埋地金属管线的杂散电流腐蚀防护研究
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摘要
正常情况下,电流应该按照设计要求在指定的导体中流动,如果由于某些原因,一部分电流离开了指定的导体而在原来不应有电流的导体中流动,即没有按照期望的路径流动的电流,这部分电流就叫作杂散电流,又叫迷走电流。杂散电流主要来源于铁路直流牵引系统、阴极保护系统、直流输电线路和电解系统等等。当杂散电流从规定的回路以外流动,流入埋地金属管线的地方带负电,称为阴极,处于阴极区的管线一般不会受到杂散电流腐蚀侵害的影响,若阴极区的电位值过负时,金属管线表面会发生析氢反应,造成此区域防腐涂层的剥落。电流流出的部位带正电称为阳极,在杂散电流的作用下,阳极区域发生激烈的电化学反应,从而造成埋地金属管线的电化学腐蚀侵害,即为杂散电流腐蚀。杂散电流的腐蚀作用严重影响到埋地金属管线的使用寿命和安全,极端情况下可以造成金属管线的泄露、土壤环境的污染等等。
本文设计了杂散电流实验室模拟装置,并用此装置研究了土壤电阻率、管线埋地深度和管线涂层破损率等因素对埋地金属管线中杂散电流影响规律,实验结果可以为埋地金属管线的施工、设计提供理论依据,亦可为防止埋地金属管线的杂散电流腐蚀提供相关的数据。
人工神经网络(ANN)是对人脑或自然神经网络若干基本特性的抽象和模拟,是一个非线性动力系统,具有大规模的并行处理和分布式的信息处理能力,具有良好的自适应性、自组织性及很强的学习、联想、容错和抗干扰能力,其中反向传播BP前馈网络即误差反传网络是人工神经网络中应用最为广泛的一种,适合用于复杂的逻辑操作和非线性关系的实现。为分析和评价杂散电流对埋地金属管线的腐蚀侵害作用,根据其不同的影响因素,采用部分实验数据基于BP神经网络方法分别构建了埋地金属管线的杂散电流预测模型和杂散电流密度预测模型,预测结果与实测结果的误差均小于10%,人工神经网络技术在杂散电流腐蚀预测中的可行性得到验证。
在稳恒电流条件下,导线表面会有表面电荷的分布,则在导线外亦会形成外电场,本文采用感应电场理论提出了基于感应电场理论的杂散电流分布模型,并进行了实验验证,模拟计算结果与实验结果相符。
杂散电流可以造成金属的电解腐蚀侵害,在实验室模拟装置中,采用动电位扫描和恒电流极化方法模拟杂散电流,研究了其对土壤环境中A3、16Mn和X70钢的电解腐蚀行为,并用数码相机和扫描电子显微镜对腐蚀产物及其表面钝化膜形貌进行了表征,探讨了其腐蚀机理,同时研究了杂散电流腐蚀的危害指标和焊缝的腐蚀情况。
有机涂层作为经典的防腐蚀技术得以广泛的应用,已成为金属防腐保护方法中应用最广泛的手段之一,有机涂层和金属基体良好的附着、结合性能是保证防腐蚀效果的重要条件。当埋地金属管线表面涂层发生破损后,如果杂散电流从此破损点流进金属管线时,形成杂散电流反应的阴极区,极易造成金属管线表面涂层的阴极剥离作用,通过实验研究提出了氢和氢氧根离子(主要为氢)在涂层与金属基体界面间迁移导致二者之间附着力减弱,造成了涂层剥离的反应机理。
最后研究了杂散电流对埋地金属管线阴极保护的影响作用,介绍了杂散电流的排流防护措施。
The current deviated from its intended path and escaped to the electrolyte (the soil, concrete or seawater) is called leakage current or stray current. Stray current may originate from the electrical railways, cathodic protection systems, electrolysis plants, electric cables and large electric plants. Stray current corrosion process in the metallic structure is totally similar to the classic one: current flows from anode to cathode through the electrolyte by ionic conductivity and from cathode to anode through the metal by electric conductivity. At the anode the metal oxidation occurs, and a total metal loss can be visible as the result of anodic dissolution. Whilst at the cathode hydrogen or oxygen reduction occurs, avoiding corrosion hazard to the cathode. However, organic coating at the cathodic region will be delaminated by stray current. Moreover, stray current density in the points where the current enters and leaves the structure is extremely high, a threshold ranging between 2 and 20mA/cm2 has been proposed. Stray current corrosion may influence the lifetime of the buried metallic structures, and in a few extreme cases, it can also induce big accident such as gas explosion, soil pollution, and so on.
In this paper, the impacts factors of stray current in the buried metallic pipeline, such as the soil resistivity, the depth of the buried metallic pipeline and the pipeline dilapidation ratio, were studied by the laboratory simulation system. Pertinent experiment data are provided for the buried metallic pipeline in design, construction and the protection of corrosion.
To analyze and estimate stray current corrosion hazard of the buried metallic pipeline, according to the BP neural network method and the part of experimental data, two predictive models for stray current of the buried metallic pipeline were built. Artificial neural network (ANN) has powerful, nonlinear, mapping ability, and the modeling process is easier and more direct than for empirical model. Feed-forward multilayer network with back propagation error is called BP network, which is a kind of ANN used the most widely, it provides a new method to solve the prediction and control problem for a non-linear system, and to be of widespread utility in engineering and is steadily advancing into new areas. The accuracy of BP neural network predictive model was tested by the test sample, and the feasibility of the BP neural network to forecast stray current of the buried metallic pipeline was testified, too.
When the constant current flows through the stationary resistive wire connected to DC Power Supply, the inside inducted electric field driving the conduction electrons against the resistive friction of the wire is due to the free charges distributed along the surface of the wire, and generate as well an electric field outside the wire. The distribution model of stray current was discussed by the inducted electric field theory, which in accordance with the experiment results.
Stray current corrosion behavior of steel in soil environments was investigated by using potentiodynamic polarization and constant current polarization methods in laboratory, the corrosion products and surface passive films morphology were observed with digital camera and scanning electron microscope. Stray current corrosion critical current density and potential and the weld corrosion were studied.
In order to prevent aggressive species from direct contact with the metallic structure surface, organic coating is extensively applied to prevent corrosion of the metallic structure buried in soil or immersed in seawater because of the high corrosion resistance. To protect the metallic structure from corrosion, organic coating must maintain adequate adhesion to the metallic structure surface during environmental exposure. However, if organic coating has a defective region, the delamination of organic coating is easy to occur by stray current, which will lead to the adhesion degradation, and the delaminated rate is extremely rapid. Stray current delamination of organic coating on the metallic structure is caused by hydrogen and hydroxyl ions, which degrade the adhesive strength between the coating and the metal and lead up to organic coating delamination.
In the end, the infection of cathodic protection by stray current in the soil and the means protecting from corrosion of stray current were studied.
本文设计了杂散电流实验室模拟装置,并用此装置研究了土壤电阻率、管线埋地深度和管线涂层破损率等因素对埋地金属管线中杂散电流影响规律,实验结果可以为埋地金属管线的施工、设计提供理论依据,亦可为防止埋地金属管线的杂散电流腐蚀提供相关的数据。
人工神经网络(ANN)是对人脑或自然神经网络若干基本特性的抽象和模拟,是一个非线性动力系统,具有大规模的并行处理和分布式的信息处理能力,具有良好的自适应性、自组织性及很强的学习、联想、容错和抗干扰能力,其中反向传播BP前馈网络即误差反传网络是人工神经网络中应用最为广泛的一种,适合用于复杂的逻辑操作和非线性关系的实现。为分析和评价杂散电流对埋地金属管线的腐蚀侵害作用,根据其不同的影响因素,采用部分实验数据基于BP神经网络方法分别构建了埋地金属管线的杂散电流预测模型和杂散电流密度预测模型,预测结果与实测结果的误差均小于10%,人工神经网络技术在杂散电流腐蚀预测中的可行性得到验证。
在稳恒电流条件下,导线表面会有表面电荷的分布,则在导线外亦会形成外电场,本文采用感应电场理论提出了基于感应电场理论的杂散电流分布模型,并进行了实验验证,模拟计算结果与实验结果相符。
杂散电流可以造成金属的电解腐蚀侵害,在实验室模拟装置中,采用动电位扫描和恒电流极化方法模拟杂散电流,研究了其对土壤环境中A3、16Mn和X70钢的电解腐蚀行为,并用数码相机和扫描电子显微镜对腐蚀产物及其表面钝化膜形貌进行了表征,探讨了其腐蚀机理,同时研究了杂散电流腐蚀的危害指标和焊缝的腐蚀情况。
有机涂层作为经典的防腐蚀技术得以广泛的应用,已成为金属防腐保护方法中应用最广泛的手段之一,有机涂层和金属基体良好的附着、结合性能是保证防腐蚀效果的重要条件。当埋地金属管线表面涂层发生破损后,如果杂散电流从此破损点流进金属管线时,形成杂散电流反应的阴极区,极易造成金属管线表面涂层的阴极剥离作用,通过实验研究提出了氢和氢氧根离子(主要为氢)在涂层与金属基体界面间迁移导致二者之间附着力减弱,造成了涂层剥离的反应机理。
最后研究了杂散电流对埋地金属管线阴极保护的影响作用,介绍了杂散电流的排流防护措施。
The current deviated from its intended path and escaped to the electrolyte (the soil, concrete or seawater) is called leakage current or stray current. Stray current may originate from the electrical railways, cathodic protection systems, electrolysis plants, electric cables and large electric plants. Stray current corrosion process in the metallic structure is totally similar to the classic one: current flows from anode to cathode through the electrolyte by ionic conductivity and from cathode to anode through the metal by electric conductivity. At the anode the metal oxidation occurs, and a total metal loss can be visible as the result of anodic dissolution. Whilst at the cathode hydrogen or oxygen reduction occurs, avoiding corrosion hazard to the cathode. However, organic coating at the cathodic region will be delaminated by stray current. Moreover, stray current density in the points where the current enters and leaves the structure is extremely high, a threshold ranging between 2 and 20mA/cm2 has been proposed. Stray current corrosion may influence the lifetime of the buried metallic structures, and in a few extreme cases, it can also induce big accident such as gas explosion, soil pollution, and so on.
In this paper, the impacts factors of stray current in the buried metallic pipeline, such as the soil resistivity, the depth of the buried metallic pipeline and the pipeline dilapidation ratio, were studied by the laboratory simulation system. Pertinent experiment data are provided for the buried metallic pipeline in design, construction and the protection of corrosion.
To analyze and estimate stray current corrosion hazard of the buried metallic pipeline, according to the BP neural network method and the part of experimental data, two predictive models for stray current of the buried metallic pipeline were built. Artificial neural network (ANN) has powerful, nonlinear, mapping ability, and the modeling process is easier and more direct than for empirical model. Feed-forward multilayer network with back propagation error is called BP network, which is a kind of ANN used the most widely, it provides a new method to solve the prediction and control problem for a non-linear system, and to be of widespread utility in engineering and is steadily advancing into new areas. The accuracy of BP neural network predictive model was tested by the test sample, and the feasibility of the BP neural network to forecast stray current of the buried metallic pipeline was testified, too.
When the constant current flows through the stationary resistive wire connected to DC Power Supply, the inside inducted electric field driving the conduction electrons against the resistive friction of the wire is due to the free charges distributed along the surface of the wire, and generate as well an electric field outside the wire. The distribution model of stray current was discussed by the inducted electric field theory, which in accordance with the experiment results.
Stray current corrosion behavior of steel in soil environments was investigated by using potentiodynamic polarization and constant current polarization methods in laboratory, the corrosion products and surface passive films morphology were observed with digital camera and scanning electron microscope. Stray current corrosion critical current density and potential and the weld corrosion were studied.
In order to prevent aggressive species from direct contact with the metallic structure surface, organic coating is extensively applied to prevent corrosion of the metallic structure buried in soil or immersed in seawater because of the high corrosion resistance. To protect the metallic structure from corrosion, organic coating must maintain adequate adhesion to the metallic structure surface during environmental exposure. However, if organic coating has a defective region, the delamination of organic coating is easy to occur by stray current, which will lead to the adhesion degradation, and the delaminated rate is extremely rapid. Stray current delamination of organic coating on the metallic structure is caused by hydrogen and hydroxyl ions, which degrade the adhesive strength between the coating and the metal and lead up to organic coating delamination.
In the end, the infection of cathodic protection by stray current in the soil and the means protecting from corrosion of stray current were studied.
引文
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