Cathodic Corrosion Protection

CCP solutions for pipes with ACOS CPS,

ACOS 720 and WinKKS

What is corrosion?

Corrosion, also known more colloquially as rust, is

the reaction of a metal material to its environment,

which results in a measurable change in the material

and leads to its eventual destruction. Passive corro-

sion protection, that is, covering the material with pro-

tective coatings such as polyethylene or bitumen,

provides only insufficient protection against corro-

sion.

What is CCP?

Cathodic corrosion protection (CCP) is an electroche-

mical procedure in which an electrical direct current

flows from galvanic anodes, mostly consisting of fer-

rosilicon, graphite or magnetite, through the ground

to the critical areas of the pipe, and penetrates the

damaged points in the jacket. This protective current

causes cathodic polarisation in the electrolyte on the

metal surface: the metal ions cannot release them-

selves from the metal surface, so that no corrosion

can take place.

The amount of current required for optimum cathodic

protection depends upon the material and surface

finish of the pipe. Controllable rectifiers are therefore

used, to enable the protective current to be infinitely

adapted to suit all requirements. The potential of the

object requiring protection is measured by means of

a reference electrode, which is installed next to the

pipe.

A telecontrol function then sends all the values recor-

ded and measured by the protection station to a

management or control system, where they are ana-

lysed. With this collected and analysed data, the con-

dition of pipes can be monitored and repair measures

planned.

The building of pipes requires huge investment. When a pipe

is damaged by corrosion, enormous expense can be required

for dealing with damage to property and the environment, as

well as production downtime. In the worst cases, persons

may even suffer injury. Cathodic corrosion protection is the

most effective method of preventing this, and of protecting

people and the environment.

The ensuing cost of pipe maintenance amounts to a mere

fraction of the costs that would have been incurred by a

leaky pipe. And this can be further reduced by applying a

comprehensive approach to cathodic corrosion protection

(CCP).

The scope of delivery supplied by IDS GmbH covers the enti-

re product chain, from the ACOS CPS cathodic protection

system in the field to data transmission via the ACOS 720

miniature telecontrol device, right up to the WinKKS evalua-

tion and analysis tool.

CCP – Cathodic Corrosion Protection

Protection station

Measuring point

Reference electrodeProtected pipe

Anode cable(+)

+ -

Cathode connection (-)

Protective current

Pipe damaged by corrosion

ACOS CPS 300 ACOS CPS 600 ACOS CPS 1200

Protective current 0...30V

0...10A

0...30 V, 0...20 A oder

0...50 V, 0...12 A

2 x (0...30 V, 0...20 A) or

2x (0...50 V, 0...12 A) or

0...30 V, 0...20 A;

0...50 V, 0...12 A

Power supply 185...265 Veff / 50 Hz

Efficiency 85%

Dimensions (H x W x D) 230 x 175 x 135 mm 230 x 350 x 270 mm

Standards DIN EN 60 950, DIN EN 55022, DIN EN 61000-3-2,3, DIN EN 61000-6-2

Ambient conditions -10°... +50°C

ACOS CPS – Cathodic Protection Station

IDS solution

With the ACOS CPS cathodic protection station,

ACOS 720 telecontrol and automation unit and

WinKKS management system, IDS GmbH offers a

highly integrative system solution, which satisfies the

requirements of operators of both long-distance pipe-

lines and local networks, and ensures compliance

with applicable standards G 412 and GW 12. The

systems’ service life is increased manifold, guarante-

eing reliability of supply. Measures taken are compre-

hensively documented and archived.

The ACOS CPS cathodic protection station impres-

ses through its high reliability and full automation of

processes.

Construction

The protection station features a two-way rectifier

with an infinitely adjustable power unit and a suitable

measuring device for monitoring function. An advan-

tage of this rectifier is that the anodes can be used

without any galvanic loss of material for an almost

endless period of time.

An input filter is integrated in the reference electrode

(Cu/CuSO4), which suppresses interference to the

induced alternating voltage, produces electrical isola-

tion and increases internal resistance. The station’s

supply voltage input and voltage output are protected

against overvoltage. The voltage status is monitored

by measuring equipment.

In order to guarantee faultless operation even in the

event of power failure, the station is supplied with two

12 V rechargeable batteries, each with a capacity of

7.2 ampere hours.

Automatic regulation of the protection potential and

current density substantially reduces the energy

required by the pipeline protection system as a

whole. ACOS CPS is protected against unauthorised

access.

Control

The station can be operated either directly on site via

the operator panel, or remotely via the ACOS 720

telecontrol device. The station parameters are set on

the basis of the setpoints output current, output volta-

ge, protective voltage and percentage of voltage out-

put.

Versions

The system is available in the versions ACOS CPS

300, ACOS CPS 600 and ACOS CPS 1200, which

cover a broad range of protective current. Conse-

quently, a suitable station can always be selected for

every requirement.

Output parameters

The measured values protection potential, source

output voltage and source output current are recor-

ded cyclically or on an event-driven basis.

The ACOS 720 telecontrol and automation unit is

responsible for data acquisition, remote transmission

and control of the cathodic corrosion protection. The

ACOS 720 is fitted onto a 35mm DIN rail. With four

digital inputs, four digital outputs, two analog inputs

and one analog output, the scope of its data is such

that typical small-scale systems can be monitored,

controlled and automated. It can be expanded by the

connection of up to eight compact I/O modules via a

100 Mbit EtherCAT bus.

Automation

Automation tasks are achieved by means of an inte-

grated programmable logic controller (PLC) accor-

ding to IEC 61131-3.

Configuration

The ACOS 720 can be brought into operation locally

using the ACOS ET engineering tool via a USB or

network connection, or configured remotely by

means of the data transmission infrastructure.

The integrated PLC is programmed using CoDeSys®

V3. As an option, the configuration and archive

values can be stored on a microSD card. This ena-

bles faulty units to be replaced without the need for

configuration tools.

Communication

The ACOS 720 features a network interface and two

serial RS232 interfaces. These can be used both for

remote data transmission and for connecting the

local operator panel. An internal GSM/GPRS modem

is also available as an option. The following protocols

are supported

IEC 60870-5-101 master/slave

IEC 60870-5-104 client/server

IEC 60870-5-103 master

Modbus RTU master/slave

Modbus TCP client

PPP protocol

OpenVPN is available for secure remote data trans-

mission. As an OpenVPN client, the ACOS 720 tele-

control and automation unit can establish a connec-

tion to an OpenVPN server.

ACOS 720 – Automation and Telecontrol Device

ACOS 720 Technical Data

Power supply 24 VDC / 15 W ± 20%

with electrical isolation

4 digital inputs Rated voltage 24 V DC ± 20 %

with a common root

4 Digital outputs Rated voltage 24 V DC ± 20 %

with a common root

Designed as transistor outputs

2 Analog inputs Input range ± 25 mA

16 bits

1 Analog output Output range ± 20 mA

16 bits

Output load < 450 Ω

EtherCAT Bus connection for expansion with up to 8

compact IO modules

Communication

interfaces

2 x RS232

1 x Ethernet

Service interface Mini USB socket, type B

Dimensions (H x W x D) 183 x 132 x 46mm

In addition to the data from the cathodic protection

station, which are transferred by the ACOS 720, huge

volumes of data are produced from different software

systems and other measurements during the execu-

tion of necessary activities in the CCP, which must

also be archived for many years as proof of CCP.

WinKKS, the innovative information system for docu-

menting and analysing inventory and movement

data, enables master data on pipeline systems, CCP

networks and measuring points to be centrally mana-

ged. WinKKS provides a homogeneous platform with

which the protection station can carry out analyses

and optimise processes on the basis of extensive

data: the intensity of maintenance can be configured

at attribute level, the close connection guarantees a

reliable basis for analysis.

Document management

In addition, integrated document management

assists you with the preparation of information. In this

way, you will always be kept comprehensively infor-

med about the status of your equipment, and can use

this information to efficiently plan measurements and

service activities, including schedule adjustments.

The up-to-date master data can be forwarded to

measuring systems.

Measurement evaluation

For all measurement methods, WinKKS provides

functions for optimum evaluation, from the display of

potential plans and other measurement charts

through test records and statistics right up to the

automatic detection of limit violations.These evalua-

tions can be printed out for particular areas or com-

plete measurements. You can scroll through the gra-

phic display of a pipe’s course as you wish - you are

not restricted to a page-by-page display.

Integration in GIS and SAP R/3

WinKKS can be linked up to your geoinformation

(GIS/ NIS) or maintenance system without problem –

irrespective of the manufacturer. This is made possi-

ble through the intelligent, individually configurable

CORBA and XML interfaces. The SAP R/3 PM is

integrated via the Business Connector at process

level, and by the WinKKS Business Package for the

SAP Enterprise Portal at user level. Thanks to its

direct connection to your basic applications, WinKKS

is therefore universal. As well as time savings, this

also brings you considerable cost advantages.

WinKKS – Management System for

Cathodic Protection

Topologie-EditorRemote monitoring measurements

Overview of monitoring measurement series Monitoring measurement series

IDS GmbH

Nobelstraße 18

D-76275 Ettlingen

Phone +49 72 43 218-0

Fax +49 72 43 218-1 00

E-Mail info@ids.de

Internet www.ids.de • Technical changes reserved

Topology Editor

The Topology Editor is used specifically for acquiring,

updating, navigating and graphically viewing data,

and its streamlined design makes it particularly suita-

ble for mobile use. It offers two different views, topo-

logical and schematic. Therefore, as well as a posi-

tionally accurate display of objects with scale or vec-

tor data in the background, schematic diagrams can

be employed for the purpose of orientation.

Mobile data acquisition

The system guarantees both mobile offline use in the

field, and automatic synchronisation of data online:

measured data from a mobile data system can be

further processed, as can data from various remote

monitoring systems. The relevant master data are

updated in WinKKS, and forwarded to mobile data

acquisition or remote monitoring units when necessa-

ry. Conversely, WinKKs retrieves data acquired here

either automatically or on request. "CCP in the pipe

trench" – thanks to WinKKS, this is no longer a pipe

dream, but reality.

Scalability of WinKKS

For WinKKS, both client/server products and a low-

cost standalone version are available

Key tasks

All CCP-relevant data are merged and

archived to ensure a rapid overview

Optimised planning of CCP systems

Simplified planning and schedule tracking for

maintenance activities

Fast access to documents and measurements

Different measurement methods are comparable

Evaluation of deviations and errors

Direct link between network topology

and CCP data

Homogeneous database without redundancies

WinKKS – Management System for

Cathodic Protection