Gas Pipeline Active Cathodic Protection

As we know that metal in contact with sea water and soils gets corrode. This Corrosion leads to the loss of performance and failure of the components. In order to control the corrosion we make metal or Gas pipeline, which is to be protected from corrosion, the cathode of Electrochemical cell an

Project Title

Gas Pipeline Active Cathodic Protection

Project Area of Specialization

Electrical/Electronic Engineering

Project Summary

As we know that metal in contact with sea water and soils gets corrode. This Corrosion leads to the loss of performance and failure of the components. In order to control the corrosion we make metal or Gas pipeline, which is to be protected from corrosion, the cathode of Electrochemical cell and connect it to more easily corroded metal which act as anode and is also called sacrificial metal. The main electronic part here is the DC Power supply which can deliver the required current and voltage depending on the resistivity of the soil.

There is already installed Cathodic Protection Scheme. The already installed scheme occupy alot of space, not automatic but is manually controlled and is expensive as well. In already installed Cathodic Protection scheme we get 220V from the utility which is step down to required voltage level which is 25V AC and which is further converted to controlled DC voltage. As the 50Hz frequency is very low so large size of transformer is installed. This will occupy space, manual controlled and is costly as well.

This means that we have to installed such a system which will supply the required monitor and controlled current depending upon the resistivity of the soil. Also the size and cost will be reduce.

First we will design a variable Power Supply i-e Switch Mode Power Supply which actually uses a Forward DC to DC Converter. Here we are using Active Cathodic Protection or Imersed Current Cathodic Protection. This Power Supply has ratings of 25V 25A. Here 25V is fixed and we can vary the current according to resistivity of the soil. This 25A is maximum current rating. In this Power supply we actually use Transistors, whose value depends on duty cycle, who can increase the frequency which will reduce the size and cost as well.

After designing such variable power supply we will automate it. As resistivity of soil changes with time so there must be a device called moisture sensor which will regularly measure the moisture which is then timely send to a user phone with the help of ESP-32 Bluetooth/WiFi wireless device. Then user after reading a resistance value of the soil send signal again using another ESP-32 Bluetooth/WiFi to digital potentiometer or Programmable Potentiometer which is directly connected to Variable Power Supply and the value of the current of Power Supply change accordingly. Thus we obtain avtive cathodic protection more efficiently, controlled and effectively.

Project Objectives

Following are the main Objectives of the Project.

• High Power (25V,25A) Switch Mode Power Supply.
• Properly monitored and controlled Active Cathodic Protection system.
• Automatic and user Friendly controlled Active Cathodic Protection system.
• More Efficient and Effective Active Cathodic Protection system.
• Reduce size than already installed Cathodic Protection system.
• Reduce cost than already installed Cathodic Protection system.
• Additional IoT features.

Project Implementation Method

First we will do mathemetical analysis by Differential Equation and small signal AC Analysis. Then we will do simulations of the results obtained using MATLAB, LTspice and Plecs.

Then we do hardware implementation by making Library and project schematic of the 25V 25A Switch Mode Power on the software named Altium Designer. Than After successful simulations we obtain the desired results. Then the design is send for PCB board. After we get the Power supply in hard form. Then we will do No load and Full load test of the project. Then we will automate it. So for automation first we will measure the reisistivity of the soil using moisture sensor and code it using Arduino software. When moisture reads the value then with the help of Arduino atMega 2560 microcontroller and ESP-32, which are interlinked with each other, we will send signal to user Phone using an Arduino App. Then by reading the value of moisture user send the value of resistance to digital or programmable potentiometer by using ESP-32 module which will change the resistance due to which the current of Power Supply changed accordingly and we can protect the metal from corrosion more efficiently and effectively.

Benefits of the Project

Following are the main Benefits of project.

• High Power 25V 25A switch mode power suppy.
• Reduce size than already installed Cathodic Protection system.
• Low cost than already installed Cathodic Protection System.
• Continuously Monitored and controlled Cathodic protection system.
• Low cost and easy maintenance.

Technical Details of Final Deliverable

We will make a variable power supply having 25V and 25A voltage and currents ratings which means it is 625 watt power supply. Here we can change the value of current by changing the resistance value and the voltage is constant 25. The current can varry from 0A to 25A. So 25A is maximum current rating.

Here we are making switch mode power supply whose frequency is high due to high switching speed of transistors used and size is small.

Efiiciency and time of operation is high.

Properly controlled, automatic and monitor by the user.

We are using Digital or Programmable Potentiometer X9C104S. It is three terminal device whose resistance value can be changed by adjusting wiper position. We can get output from any two of terminals(center and right or center and left).

we are using ESP-32 wireless module for sending signals wirelessly. These are attached with Aurduino atMega 2560 microcontroller.

Final Deliverable of the Project

HW/SW integrated system

Core Industry

Energy

Other Industries

Others

Core Technology

Others

Other Technologies

Internet of Things (IoT)

Sustainable Development Goals

Industry, Innovation and Infrastructure

Required Resources

If you need this project, please contact me on contact@adikhanofficial.com