Application in deep vertical groundbeds of linear flexible anodes
- 1. ELECTROCHEMISTRY AT YOUR SERVICETM SPECIALTIES & NEW APPLICATIONSPOOLS & ELECTROCHLORINATIONELECTRONICS & SURFACE FINISHINGCHLORINE & CAUSTIC INDUSTRY APPLICATION IN DEEP VERTICAL GROUNDBEDS OF LINEAR FLEXIBLE ANODES Simone Tremolada
- 2. 1 2 4 5 3 6 ELECTROCHEMISTRY AT YOUR SERVICETM 2 What is linear flexible anode? Technical specifications of the product Product Design Options Case History: Installation in deep well groundbed. Installation Cost Savings Conclusions Presentation Outlook
- 3. ELECTROCHEMISTRY AT YOUR SERVICETM 3 This system is considered the ideal solution when the anode has to be installed very close to the structure to protect in confined spaces. Linear Flexible anode Linear flexible anodes were designed for the cathodic protection of pipelines, tanks (AST or Mounded LPG Storage Bullets) in soil or sand and reinforced concrete structures. Linear flexible anode designed for close by Cathodic Protection in HDD applications.
- 4. ELECTROCHEMISTRY AT YOUR SERVICETM 4 Linear Flexible anode The anode is assembled inside a protective sock that prevents accidental contacts with the cathode and is surrounded by calcinated petroleum coke. A protective braid is increasing mechanical resistance. The product core is a pure titanium wire Grade 1 according to ASTM B 863 thermally coated with mixed metal oxides of group VIII. This design allows to optimize the current distribution and to reduce the resistance at the anode-soil interface of the groundbed, either horizontal or vertical.
- 5. ELECTROCHEMISTRY AT YOUR SERVICETM 5 Linear Flexible Anode easy and timesaving installation procedure accurate QC on the factory-made conductive connections optimization of the current distribution green product: zero discharge of pollutants and energy saving Advantages for the installators of impressed current cathodic protection groundbeds:
- 6. ELECTROCHEMISTRY AT YOUR SERVICETM 6 Max current density 100 A/m2 Anodic titanium wire diameter 1,5mm Ø 3mm Ø Current output at the Max current density 470 mA/m 940 mA/m Expected design life 25-30 years Technical specifications. Flexible product in current output and expected design life.
- 7. 1 2 4 5 3 6 ELECTROCHEMISTRY AT YOUR SERVICETM 7 Mixed metal oxide titanium diameter: 1.5mm, 3mm Feeding cable cross section: 10mm2 or 16mm2 Feeding cable insulation: XLPE/PVC or Kynar/HMWPE Anode to cable splicing interval: at every interval of: 10 metres or as required by the design Anode backfill composition: Calcined Petroleum Coke Breeze; Fixed Carbon 98 % - 99% Coating load can be optimized for the required design life up to 25-30 years. Product design options. The product is flexible even in design. It is possible to select several parameters:
- 8. 1 2 4 5 3 6 ELECTROCHEMISTRY AT YOUR SERVICETM 8 Mixed metal oxide titanium diameter: 1.5mm, 3mm Feeding cable cross section: 10mm2 or 16mm2 Feeding cable insulation: XLPE/PVC or Kynar/HMWPE Anode to cable splicing interval: at every interval of: 10 metres or as required by the design Anode backfill composition: Calcined Petroleum Coke Breeze; Fixed Carbon 98 %- 99.4% Coating load can be optimized for the required design life up to 25- 30 years. Product design options. Optimization for impressed current vertical groundbed, in deep vertical well in Italy:
- 9. ELECTROCHEMISTRY AT YOUR SERVICETM 9 Case History In 2015 this product was introduced for the first time in Italy, optimized for an impressed current vertical groundbed, in a 61m deep vertical well, where a traditional anode was replaced. The installation was performed on March, 3rd 2015 in Northern Italy in a vertical well.
- 10. ELECTROCHEMISTRY AT YOUR SERVICETM 10 Length of the groundbed 61 m Active part of the groundbed length 15m Depth of the groundbed active zone 46m Well Casing plastic pipe with holes in the active part Water table depth 6 m Hydrochloric acid and gaseous chlorine could be present Deep well groundbed design.
- 11. ELECTROCHEMISTRY AT YOUR SERVICETM 11 The anode, hanged to a dead weight, was very easily installed without the use of special tools. It was connected to a transformer rectifier equipped with a remote monitoring system. The anode was very easily installed without the use of special tools Flexible anode installation in deep vertical groundbed.
- 12. ELECTROCHEMISTRY AT YOUR SERVICETM 12 This system allows the daily reading of minimum, medium and maximum current output and DC voltage values to monitor the groundbed resistance evolution. This data collection is aimed to assess the presence of seasonal effects on the anode performance. Any seasonal effect on the anode perfromance ? Remote monitoring system.
- 13. ELECTROCHEMISTRY AT YOUR SERVICETM 13 Parameter unit Deep well Water main pH pH 1.35 7.2 Conducibility at 20°C µS/cm 15.580 1055 Chlorides mg/l 394 104 Sulphates mg/l 254 179 Nitrates mg/l 57 29 Sodium mg/l 290 76 Potassium mg/l 15.7 2.4 Magnesium mg/l 120 24 Calcium mg/l 247 147 Hardness °F 111 46 Ammonia mg/l 7.2 <0.05 Nitrites mg/l 3.9 <0.05 The chemical analysis of the water flooding the well allows to check other parameters that can influence the anodic system durability like pH, chloride content, and the concentration of potential pollutants like ammonia, sulphates and nitrites. Any chemical may influence anode system performance? Chemical analysis of the water.
- 14. ELECTROCHEMISTRY AT YOUR SERVICETM 14 Reduced diameter of this anodic system (38mm) will enable to design new wells with consistently reduced borehole diameter. Further cost optimization can be reached concentrating the length of the active part of the anodic system, this resulting in a reduced perforation depth. Reduced borehole diameter, Concentrated active part of the anodic system for minimum perforation depth Installation Cost Savings
- 15. ELECTROCHEMISTRY AT YOUR SERVICETM 15 Design life (DL):25 years Groundbed design current (IGB):12 A Soil resistivity, r: 20 ohm.m. Transformer rectifier rating: 15 V /15 A The maximum linear anode current output is 940 mA/m at 100 A/m2 current density. Therefore the minimum required length of the anode is 12/0.940= 12.8 m. Conservatively this minimum length is rounded to 15m. Deep Vertical Groundbed calculation Anode material: - Mixed metal oxide coated titanium wire anode type suitable for installation in soil - length, l: 15 m; - diameter, d: 3 mm; - anode current output, ia: 15 A
- 16. ELECTROCHEMISTRY AT YOUR SERVICETM 16 Based on maximum transformer DC output voltage (15 V) and max. Groundbed design current (12 A), groundbed resistance, RGB shall be not greater than 1.25 ohm (15V/12A). Based on the above groundbed resistance, the groundbed active length – anodes + backfill – was calculated solving numerically the Dwight formula: RGB = rsoil / (2πL)x(ln (8L/D-1)) where: - rsoil: soil resistivity (ohm.m); - L: minimum groundbed active length (m); - D: groundbed diameter (m) The calculated minimum groundbed active length is 12 m, conservatively groundbed active length is increased to 15 m. Groundbed active length
- 17. ELECTROCHEMISTRY AT YOUR SERVICETM 17 0 1 2 3 4 5 6 7 02/03/2015 04/03/2015 06/03/2015 08/03/2015 10/03/2015 12/03/2015 14/03/2015 16/03/2015 18/03/2015 20/03/2015 22/03/2015 24/03/2015 27/03/2015 29/03/2015 31/03/2015 02/04/2015 04/04/2015 06/04/2015 08/04/2015 10/04/2015 12/04/2015 14/04/2015 16/04/2015 18/04/2015 20/04/2015 22/04/2015 24/04/2015 26/04/2015 28/04/2015 30/04/2015 02/05/2015 04/05/2015 06/05/2015 08/05/2015 10/05/2015 12/05/2015 14/05/2015 16/05/2015 Ω Av. V Av. A Av. Installation: reduction of groundbed resistance from 0.95 to 0.91 Ω. Average cell voltage decreased from 6.25V to 5.9V. Results
- 18. ELECTROCHEMISTRY AT YOUR SERVICETM 18 0 1 2 3 4 5 6 7 02/03/2015 04/03/2015 06/03/2015 08/03/2015 10/03/2015 12/03/2015 14/03/2015 16/03/2015 18/03/2015 20/03/2015 22/03/2015 24/03/2015 27/03/2015 29/03/2015 31/03/2015 02/04/2015 04/04/2015 06/04/2015 08/04/2015 10/04/2015 12/04/2015 14/04/2015 16/04/2015 18/04/2015 20/04/2015 22/04/2015 24/04/2015 26/04/2015 28/04/2015 30/04/2015 02/05/2015 04/05/2015 06/05/2015 08/05/2015 10/05/2015 12/05/2015 14/05/2015 16/05/2015 Ω Av. V Av. A Av. After over 2 months : average cell voltage increase: 5,9 V to 6,1 V Resistance value stabilized at 0,94 Ohm. Results
- 19. ELECTROCHEMISTRY AT YOUR SERVICETM 19 Conclusions Linear flexible anode properly designed can be an effective solution in deep well groundbed Installation is fast and easy without the use of special tools Design of new groundbeds with reduced borehole diameter and depth. 0 1 2 3 4 5 6 7 02/03/2015 11/03/2015 20/03/2015 30/03/2015 08/04/2015 17/04/2015 26/04/2015 05/05/2015 14/05/2015 Average cell voltage and groundbed resistance are low and stable
- 20. ELECTROCHEMISTRY AT YOUR SERVICETM 20 Thanks for your time. Any question?
- 21. ELECTROCHEMISTRY AT YOUR SERVICETM SPECIALTIES & NEW APPLICATIONSPOOLS & ELECTROCHLORINATIONELECTRONICS & SURFACE FINISHINGCHLORINE & CAUSTIC INDUSTRY APPLICATION IN DEEP VERTICAL GROUNDBEDS OF LINEAR FLEXIBLE ANODES Simone Tremolada