JOURNAL OF INFORMATION, KNOWLEDGE AND RESEARCH IN ELECTRICAL ENGINEERING CATHODIC PROTECTION SYSTEM AND IT’S CONDITION MONITORING IN PETROLEUM REFINERIES USING GSM BASED REMOTE MONITORING UNIT RMU 1 MR. PRASHANT KORADIA, 2 PROF. M N BHUSAVALWALA 1 Prashantkumar Koradia ,ManageEssar Oil Ltd. ,Refinery Site, 39 KM, JamnagarOkha Highway , Vadinar - 361305 2 Prof. M. N. Bhusavalwala M.E.. Associate Professor, Head Of The Department ,S V National Institute of Technology (SVNIT), Surat Prashantkumar.Koradia@essar.com, mnb@eed.svnit.ac.in ABSTRACT— Cathodic protection is technique used to protect steel materials against corrosion i.e. underground vessels, pipelines, storage tank bottoms etc. buried underground or in sea water against corrosion. The condition monitoring of cathodic Protection systems have received considerable attention in recent years because corrosion may lead to spillage of oil and leakage of gases from storage tanks and Pipelines. Routine measurements of CP level are required to comply with regulatory safety standards. In most of cases, the length of pipelines for which CP level are to be measured are in lengths of kilometers. This paper includes the method of condition monitoring of cathodic protection system in petroleum refinery using GSM based remote monitoring unit (RMU). Keyword:- Corrosion, Cathodic Protection, Condition Monitoring, GSM Based Remote Monitoring System, Pipe To Soil Potential And Tank To Soil Potential. I. INTRODUCTION In petrolieum refineries and petrochemical plants, steel tanks and underground vessels for the storage of crude oil and products as well as pipelines for transferring the crude and products from crude distrillation plant to storage area and then to product storage & dispatch area are among the most parts of the fixed plant facilities. Corrossion leads to not only lossess of the metal and disconnection of the tank and pipelines from the regular plant operation, but also lossess of the product and severe environment problems. Corrossion was a factor in 21.5% (28/128) of all accidents in refineries reported to the MARS database. Since 1980, 3 accidents account for the majority of 60 deaths and 370 injuries arising from these events (if BP Texas city -2005 is included). An accident in Germany in 2006 estimated € 9.5 million in environmental damage. Cathodic Protection is a technique to reduce the corrosion of a metal surface by making that surface the cathode of that electrochemical cell.[1] In 1971 Galvani noticed that when two metals having different energy level or potential are coupled together current will flow. The direction of positive current flow will be from the metal with more negative potential through the electrolyte to that which is more positive. Corrosion will occur at the point where positive current leaves the metal surface. Corrosion is degradation of a metal by its chemical combination with nonmetal such as oxygen sulphur etc. [2] Cathodic protection is an electrical method of mitigating corrosion on structures that are exposed to electrolytes such as soils and waters. Corrosion control is achieved by artificially causing direct current to flow from auxiliary anodes, through the electrolyte (soil or water), and onto the structure to be protected. It is a scientific method which combats corrosion by use of the same law which causes the corrosion process. It has widespread application on underground pipelines, water storage tanks, lack and gate dams, storage tanks bottom, Underground storage tanks, pipelines under sea water etc. It has been proven most effective corrosion control method. [3] II. WHAT IS CORROSION ? Corrosion is degradation of a metal by its chemical combination with a non - metal such as oxygen, sulphur etc. It is return of the metal to the form in which it originally existed as an ore with complete loss of its metallic properties. Naturally occurring ores are oxides, sulfides or carbonates, and energy must be expended in converting these ores to metal. Corrosion is reverse process and it requires no energy. Metals most easily obtained from their ores requiring less energy in smelting least prone to corrosion. Corrosion on underground pipeline if not mitigated results in metal loss. One ampere of direct ISSN: 0975 – 6736| NOV 11 TO OCT 12 | VOLUME – 02, ISSUE - 01 Page 90 JOURNAL OF INFORMATION, KNOWLEDGE AND RESEARCH IN ELECTRICAL ENGINEERING current discharging into the usual soil electrolyte can remove approximately 9 Kg. of steel in one year. In other words, corrosion is the wearing away of metals due to a chemical reaction [4] 1. Electrolytic corrosion. Electrolytic corrossion is a result of direct current from outside sources entering and then leaving a particular metallic structure by way of electrolyte. When current enters the structure, that part is usually unaffected or is provided with some degree of protection but when the current leaves the structure, corrossion occurs. In underground work, this type of corrossion is usually reffered as stray current corrossion. This type of corrossion usually results due to current entering the soil from sources of DC like DC motors or DC powerhouse. Fig : 1 Corrosion process. Fig 4 : Stray Current Corrosion /Electrolytic Corrosion. Fig 2 : Chemical process of corrosion 2. Galvanic corrossion. All metals have specific relative electrical potential. When metals of different electrical potential are in contact in the presence of moisture, a low energy electric current flows from the metal having the higher position in the galvanic series. This is called "galvanic action." Galvanic corrosion is a form of electrochemical corrosion that occurs when two dissimilar metals come together in the presence of an electrolyte to form an electrical couple, known as a galvanic couple. The more noble or cationic the metal, the less likely it will corrode relative to the other metal with which it is in contact. The more active, or anodic, metal corrodes rapidly while the more noble, or cathodic, metal is not damaged. The difference in potential can arise from the coupling of two dissimilar metals, variation of electrolytes, nonhomogeneity of the metal, or a combination of the above.[6] Fig 3 : Underground pipelines and seawater corrosion. III. CORROSION MECHANISM Electrochemistry contributes an understanding of the mechanism that is basic to the corrosion of all metallic objects. Metals in electrolytes get corroded by the following two basic mechanisms [5] 1) Electrolytic corrosion. 2) Galvanic corrosion. Fig 5 : Electrolytic Cell. Current will be generated when two dissimilar metals are electrically connected and immersed in an ISSN: 0975 – 6736| NOV 11 TO OCT 12 | VOLUME – 02, ISSUE - 01 Page 91 JOURNAL OF INFORMATION, KNOWLEDGE AND RESEARCH IN ELECTRICAL ENGINEERING electrolyte. One of the metals will corrode. The path of the current will be from the corroding metal, through the electrolyte (soil) to the non-corroding metal and then back through the connection (conductor) between the two metals. The corroding metal is the one where the current leaves to enter the electrolyte and is called an anode. The metal that receives the current is called the cathode. The same metallic structure, when placed in an electrolyte (e.g. soil) can develop differences in potential as a result of metal grain composition, milling imperfections, scratches, threads, etc., being exposed. Those portions will usually be anodic to the remainder of the surface and will corrode. Fig 6 : Impression of local anodes and cathodes of corrosion cells occuring on the same metal surface. Corrosion can occur due to differences in the electrolyte. These differences may be in the soil resistivity, oxygen concentrations, moisture content and various ion concentrations. The variations produce current flow from one location, through the electrolyte to another portion of the same metallic structure. It has been established that electric current can generate corrosion, corrosion, in turn can generate electric current. As indicated by these phenomena, it is then possible to prevent corrosion by use of electrical current. This is the basis for cathodic protection. When direct current is applied with a polarity which opposes the natural corrosion mechanisms, and with sufficient magnitude to polarize all the cathodic areas up to the open circuit potential of the anodic areas, corrosion is arrested. IV. CATHODIC PROTECTION Cathodic protection is a technique to reduce the corrosion of a metal surface by making that surface the cathode of that electrochemical cell. [1] The concept of CP has been around for quite some time. Marine vessels have used CP for almost 200 years The first recorded use of CP occurred in the early 1800s. In 1824, Sir Humphry Davy was consulted by the British Admiralty, which was concerned about “the rapid decay of the copper sheeting of His Majesty’s ships of war and the uncertainty of the time of its duration.” Davy proposed the attachment of a small piece of zinc to nullify electrochemical action on the copper sheathing. Davy also investigated this action using an impressed current system [7]. Currently, CP is mandatory for underground, metallic pipelines of hazardous gas and liquids [8], [9], and for water storage tanks with a 250,000 gallon capacity or greater [10]. Cathodic protection also is recommended for underground piping systems located within ten feet of steel reinforced concrete. Galvanic corrosion will occur between the steel rebar and the pipeline if the two systems are too close [10], [11]. V. TYPE OF CATHODIC PROTECTION There are basically two methods of applying cathodic protection.[12] 1) Sacrificial Anode Cathodic Protection. 2) Impressed Current Cathodic Protection A) Sacrificial Anode Cathodic Protection Fig 8 : Sacrificial anode cathodic Protection This is the simplest method of installation of cathodic protection. As its name indicates, in this method, the anodes used are of galvanic type with a higher potential with respect to structure to be protected and capable of self generating the DC current necessary for the cathodic protection where the pipes/tanks are cathodes. These anodes are mitigated as the time passes and as they sacrifice themselves for protection of cathode they are called sacrificial anodes. Galvanic or sacrificial anodes are made in various shapes and sizes using alloys of zinc, magnesium and aluminum. B) Impressed Current Cathodic Protection Fig 7 : Corrosion caused by dissimilar soils ISSN: 0975 – 6736| NOV 11 TO OCT 12 | VOLUME – 02, ISSUE - 01 Page 92 JOURNAL OF INFORMATION, KNOWLEDGE AND RESEARCH IN ELECTRICAL ENGINEERING In this method, anodes are installed in the electrolyte and are connected to the positive terminal of DC power source while the structure to be protected is connected to negative terminal of source. Direct current is forced to flow from external source i.e. transformer rectifier units. As this method uses rectifier units it is referred as a rectifier type or impressed current type cathodic protection. The flow of this current is adjusted to overpower corrosion current discharging from all anodic areas it provides a complete protection. Table 2 : CP readings in tabulated form VII. DIFFICULTIES IN CATHODIC PROTECTION READINGS Fig 9 : Impressed current cathodic protection This method is widely used for pipelines and small underground tanks to large petroleum tanks ranging from 5 meter diameter to 80 meter diameter tanks. It has an advantage that we can apply uniform current of the same on piping and tanks and so through protection occurs. Moreover it has a long life of 50 years after installation if maintained properly. Table 1 : Comparison of GCP and ICCP The following difficulties have been observed during taking the CP readings: 1) Collection of periodic data is very essential as per the defined frequency considering NACE standards. Now as the pipe lines ranges in kilometers, collection of data is a time consuming job. This also needs travelling and vehicles etc to collect the data frequently. 2) Collecting data at a periodic interval manually is essentially reactive as the faults in the CP system can go undected for at least a month at TRU’s and test stations. This risks the pipeline being unprotected for a long periods, accelerates corrosion and shortens the life of structure. 3) As the pipelines passes through many geographical locations, many CP control stations are difficult to access and may need permission of land owner to access the test stations. 4) At test stations with induced AC from power lines, electric shocks can be generated from touch and step potential voltages and high current level. 5) Highly skilled engineers/technicians are needed for the data collection. There are chances of manipulation of data which are actually not taken by the engineer/technician from engineer/technician side. As the data are taken manually the accuracy of the data is not up to the desired accuracy. 6) This hard data is again needed to be converted into soft copy in form of excel sheet or word format as per the requirement and in this case also there are chances of mistakes from the data operator. 7) There are chances of insect bites, animal attacks, honeybee attacks etc near the test stations. VIII. REMOTE MONITORING OF CP SYSTEM USING GSM BASED REMOTE MONITORING DATA LOGGERS The comparison of sacrificial anode cathodic protection system and impressed current cathodic protection can be shown as above. VI. CATHODIC PROTECTION READINGS The frequency of cathodic protection readings should be weekly. The value of PSP or TSP should be noted fortnightly from each test station unit. The tabulated form of the same is shown below.[1] Fig 10 : Front view of one of RMU ISSN: 0975 – 6736| NOV 11 TO OCT 12 | VOLUME – 02, ISSUE - 01 Page 93 JOURNAL OF INFORMATION, KNOWLEDGE AND RESEARCH IN ELECTRICAL ENGINEERING of data from about 25 to 50 RMU’s in the field into the central computers kept at the control room. Fig 10B : lower view of one of RMU The present trend in remote monitoring of the cathodic protection has turned to GSM based remote monitoring units (RMU) data logger instead of manual data collection or data collection by old type of data loggers without screen and memories. GSM based remote monitoring units data logger are highly accurate, compact, low powered, low cost, microcontroller based units with built in GSM modem which enables continuous centralized monitoring of CP TR parameters at the central station wherever required. Moreover they have the facilities of configuration of mobile numbers. The unit provides data by means of SMS sent to the programmed mobile numbers. Fig 11 : Data in graphical form The RMU enables easy and wireless centralized monitoring of TR parameters like AC supply voltage and current, DC output voltage, DC output current, reference potential (PSP), AC supply voltage. Also this RTU generates alarm conditions like pipe or tank overprotection, pipeline or tank underprotection, reference fail, TR door open especially as theft monitoring. At remote end the data could be received using a GSM interface module connected to the computers installed with the CP software provided by the manufacturer of this RMU. This software displays the acquired data of TR unit in analytical and graphical formats and stores the data in the standard databases like MS ASCESS which is used for generating reports for further analysis of structure under protection. The datas can be exported into MS EXCEL spreadsheet as well as tables and graphs. The interface modules are designed to direct downloading Fig 12 : Laptop software screen for setup The data logging and broadcast schedule may be fully programmed from 1 reading in 5 minutes to 1 reading per day as per the requirement of user and this data is also directly received in the mobile phones of maintenance personnel for the reactive action against the protection of pipeline. Apart of sending the TR data to the remote stations, these RMU also logs the data in their volatile memory with accurate day-date-time stamp for each reading at the programmed logging interval and thus they also work as local data loggers. Also they have small 2 line LCD display to verify the datas and ensure that the input is connected properly and logger is receiving signals from the field. The RMU can store about 20-000 to 30-000 date readings which can be downloaded through laptop or computer using a RS 232 port. The stored data can be retained for 10 years without any external powers. These RMU also has commands for starting and stopping the unit current interruption of TR units wherever desired. This gives us flexibility of making the TRU ON/OFF from the control station whever required. The RMU also have local key pads through which set parameters for the alarm conditions can be feed or changed as per the requirement. The real time clock setting with day date and year can be done along with password protections so that the exact time stamping of data or alarms can be stored. The most important feature of these RMU is that they are housed in a compact and sturdy non corroding enclosure inside the existing TRU with direct or channel mounting and dimensions ranging from 200mm X 200mm X 150 mm to less compact size of 180 mm X 150 mm X 100 mm. These RMU are micro processor based, they can work on any supplies like 230V + 20 % AC, 20 to 120 V DC, 12V DC etc and can work in the temperature range from -10 degree celsius to 75 degree celsius. These RMU can be feed directly from the power fed to TRU. ISSN: 0975 – 6736| NOV 11 TO OCT 12 | VOLUME – 02, ISSUE - 01 Page 94 JOURNAL OF INFORMATION, KNOWLEDGE AND RESEARCH IN ELECTRICAL ENGINEERING The costs of this type of RMUs range in between 25,000 to 75,000 rupees. It has a payback period of about 3-5 years if data required monthly readings of TRU and test stations. IX. LIMITATIONS OF RMU : Along with all these there are some drawbacks of RMU’s as stated below: 1) The RMU cannot do remote monitoring at the spaces where there are weak or no signals of GSM. 2) The cost of GSM SIM card is one time amount to be paid to GSM network operator. Also monthly amount to operate this card is to be paid to GSM network operating from which SIM is purchased as a billing amount each month. X. LIST OF ABBREVATIONS : CP = Cathodic Protection. GSM = Global System for Mobile Communications. RMU = Remote monitoring unit. CM = Condition monitoring. TRU = Transformer Rectifier unit. PSP = Pipe to Soil Potential. TSP = Tank to soil potential. GCP = Galvanic cathodic protection. ICCP = Impressed current Cathodic Protection. SIM = Subscriber identity Module. XI. CONCLUSION Cathodic protection is one of the most economical methods of preventing corrosion. This method needs continuous monitoring of data as per the predefined frequency. Remote monitoring of cathodic protection on buried metal pipelines, underground vessels and tankage base was one of the significant technical challenges for petroleum industries. The development of low power consumption microprocessor based electronics with affordable communication system has helped to overcome these challenges. Petroleum and gas industries are now adopting the remote monitoring system using GSM based remote monitoring units for cathodic protection TRU’s and CP test stations. This has enabled better utilization of human reducing the shock hazards. By identifying and reporting the problems as they occur, remote monitoring units ensure continuous and effective cathodic protection and hence increase the life of structure to be protected. REFERENCES [1] NACE SP0169:2007 - Control of External Corrosion on Underground or Submerged Metallic Piping Systems. [2] The corrosion and cathodic protection. [Online]. Available: http://www.generalcorrosioncorp.com/TechInfoSubP ages/GCC_CPTraining2.pdf [3] Cathodic protection anode selection, Public work technical bulletin 420-49-27, 15th June 200. [Online]. Available: http://www.wbdg.org/ccb/ARMYCOE/PWTB/pwtb_ 420_49_37.pdf [4] Roberge, Pierre R, Handbook of Corrosion Engineering 1999. [5] Cathodic Protection [Online]. Available: cpcorrosion.blogspot.com/2009/08/corrosionmechanism.html [6] Matthew Stuart, “Dissimilar metal corrosion” [Online]. Available: http://www.pdhonline.org/courses/s118/s118.htm [7] Sir H. Davy, “On the corrosion of copper sheeting by seawater, and on methods of preventing this effect, and on their application to ships of war and other ships,” Proc. R. Soc. Lond., vol. 114, no. 1824, pp. 151–246 and vol. 115, no. 1825, pp. 328– 346. [8] Department of Transportation, Washington, DC, Transportation of Natural Gas and other Gas by Pipeline. 49 CFR, Part 192. [9] Department of Transportation, Washington, DC, Transportation of Hazardous Liquids by Pipeline, 49 CFR, Part 195. [10] Department of the Army, Washington DC, Maintenance of Mechanical and Electrical Equipment at Command, Control, Communications, Computers, Intelligence, Surveillance, and Reconnaissance (C4ISR) Facilities, TM 5-692-2, Chapter 31, Apr. 15, 2001. [11] Department of the Army, Washington DC, Electrical Design, Cathodic Protection, [12] J. Paul Gayer, An Introduction to cathodic protection, El Macero CA, 2009. ISSN: 0975 – 6736| NOV 11 TO OCT 12 | VOLUME – 02, ISSUE - 01 Page 95