LINE
PROTECTED PIPELINE
85
INTERFERENCE – FOREIGN PIPELINE RUNNING
PARALLEL LONG DISTANCES
AREA OF INFLUENCE SURROUNDING THE
GROUND BED
3LPE COATED PIPELINES

ENDWISE CURRENT FLOW
CURRENT DISCHARGE FROM FOREIGN

PIPELINE IN REMOTE AREA
RECTIFIER
o. +
o. -
CTE COATED PIPE LINE

PROTECTED PIPELINE 86
EFFECT ON FOREIGN PIPELINE PASSING THROUGH EARTH POTENTIAL
GRADIENTS AROUND CATHODICALLY PROTECTED BARE PIPELINES
FOREIGN PIPELINE TENDS TO BECOME POSITIVE TO SOIL WITHIN
THE AREA OF INFLUENCE AND FORCED TO DISCHARGE CURRENT
FOREIGN PIPELINE A
(-) 0.9V
3LPE COATED PIPE
CURRENT PICKED UP BY (-) 1.8V

FOREIGN PIPELINE OUTSIDE AREA OF INFLUENCE
THE AREA OF INFLUENCE SURROUNDING THE
PROTECTED PIPELINE
CTE COATED PIPE
PROTECTED PIPELINE B
87
The accelerated rate of corrosion and the observed corrosion morphology along
is consistent with D-C Stray Current Corrosion.
THANK YOU
89
ISOLATION JOINTS ON WATER PIPELINES
AND
DC INTERFRENCE EFFECT ON INTERNAL CORROSION
90
ISOLATION JOINTS – WHY
Cathodic protection
generally provides
protection from corrosion
to buried and immersed
pipelines and ensures safe
operation without
meaningful metal loss or
integrity issues for many
years.
However, when applying

cathodic protection,
electrical isolation is
provided to prevent
drainage of cathodic
protection current.
91
ISOLATION JOINTS – WHY
Cathodic protection
generally provides
protection from corrosion
operation without
years.

provided to prevent
protection current.
92
ISOLATION JOINTS – WATER PIPELINES – INTERNAL CORROSION
Cathodic protection
generally provides
protection from corrosion CONDUCTIVE FLUID FLOWING INSIDE THE PIPE
operation without
years.

INTERNAL CORROSION ON
provided to prevent NON-PROTECTED SIDE
protection current.
93
Stray current is defined as electric current PROTECTED SIDE NON PROTECTED SIDE
that strays from its intended path.
Stray current corrosion is caused by the NON CONDUCTIVE FLUID
electrical current discharge as it leaves the
surface of a metal to flow through an
electrolyte. In pipelines this can occur at
insulating flanges or joints, because the CP CURRENT
current (electron) flow is interrupted by the
insulating component.
Where there is a conductive fluid inside the
CONDUCTIVE FLUID
pipeline it can provide an lower resistance
pathway for CP current route from the
inside surface of the pipe on the “NON-
PROTECTED SIDE
94
95
96
CHARACTERSTICS OF INTERNAL CORROSION ATTACK
Point of Isolation
A characteristic of internal stray current
corrosion is that the attack is located
close to the point of electrical
discontinuity (isolation) on the pipeline,
but only on one side.
Theoretically the highest rate of corrosion

should be at the bare metal surface
Driving voltage closest to the position of the isolation
Stray current will only flow from one side of the
isolation to the other, if there is a driving voltage
across the isolation. External cathodic protection (CP)
can provide this voltage difference.
97
Characteristics of attack
Electrolyte
There must be a conductive solution in
the inside of the pipe (i.e. one
containing electrolyte) present to
provide an alternative path for current
flow. (Sea water, Injection water, Crude
with high water content)
.Rate of attack:
Internal stray current corrosion rates of
attack can be very high, e.g. > 5
mm/year, much higher than other
possible corrosion mechanisms
98
For internal stray current corrosion of a
pipeline to occur, all three of the following
must be present: Electrical Isolation
STRAY
CURRENT
An isolation joint (MIJ), that interrupts the CORROSION
pipeline electrical continuity.
An internal conductive electrolyte to
provide an alternative and continuous path Driving Voltage Electrolyte
or ‘bridge’ for the stray current to cross
from one side of the isolation joint to the
other.
A DC voltage difference between the two
sides of the isolation joint
99
HOW TO PREVENT…..??
• Eliminate the isolation

• Eliminate the flow of low resistivity water across the electrical
isolation
• Minimize the potential difference across the isolation
• Increase the resistance of the internal path by an internally
lined or coated pipe spool
– an internally lined or coated pipe flanged spool with insulation
gaskets
L = (400/ρ ) × D
– a non-metallic pipe spool Where:
L = length of spool (cm),
– MIJ with internal lining or coating ρ = electrolyte resistivity (Ohm.cm)
D = nominal pipe diameter (cm)
INTERNALLY COATED SPOOL PIPE-UNPROTECTED SIDE
PROTECTED SIDE UN -PROTECTED SIDE
D ρ
INTERNALLY COATED SPOOL

PIECE
L
101
INTERNALLY COATED SPOOL PIPE-LENGTH
Water Resistivity
If the resistivity of the electrolyte is Sea Water 0.3 ohm-meter
higher than 1 Ohm.m, or the volume Injection water 0.2 ohm-meter INTERNAL COATING
Waste Water 0.5-100 ohm-meter
occupied by the electrolyte is less than Drinking Water

Deionized Water
2-200 ohm-meter
18000 ohm-meter
5% of the pipeline volume, the overall

length of the isolating spool shall be four ρ
times the pipe diameter (with a minimum
of one metre).
WATER / CONDUCTIVE FLUID
If the resistivity of the electrolyte is
lower than 1 Ohm.m, or the volume of L = (400/ρ ) × D
electrolyte is more than 5% of the Where:
L = length of spool (cm),
pipeline volume, the length of an isolating ρ = electrolyte resistivity (Ohm.cm)
spool shall be determined by the D = nominal pipe diameter (cm)
following formula:
102
INTERNALLY COATED SPOOL PIPE-SELECTION OF INTERNAL COATING
INTERNAL COATING
TYPE OF INTERNAL COATINGS :
HIGH BUILD LIQUID EPOXY – 1000 MICRONS

ρ
• HIGH BUILD GLASS FLAKE LIQUID EPOXY- 1000 MICRONS
FUSION BOND EPOXY – 400 to 600 MICRONS
WATER / CONDUCTIVE FLUID

ALTERNATIVELY
PLASTIC LINER CAN BE USED:
- HDPE –20-25 mm
- PP - 20 -25 mm
- PTFE - 20 – 25 mm
103
THANK YOU
104
MOUNDED BULLETS MUTUAL INTERFERENCE
105
MOUNDED BULLETS
LONGLINE ANODE
TR 1
106
LONGLINE ANODE
TR 1
TR 2
SEPERATRE TRU FOR EACH BULLET
107
SINGLE TRU PROTECTING ALL TBULLETS IN ONE MOUND MULTIPLE TRU PROTECTING ALL BULLETS IN ONE MOUND
NO POSSIBILITY OF STRAY CURRENT

POSSIBILITY OF STRAY CURRENT INTERFERENCE
INTERFERENCE
108
WHY POSSIBILITY OF STRAY CURRENT
INTERFERENCE?
LONG LINE ANODES PROTECTING ADJACENT

A4 A1 BULLETS AND SUPPLIED BY DIFFERENT TRU’S
ARE IN CLOSE PROXIMITY
B A DISTANCE BETWEEN BULLET A & B IS
A5 A2 3 METERS
DISTANCE BETWEEN ANODE A5 & BULLET B

IS 2.5 METERS.
A6
A3
DURING 0&M CONDITIONS MAY EXIST

MULTIPLE TRU PROTECTING ALL BULLETS IN ONE MOUND WHICH MAY CAUSE BULLET B TO BE IN THE
ANODIC GRADIENT OF A4 / A5 / A6 AND
VICE VERSA
109
DURING 0&M CONDITIONS MAY EXIST
WHICH MAY CAUSE BULLET B TO BE IN THE
ANODIC GRADIENT OF A4 / A5 / A6 AND
VICE VERSA
A4 A1
B A
A5 A2
A6
A3 A B
MULTIPLE TRU PROTECTING ALL BULLETS IN ONE MOUND

BULLET B CAN BE IN ANODIC GRADIENT OF A4/A5/A6
110
EFFECT:
ON BULLET B AT DUE TO ANODIC GRADIENT

OF A4 /A5/ A6 BULLET B IS SUBJECTED TO
HIGH ON PSP LEADING TO COATING PU
COATING DAMAGE OF BULLET B
A4 A1
POSSIBLE STRAY CURRENT CORROSION ALSO
B A
A5 A2
A6
A3 A B

BULLET B CAN BE IN ANODIC GRADIENT OF ANODESA4/A5/A6
111
EFFECT:

A4 A1
POSSIBLE STRAY CURRENT CORROSION ALSO
B A
A5 A2
A6
A3
112
EFFECT:

A4 A1
AS COATING GETS DAMAGED MORE
B A CURRENT IS REQUIRED TO MAINTAIN
A5 A2 (-)0.85V – LEADING TO STRAY CURRENT
CORROSION
A6
A3
113
IN CASE MULTIPLE TR UNITS ARE BEING USED TO PROTECT BULLETS IN THE SAME MOUND – ASSET
OWNER HAS TO ENSURE THE FOLLOWING:
CP CURRENTS OF THE ANODE STRINGS TO BE MAINTAINED AS PER DESIGN DOCUMENT .

ON / INSTANT OFF PSP TO BE MAINTAINED WITHIN LIMITS.
DC STRAY CURRENT INTERFRENCE TESTING ON EACH BULLET TO BE DONE
AND
B A C
-1.1V -1.3V -1.2V -0.9 V

ON ON ON ON
114

AND
B A C
-1.2V -1.6V -1.2V -0.9 V

ON ON ON ON
115

AND
B A C
CHANGE OF PSP WHEN B TRU IS -0V -1.3V -1.2V -0.9 V

SWITCHED OFF (-)1.6 – (-)1.3= OFF ON ON ON
(-)0.3V
116

AND
B A C
CHANGE OF PSP WHEN B TRU IS -0V -1.63V -1.2V -0.9 V

SWITCHED OFF (-)1.6 – (-)1.63= OFF ON ON ON
(+)0.03v= 30mV
117
THANK YOU
118
MIJ’s ON PLANT AND DC INTERFRENCE ISSUES
119
MIJ
MIJ
120
NO CP PROTECTION
MIJ
MIJ
121
122
Isolation and Plant Piping.

Structures cathodically protected using close ground-beds (discrete / longline) shall not be
isolated from adjacent plant and earthing systems but shall be isolated from reinforcing
bars in concrete constructions associated with the structure.
Structures which are cathodically protected using remote groundbeds shall be electrically
isolated from common earthing schemes, foreign structures, pipelines and from
reinforcing bars in concrete constructions OTHERWISE STRAY
CURRENT CORROSION SHALL OCCUR.
123
SUGGESTIONS FOR BETTER DESIGN
TO AVOID AC/DC INTERFRENCE
124
SUGGESTIONS FOR BETTER DESIGN TO AVOID AC / DC INTERFERENCE
CROSS COUNTERY PIPELINES CROSS COUNTERY PIPELINES
AC INTERFERENCE AC INTERFERENCE
During construction: During construction:
Try to cross pipeline under HT Transmission Tower at

60 to 90 0. Induced Voltage is minimum.  Coupons have also to be installed at locations of
different coatings. For example – 3LPE coated pipes
Minimum distance of the pipeline from the footing of has PU or Liquid Epoxy as bend coating.
HT tower 30 to 50 meters depending on Voltage level of Install coupon at bends and at 3LPE to study the effec
the HT Tower / Fault level / Clearance time of the fault of AC on two different coatings having the same AC
and Soil resistivity / Type of coating. effect.
Install coupons at vulnerable points – Transmission

tower crossings and at points where the Transmission
Tower / Pipeline diverge / Phase transposition. (These
locations to be selected for soil resistivity <2500 ohm-
cm)
125
AC INDUCED VOLTAGE PROFILE ALONG
PIPELINE – TIPS
- Voltage peak location
Power
line
Electrically long
pipeline
Bend – highest voltage

Could be different coating
126
CROSS COUNTERY PIPELINES
AC INTERFERENCE
During O&M:
 Trained Manpower to collect readings AC Voltage / DC

ON PSP / DC Instant OFF / AC & DC current density
Soil resistivity / Spread resistance of coupon.
• Control of TRU to maintain DC current density in

coupons
• During CIPL survey check for any effect of DC de-couplers

installed at earthing points during the “Instant OFF” cycle.
• Retrieve & Check AC coupons for corrosion & carbonate

formation. (Both AC / DC coupon of size 1cm2
127

DC Interference
DC Interference
During construction:
During construction:
 Ensure Foreign Anodes beds are minimum 100 meters
 At foreign pipeline crossing – know coating of the
away.
foreign pipeline. CTE and FBE coated pipes at crossing
with 3LPE coated pipes can cause DC stray current
If not possible do voltage gradient calculations
interference on 3LPE coated pipes. Ensure TLP’s are
considering the type of ground bed, maximum current
erected near the crossing (within 5 meters)
output of the anode bed, maximum soil resistivity.
 At the crossing point apply additional coating cold
•Pipe has to be in remote earth.
applied tape over the pipelines ten meters upstream /
down stream of the crossing.
•Regular monitoring of ON PSP near foreign anode
Beds. (If required install TLP)
•For pipelines in same ROW if the coatings are same, use
common CP system.
128
MOUNDED BULLLETS PLANT PIPING & MIJ’s
Do not use multiple TRU’s in for protecting bullets in the same Do not use MIJ’s for cathodic protection of plant piping.
mound.
CP deign of plant piping has to be based on target pipes and
Due to multiple anodes with different power sources in other buried incidental structures and plant earthing to
confined space, threat exists for damage to coating and be electrical continuous (excluding RCC foundations)
accelerated corrosion of steel. Further DC stray current testing
is very complicated. CP design to be based on close anode bed design and not on
remote anode bed design.
Ensure proper electrical isolation so that there is no CP current
drain. For congested piping with many RCC foundations, linear
anodes to be used as generally the anode gradient of the
MIJ’s have to be properly located & installed and there should linear anode is limited to 100mm and there will be no stray
be proper electrical isolation of cables connecting to the current interference with nearby RCC structures.
instrumentation mounted on the vessels.
129

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REGISTRATION FORM

NIGIS EDUCATIONAL ONLINE TRAINING PROGRAMME ON

Designation : ________________________ Email id : _______________________________________

Tel : ________________________________ Mobile no.:_____________________________________

For Invoice / Receipt of payment, please fill up the following information

Organisation / Company : _____________________________________________________________

__________________________________________________ Pin Code: ________________________

City : _________________State : ______________________ Country :_________________________

GST No.___________________________________________ PAN No : ________________________

Email id: ___________________________________________ Tel : _____________________________

Account Branch Powai, Mumbai, India UTR No.

Area of AC Interference of pipelines, Earthing & Lightning

Papers published in many journals and magazines.

Presentation on : AC Interference Study of CGD Network

• Standards, Regulations and Guidelines

• Factors affecting AC Interference

• Comparison – Conventional Vs Software Modelling

• Inputs & Data Collection

• Importance of SOIL RESISTIVITY

• Selection of AC Interference Modelling Software

• Typical AC Interference Software Model and Validation

• Conclusion and Recap

 High dielectric coating on pipeline.

 Significant increase in the load and short –circuit

 Rapid expansion of power transmission systems and

 Damages pipelines causing, perforations / melting of

 CP equipment damage due to high transient voltages

 Endangers operating personnel due to high touch

Steady State Fault State

Capacitive coupling Only for aboveground sections of pipeline

 Coating Stress Voltage depending coating type

 During short-circuit/fault conditions, the permissible AC touch-and-step

In reference to clause 3.4.2. of NACE SP 0177 which states "Grounding is usually

• Installing grounding at one location can make matters significantly worse

•Furtherwhile designing mitigation measures, the pipeline from IJ to IJ shall be

• Clause 6.2. AC Interference

During short-circuit/fault conditions, the permissible AC touch-and-step voltages at above grade

 Transmission line convergence / divergence / Crossing

 Parallel sections of pipeline

 HT cable crossing and parallelism

 Method of Cable Laying and construction

 Special design transformers located near pipeline

Conventional Vs Software Modelling

AC Interference with Computer

Shifting of voltage elsewhere

TL1 with centre TL2 with centre

Phase current 680A 560A

Peak Shield wire

DC-PSP Reading AC-PSP Reading AC/DC-DATA-LOGGING

Coupon Coupon fixed Coupon Circuit

 Acceptable limit of current density - 30 A/M2

 Size of holiday - 1 cm2

 Limit of Longitudinal current exiting from a 1cm2 holiday

 For current density of 900 A/M2

 Longitudinal current exiting from a 1 cm2 holiday =

Validation Graph Inductive Results

Validation Graph with Total Interference

Proposed Grounding System Modelled

• Vulnerable locations for AC Corrosion can be entirely different from

• To make pipeline free from AC Corrosion, detailed study is required where

• Pipeline section from IJ to IJ shall only be considered for AC Interference

• Study performed by skilled and experienced professionals with Computer

ECDA, Cathodic Protection, Corrosion

Designation : Email id : _______________

Tel : Mobile no.:_____

__________________________ Pin Code:

City : _State : Country :___________

GST No.___________________ PAN No :

Email id: _______________ Tel : _