Cathodic protection specialist, Omniflex has collaborated with researchers at Deakin University to develop corrosion monitoring electronics for a novel closed-loop cathodic protection system for localised corrosion control in challenging industrial environments.
Cathodic protection specialist, Omniflex, has collaborated with researchers at Deakin University to develop corrosion monitoring electronics for a novel closed-loop cathodic protection (CP) system for localised corrosion control in challenging industrial environments. These include floating wind turbines and underground or sub-sea oil and gas pipelines. Prototype field tests demonstrated the technology’s ability to reduce corrosion by around 90%, which can more than double operational lifetimes of these structures when exposed to harsh environments. With prototype field tests now completed, the project is entering the commercialisation phase and is now available to the wider CP market.
The closed-loop probe is the outcome of several years of research by the team at Deakin University supported by the Energy Pipelines CRC, Future Fuels CRC, the Australian Economic Accelerator project, Omniflex and specialist pipeline operators.
The technology facilitates better-than-ever localised corrosion control in complex and varying environmental conditions. The potential applications include protecting offshore structures, such as wind turbines and oil and gas platforms, as well as underground infrastructure like steel pipelines and storage tanks.
“Currently, corrosion under disbonded coatings is a major issue impacting the safe operational life of underground gas pipelines and future hydrogen pipelines,” explained Professor Mike Tan, professor of applied electrochemistry and corrosion techniques at Deakin University. “Another key problem that the technology addresses is the lifecycle of offshore wind farms, which is currently too short at around 25 years. This is unsustainable from a lifecycle assessment perspective.
“In one of our prototype tests on a underground gas pipeline, we reduced localised corrosion by roughly 90 per cent. This level of corrosion reduction can more than double operational lifetimes, making installations more sustainable and cost effective. This capability of closed-loop control of cathodic protection not only mitigates corrosion, but also avoids over protection that can cause issues like hydrogen embrittlement and cathodic disbondment of coatings.”
Omniflex worked with the Deakin University team to develop the technology’s electronics, integrate sensors and facilitate remote monitoring and control capabilities.
“Traditional CP systems don’t change output voltages and currents under constantly varying conditions by directly measuring corrosion current, meaning there is a risk of over- or under-protection,” explained David Celine, managing director of Omniflex. “Some may assume that you can’t have too much protection, but this is not the case with CP systems. Apart from wasting energy, over-protection can produce hydrogen and cause embrittlement, ultimately causing structural failure. The closed-loop CP probe, with in-built remote monitoring and control capabilities, allows us to account for ongoing variances caused by factors like stray current and leakage and consistently maintain optimal protection levels.”
“Omniflex is an extremely important partner for us as it brings electronics, data collection and remote monitoring expertise that we would not otherwise have access to. We chose it as the equipment manufacturer and supplier as it is the only company who can provide the unique set of skills that we are looking for as a partner. We have worked with them for over eight years now and will continue to work together on various projects for the global CP market in the coming years,” concluded Tan.
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