Electrical engineering courses

CORROSION AND CATHODIC PROTECTION

Ref No: 2015028

When an experienced plant technician explains why additional cathodic protection is needed, do you understand?  When there is a discussion about the cause of the last tank or pipe rupture, do you know why inadequate cathodic protection could be the cause?
To learn the principles of cathodic protection, how it is applied and what problems it causes.  To learn how to test and maintain cathodic protection systems, as well as how to troubleshoot them.  Then you must attend this course.
AIMS AND OBJECTIVES
Upon completion of this training kit, you will be able to:
1-Describe the purpose and importance of cathodic protection systems
2-Describe the use of cathodic protection at industrial facilities
3- Explain the principles of corrosion
4- Explain the difference between electron flow and current flow
5- Describe electrical potential difference and its relationship to corrosion
6- Identify the key components and functions of the different types of cathodic protection systems
7- Describe the operator's monthly inspection of cathodic protection systems including: 
 visual inspection of the cathodic protection equipment 
 adjustment of the cathodic protection system power supply 
identification of cathodic protection system problems
8- Describe basic procedures used by electricians to troubleshoot and repair cathodic protection systems
9- Explain the purpose and importance of electrical isolation connections
10- Identify possible equipment installation conditions where electrical isolation may be compromised

 

CHAPTER1- BASICS OF CORROSION
1- INTRODUCTION
2- THE COST OF CORROSION
3- WHY METALS CORRODE?

  • 3-1 Corrosion Requires Energy
  • 3-2 High Energy State of Refined Metals
  • 3-3 Forms of Corrosion
  • 3-4  Galvanic Series of Metals
  • 3-4 Conditions Necessary for Corrosion

4- CHEMISTRY AND ELECTROCHEMISTRY OF CORROSION

  • 4-1 The Nature of Matter
    • 4-1-1 The atom
    • 4-1-2 Ions
    • 4-1-3 Molecules
    • 4-1-4 Acids and bases
  • 4-2 Characteristics of the Basic Corrosion Cell
  • 4-3 Anodic Half-Cell Reactions
  • 4-4 Cathodic Half-Cell Reactions
  • 4-5 Oxidation—Reduction (Redox) Reactions
  • 4-6 Equivalent Electrical Circuit for a Corrosion Cell
  • 4-7 Polarization
  • 4-7 What is Cathodic Protection?

CHAPTER 2- CORROSION IN SOIL
1- INTRODUCTION
2- FACTORS THAT INFLUENCE CORROSION IN SOIL

  • 2-1 Water and Moisture Content
  • 2-2 Degree of aeration
  • 2-3 Soil pH (acidity of the soil)
  • 2-4 Soil resistivity
  • 2-5 Presence of Chlorides and Sulphates
  • 2-6 Microbiologically Influenced Corrosion (MIC)

3- TYPES OF CORROSION

  • 3-1 General Corrosion
  • 3-2 Concenetration Cell Corrosion
    • 3-2-1 Dissimilar Environment
    • 3-2-2 Different Aeration (Oxygen Concentration Cells)
    • 3-2-3 Moist/Dry electrolyte
    • 3-2-4 Non-homogeneous soil
    • 3-2-5 Concrete/Soil interface
    • 3-2-6 Biological effects
  • 3-3 Galvanic Corrosion
    • 3-3-1 Dissimilar Metals
    • 3-3-2 Old-to-new syndrome
    • 3-3-3 Marred or Scratched Surface. 
    • 3-3-4 Stresses metallic section
    • 3-3-5 Different Temperature (Temperature Cells)
    • 3-3-6 Simultaneous sources of corrosion
  • 3-4 Stray Current Cells Corrosion (Electrolytic Corrosion)
    • 3-4-1 DC transit system
    • 3-4-2 High voltage direct current (HVDC) electric transmission lines 
    • 3-4-2 High voltage direct current (HVDC) electric transmission lines 
    • 3-4-3 Cathodic protection systems
  • 3-5 Telluric Currents

CHAPTER 3- CATHODIC PROTECTION BASICS
1- INTRODUCTION
2- HOW CATHODIC PROTECTION WORKS
3- USES OF CATHODIC PROTECTION
4- PROTECTION CRITERIA
5- TYPES OF CATHODIC PROTECTION

  • 5-1 Sacrificial or Galvanic Anodes
  • 5-2 Impressed Current Systems
    • 5-2-1 Power sources
    • 5-2-2 Anodes
  • 5-3 Comparison of Cathodic Protection Types

6-  SACRIFICIAL ANODE CP SYSTEMS DESIGN

  • 6-1 Typical Uses
  • 6-2 Advantages and Disadvantages
  • 6-3 Design Process
    • 6-3-1 Design parameters
    • 6-3-2 Current requirements
    • 6-3-3 Anode selection 
    • 6-3-4 Anode requirements
    • 6-3-5 Anode life
  • 6-4 Grouped Anodes
  • 6-5 Anode Installation

7- IMPRESSED CURRENT CP SYSTEMS DESIGN

  • 7-1 Typical Uses
  • 7-2 Advantages and Disadvantages
  • 7-3 Design Process
    • 7-3-1 Design parameters
    • 7-3-2 Current requirement
    • 7-3-3 Anode selection
    • 7-3-4 Anode requirements and life
    • 7-3-5 Groundbed resistance
  • 7-4 Types of Impressed Current Anode beds
    • 7-4-1Vertical Remote Impressed Current CP Systems. 
    • 7-4-2 Horizontal remote impressed current CP systems
    • 7-4-2 Distributed Impressed Current CP Systems.
    • 7-4-3 Deep remote impressed CP systems

8- CATHODIC PROTECTION CURRENT DISTRIBUTION
9- CATHODIC PROTECTION ATTENUATION
10- CATHODIC PROTECTION HARDWARE

  • 10-1 Test Station
  • 10-2 Electrical Isolation
  • 10-3 Anodes
  • 10-4 Cables
  • 10-5 Backfill
  • 10-6 Rectifier Units
    • 10-6-1 Rectifier Selection. 
    • 10-6-2. Standard rectifier types.
  • 10-7 SOLAR POWER CP-SYSTEM

11- EXAMPLES OF GALVANIC CATHODIC PROTECTION DESIGN

  • 11-1 Aircraft Multiple Hydrant Refueling System.
    • 11-1-1. Design data.
    • 11-1-2. Computations.
    • 11-1-3. Placement.
  • 11-2 Underground Steel Storage Tank
    • 11-2-1 Design data
    • 11-2-2 Computation
    • 11-2-3 Placement

12- EXAMPLES OF IMPRESSED CATHODIC PROTECTION DESIGN

  • 12-1 Steel Gas Main
    • 12-1-1. Design data.
    • 12-1-2 Computations
    • 12-1-3. Select rectifier. 
  • 12-2 Heating Distribution System
    • 12-2-1  Design data.
    • 12-2-2. Computations.
    • 12-2-3  Groundbed design.
    • 12-2-4 Rectifier location.
  • 12-3 Black Iron Hot Water Storage Tank
    • 12-3-1  Design data.
    • 12-3-2. Computations.

CHAPTER 4- CORROSION INSPECTION AND MONITORING
1- INTRODUCTION
2- INSPECTION METHODS AND STRATEGIES

  • 2-1 The Maintenance Revolution
  • 2-2 Maintenance Strategies
  • 2-3 Selection of Inspection Points
  • 2-4 Risk Based Inspection (RBI)

3- CORROSION MONITORING

  • 3-1 Corrosion Monitoring Basics
  • 3-2 Need and Importance of corrosion Monitoring
  • 3-3 Elements and Techniques of Corrosion Monitoring 
  • 3-4 Selecting Monitoring Points
  • 3-5 Data Integration in Corrosion Monitoring

CHAPTER 5- CATHODIC PROTECTION TESTING AND MONITORING
1- CATHODIC PROTECTION TESTING EQUIPMENTS

  • 1-1 Standardized Test Equipment
  • 1-2 Portable Voltmeter/Ammeter
  • 1-3 The TINKER & RASOR Model CPV-2 Cathodic Protection Voltmeter
  • 1-4 Recording Voltmeters and Ammeters
  • 1-5 Connection of Recording Voltmeter
  • 1-6 Connection of Dual-Pen Recorders
  • 1-7 Reference Electrodes (Half-Cells)
    • 1-7-1 Maintenance of Cu/CuSo4 Half-Cells
    • 1-7-2 Calibration of Cu/CuSo4 Half-Cells
  • 1-8 Test Cables/Test Probes/Miscellaneous
  • 1-9 Instrument Accuracy

2- CATHODIC PROTECTION TESTS

  • 2-1 Structure Potential
  • 2-2 Effect of Cathodic Protection on Structure Potentials
  • 2-3 Pearson Survey
  • 2-3 Direct Current Voltage Gradient (DCVG) Surveys:
  • 2-4 Soil Resistivity Measurements
  • 2-5 Cell to Cell Potential Testing Procedure
  • 2-6 IR Drop Method
  • 2-7 Current Requirement Testing
  • 2-8 Rectifier Efficiency Testing Procedure

3- MONITRING OF CATHODIC PROTECTION

  • 3-1 Introduction
  • 3-2 Why Monitoring
  • 3-3 Remote Monitoring Unit (RMU) Configuration
    • 3-3-1 Site selection
    • 3-3-2 Common Features and Characteristics
    • 3-3-3 Unit-Specific Features
  • 3-4 Life-Cycle Costs and Benefits

CHAPTER 6- STRAY CURRENTS INTERFERENCE
1- INTRODUCTION
2- DIRECT CURRENT CORROSION

  • 2-1  Anodic Interference: 
  • 2-2  Cathodic Interference: 
  • 2-3 Combined Interference:

3- ALTERNATING STRAY CURRENT
4- DETECTION OF STRAY CURRENTS
5- LOCATING THE SOURCE OF INTERFERENCE

  • 5-1 Static Stray Current Flow
    • 5-1-1 Outside structure
    • 5-1-2 Through structure
  • 5-2 Dynamic stray current

6- MITIGATION OF STRAY CURRENT CORROSION

  • 6-1 Controlling Stray Currents at the Source
  • 6-2 Use of Electrical Bonding
  • 6-3 Cathodic Shielding
  • 6-4 Mitigation Bonds
  • 6-5 Sacrificial Anodes
  • 6-6 Protective Coating
  • 6-7 Installation of Nonmetallic Sections or Isolators

7- STRAY CURRENT CASE STUDY – DC RAIL TRANSIT SYSTEMS

CHAPTER 7- CORROSION CONTROL IN ELECTRIC POWER SYSTEMS
1- CATHODIC PROTECTION FOR TOWER FOUNDATIONS USING INDUCTION FROM THE TRANSMISSION LINE ELECTRIC FIELD

  • 1-1 Corrosion Costs
  • 1-2 Description of the New Method
  • 1-3 Design of Anode Bed

2- DRAINAGE PROTECTION OF EARTH-RETURN CIRCUITS LAID IN STRAY CURRENTS AREA
3- ISOLATION APPLICATION

  • 3-1 Purposes
  • 3-2 Examples using insulating joints

4- CONDUCTING COMPOSITES AS CABLE ANODES IN CATHODIC PROTECTION
5- CATHODIC PROTECION OF PIPE TYPE CABLES

  • 5-1 Basic Requirements
  • 5-2 Low-Pressure Oil Filled (LPOF)
  • 5-3 High-Pressure Oil Filled (HPOF} Cable
  • 5-4 Gas Pressure Cables
  • 5-5 DC Oil Filled Cable

6- OPTIMIZATION TECHNIQUE FOR THE CATHODIC PROTECTION OF COMPLEX UNDERGROUND CONDUCTOR NETWORKS
7- STEEL GROUNDING SYSTEM IN A HEAVY INDUSTRIAL PLANT
8- CORROSION CONTROL BY DESIGN

  • 8-1 Corrosion Prevention Starts with Design
  • 8-2 Establishment of Basic Prerequisites
  • 8-3 Design Principles with Regard to Corrosion

9- CORROSION CONTROL IN ELECTRIC POWER PLANTS

  • 9-1 Corrosion and Power Plant Components
    • 9-1-1 Boiler
    • 9-1-2 Turbine-Generator System
    • 9-1-3 Heat Exchangers and Piping 
    • 9-1-4 Coal-Handling Equipment
    • 9-1-5 Flue Gas Systems
    • 9-1-6 Ash-Handling Equipment
    • 9-1-7 Electric Power and Instrumentation and Control 
    • 9-1-8 Miscellaneous Power Plant Equipment
  • 9-2 Corrosion Control
  • 9-3 On-Line Monitoring

 

Anyone who is responsible for corrosion control involved in design, operation, monitoring and maintenance of all types of Cathodic protection systems in industrial plants, process operation, oil fields refineries, petrochemical plants, inspection and maintenance, power stations and terminals.
He will benefit from this course as it provides a framework of discipline to carry out activities which require consistent field data, and other information, to make it effective.

He will benefit from this course as it provides a framework of discipline to carry out activities which require consistent field data, and other information, to make it effective.

Trainees shall receive a portfolio containing a comprehensive course manual.

Attendees shall receive a certificate of attendance from AMAD Tech.