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EPPCT 2020 IOP Publishing
IOP Conf. Series: Earth and Environmental Science 474 (2020) 052089 doi:10.1088/1755-1315/474/5/052089

Numerical Simulations of Factors Affecting Stray Current

Corrosion on Pipeline

Yong Yang1, Weiguo Zeng1*, Li Wang2, Yongguo Liu3 and Jianli Ji1
1
China Special Equipment Inspection and Research Institute, Beijing, 100000, China
2
The Third Gas Production Plant of Changqing Oilfield Branch, Xi’an, Shanxi,
710000, China
The Fifth Gas Production Plant of Changqing Oilfield Branch, Xi’an, Shanxi, 710000,
3

China
*Corresponding author, Email: [email protected]

Abstract. Stray current can cause severe corrosion on buried steel pipelines. To investigate the
corrosion effect of stray current, originating from impressed current cathode protection system
of pipeline, on interference pipeline, a numerical model based on boundary elements using
commercial software COMSOL Multiphysics was developed to simulate corrosion potential
and stray current density distribution on interference pipeline. The model geometry was
comprised of the cathodically protected pipeline, interference pipeline and an auxiliary anode.
The effects of crossing angle and crossing distance of the two pipelines, output current and
location of anode, soil resistivity and coating surface resistivity were investigated. The results
demonstrated that the impressed current cathode protection system substantially affects the
corrosion potential and current density distribution of interference pipelines in vicinity of
crossing. The crossing angle and vertical distance of two pipelines have no important influence
while the anode output current, anode location, soil resistivity and coating surface resistivity
have significant influence to stray current corrosion on interference pipeline.

1. Introduction
The buried pipeline external corrosion protection techniques that are used most often are cathodic
protection (CP) and protective coating [QIU (2003)]. Chemical degradation of pipeline steels at
coating failure sites is lessened by CP systems [Gadala (2016)], but the pipelines which are present
within the current flow of the impressed current CP (ICCP) system may suffer the direct current stray
current corrosion originating from ICCP leading [CAO (2010); ZHAO (2016)]. With the development
of electrochemical theory and computer technology, numerical simulation methods have been proved
to be powerful tools to investigate the effectiveness of CP system and stray current corrosion on
pipelines [KOU (2017); LIU (2015); Gan (2016)]. Numerical methods applied to corrosion studies
have included the finite-difference method (FDM), the finite-element method (FEM) and the boundary
element method (BEM) [IMetwally (2007)]. The BEM has the distinct advantage over the other two
methods to apply to systems that include an infinite domain and the domain whose boundary only is
required to be discrete, such as cathodic protection of pipelines and offshore structures [IMetwally
(2007); Abootalebi (2010)]. The BEM needs fewer equations and a smaller matrix size than FEM and
can solve both finite and infinite domain problems [Jia (2004)].
LI et al. [li (2013)] deduced the mathematics model of the potential distribution by the tube element
Content from this work may be used under the terms of the Creative Commons Attribution 3.0 licence. Any further distribution
of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
Published under licence by IOP Publishing Ltd 1
EPPCT 2020 IOP Publishing
IOP Conf. Series: Earth and Environmental Science 474 (2020) 052089 doi:10.1088/1755-1315/474/5/052089

method of boundary element algorithm. Using Matlab programming tools, the cathodic protection
potential distribution of long distance pipeline was calculated and its comparison with that of the
experimental designed pipeline showed similar results. Liu et al.[Liu (2011)] used numerical
simulation calculation software Beasy to study the applied cathodic protection of platform. The results
show that numerical simulation calculation can analyze the anode distribution and potential
distribution on the surface of platform. Gan et al.[Gan (2016)] used the numerical simulation program
BEASY to study the corrosion effect of DC stray current that an auxiliary anode bed generated in an
impressed current cathodic protection system. The effects of crossing angle, crossing distance,
distance of the two pipelines, anode output current, depth, and soil resistivity were investigated. In the
study, the pipeline coating resistivity and anode location were not taken into account, so research
results could be not conform with reality.
In this paper, a boundary elements model was developed to simulate electrode potential and stray
current density distribution on interference pipeline (crossing with the ICCP Pipeline), to investigate
the effects of crossing angle and vertical distance of the two pipelines, output current and location of
anode, soil resistivity and coating resistivity on the stray current corrosion.

2. Numerical simulation

2.1 Governing equation and Boundary Conditions

Some assumptions are made here: the solution (soil) around the pipeline is uniform and electroneutral,
and there is no concentration gradient in the solution. Since the soil is assumed to feature only charge
transport with normal ohmic resistivity effects, the Laplace equation governs potential in the
electrolyte [Bortels (2007)]:
▽•(i)=0 i=-σ▽φ (1)
where i is the current density in mA/m2; σis the electrical conductivity of soil in S/m; andφis the
potential in V. For domains with a constant electrical conductivity σ, governing Equation (1) simplifies
to:
▽2φ=0 (2)
the Laplace equation is solved using the following boundary conditions [Abootalebi (2010)]:
φ=φ0, i=i0, ia=fa(φa), ic=fc(φc) (3)
whereφ0 and i0 are given constant values of potential and current density, respectively. fa(φa) and fc(φc)
are linear or non-linear functions that describe the anode and cathode electrode kinetics , respectively.
The boundary elements is to convert the partial differential equation to an integral equation, which
is then discretized. The boundary integral equations for all elements can be assembled into system of
linear simultaneous equations, which is expressed in a matrix form as follows [Bortels (2007)]:
Hφ=Gi (4)
where H and G are problem influence matrices, respectively. The size of the system of equations is
defined by the number of nodes. Partitioning the φ and I into those nodes which form the anode and
the cathode regions, and the potential and current densities can be calculated using related equations.

2.2 Simulation with COMSOL

In this paper, the boundary element numerical simulation software COMSOL Multiphysics 4.3a was
used. The simulation model was performed in accordance with Fig. 1 [Gan (2016)].

2
EPPCT 2020 IOP Publishing
IOP Conf. Series: Earth and Environmental Science 474 (2020) 052089 doi:10.1088/1755-1315/474/5/052089

Figure 1. Model geometry comprises of anode, pipeline protected and interference pipeline which are
surrounded by soil domain.
The model geometry is comprised of the protected pipeline, interference pipeline and anode, see
figure 1. Both the protected and interference pipelines are 1.6 km long and cross each other at an angle
of 90ºand at middle of their lengths. The protected pipeline diameter is 0.813 m, the interference
pipeline diameter is 0.406 m. The material of both pipelines are APL X80. The auxiliary anode which
is vertically buried has the following parameters: two endpoint coordinates (-800 m, -200 m, -30 m)
and (-800 m, -200 m, -50 m), diameter 0.2 m, constant current1.6A. Soil conductivity in the area of the
buried pipelines is 0.02 S/m. The resistivity of coating on protected pipelines is assumed to 5000Ω•m2.
The polarization on the surface of the anode was ignored. The polarization curve of steel X80 was
measured in the soil environment using a conventional three-electrode cell assembly. The polarization
curve is used as the cathode boundary condition, but it is a nonlinear curve, so we have to use
polarization data in a piecewise linear interpolation approach, shown in Fig. 2. In order to purpose of
this study, crossing angle and crossing distance of the two pipelines, output current and distance of
anode, soil resistivity and coating resistivity take several different values during simulation and
analysis. All simulated potential data below are with respect to the saturated copper sulfate reference
electrode.

Figure 2. The polarization curve. a Experimental polarization curve. b Piecewise linear polarization
curve

3
EPPCT 2020 IOP Publishing
IOP Conf. Series: Earth and Environmental Science 474 (2020) 052089 doi:10.1088/1755-1315/474/5/052089

3. Results and discussion

3.1 Effect of pipeline crossing

Considering the situation of two pipelines intersecting, the setting of each parameter is the same as in
Sect. 2. Both potential distribution and current density distribution of interference pipeline are
obtained by simulation, and the results are shown in Fig. 3.
As shown in Fig. 3, the change in the potential and current density distribution of interference
pipeline is very large where the two pipelines intersect. The corrosion potential near the intersection is
higher than the self-corrosion potential Ecorr, and the current density is more positive than
self-corrosion current density icorr. The potential at each end of the pipeline is lower than Ecorr, and the
current density at each end of the pipeline is negative. That means the section of the pipeline near
crossing suffers corrosion more severe, while the each end of the pipeline receives some cathodic
protection which reduces corrosion.

Figure 3. Effect of pipeline crossing. a Potential distribution. b Stray current density distribution

3.2 Effect of crossing angle

The four different angles of 30º, 45º, 60ºand 90ºare simulated by rotating interference pipeline
anticlockwise, while all other parameters remain unchanged. As results of simulation, the both
corrosion potential and current density distribution of interference pipeline are shown in Fig. 4.
Figure 4a reveals that the potential near the intersection becomes increasingly negative on
decreasing the crossing angle from 90ºto 30º. However, the change of potential is less than 10 mV. On
the other hand, the calculated potential change at one end of the pipeline is relatively large. This is
because the relative position between the pipeline and the auxiliary anode has changed more
significantly while the location of both anode and intersection remains unchanged. The chance of
current density is similar to potential, as shown in Fig. 4b.
-0.58
a 10-5 b
90 16 90
60 60
14
-0.59 45 45
12
30 30
Current density i, A/m2

10
-0.60
Potential E, V

8
6
-0.61
4
2
-0.62
0
-2
-0.63
-4
-6
-0.64
-800 -600 -400 -200 0 200 400 600 800 -800 -600 -400 -200 0 200 400 600 800
Distance X , m Distance X, m

Figure 4. Effect of different crossing angles. a Potential distribution. b Stray current distribution

3.3 Effect of crossing distance

The potential and current density distribution of interference pipeline buried at depths 1, 2, 3 and 8 m
is simulated, while other parameters remain unchanged. The results are shown in Fig. 5.

4
EPPCT 2020 IOP Publishing
IOP Conf. Series: Earth and Environmental Science 474 (2020) 052089 doi:10.1088/1755-1315/474/5/052089

The results indicate that both the pipeline corrosion potential and the current density only have
small change at the point of crossing, the rest section are almost same completely. The change in depth
of pipeline, in other words, vertical distance of two pipelines, is very limited, so the effects on
interference pipeline is mild.
10-5
-0.590 12
a b 1m
1m 2m
-0.595 10
2m 3m
3m 8m

Current density i, A/m2

-0.600 8
8m
6
-0.605
Potential E, V

4
-0.610

2
-0.615
0
-0.620
-2
-0.625
-4
-800 -600 -400 -200 0 200 400 600 800 -800 -600 -400 -200 0 200 400 600 800
Distance X , m Distance X, m

Figure 5. Effect of changing the vertical crossing distance. a Potential distribution. b Stray current
distribution

3.4 Effect of anode output current

The range of protection potential is generally -0.85 to -1.2V for steel pipeline regulated by related
standard. We calculate the potential distribution and the current density distribution of interference
pipeline for four anode output currents: 0.8, 1.2, 1.6 and1.8 A, which can keep potential of protection
potential within -0.85 to -1.2V. All other parameters remain unchanged. The results are shown in Fig.
6.
The anode output current has a strong influence on the magnitude of the stray current. Both the
corrosion potential distribution and the current density distribution around interference pipeline
change significantly with an increase in the anode output current. When the anode output current
increases, at each end of the pipeline the potential is more negative and current flowing into pipeline is
larger, but potential near the crossing is more positive and current flowing out pipeline is larger. That
means the corrosion near the crossing is more serious.
-0.590
a 10-5 b 1.8A
1.8A 12
1.6A
-0.595 1.6A
10 1.2A
1.2A 0.8A
-0.600 0.8A
Current density i, A/m2

8
Potential E, V

-0.605
6

-0.610
4

-0.615 2

-0.620 0

-0.625 -2

-0.630 -4
-1000 -800 -600 -400 -200 0 200 400 600 800 1000 -800 -600 -400 -200 0 200 400 600 800
Distance X , m Distance X, m

Figure 6. Effect of the anode output current. a Potential distribution. b Stray current density
distribution

3.5 Effect of anode location

The auxiliary anode can cause changing of soil nearby, so we change anode location to change
distance between anode and pipelines. The potential and current density distribution of interference
pipeline is simulated with anode X、Y coordinates (-0.2km, -200m), (-0.4km, -200m), (-800 m, -200m),
(-1800 m, -200m), (-10.8 km, -200 m), while other parameters remain unchanged. The results are
shown in Fig. 7.
The results indicate that both the potential and the current density of interference pipeline change
significantly at the coordinates (-0.2km, -200m), (-0.4km, -200m), remain practically unchanged at

5
EPPCT 2020 IOP Publishing
IOP Conf. Series: Earth and Environmental Science 474 (2020) 052089 doi:10.1088/1755-1315/474/5/052089

rest locations. The reason is that the electric field produced by anode current change the electrode
potential, and change the current by electrode reaction.

Figure 7. Effect of the anode location. a Potential distribution. b Stray current density distribution

3.6 Effect of soil resistivity

We simulate both the corrosion potential and the current density distribution for the pipeline with soil
resistivity of 10, 50, 100, 200 and 500 Ωm. All other parameters remained unchanged. The results are
shown in Fig. 8.

Figure 8. Effect of the soil resistivity. a Potential distribution. b Stray current density distribution
The results indicate that both the potential and the current density of interference pipeline change
significantly with different soil resistivities. When soil resistivity is small, the potential of interference
pipeline is near to Ecorr and the current density is almost zero. With increasing of soil resistivity, the
potential and the current density of interference pipeline become very uneven. The potential is more
positive near the intersection, and more negative at the each end of the pipeline, while current density
is also more positive near the intersection, and more negative at the each end of the pipeline. That
means that the corrosion on pipelines is more severe when soil resistivity become larger.

3.7 Effect of coating resistivity

The ICCP can automatically adjust the magnitude of anode current to control the electrode potential of
the protected pipeline within an adaptable arrange, such as from -0.85 to -1.25V. When the coating
resistivity of protected pipeline is changed, the anode current will be changed accordingly to keep
much the same electrode potential. The electrode potential of protected pipeline controlled at about
-1.1V, the values of anode current calculated are 2.4, 1.5, 0.38, 0.2 and 0.04A respectively when
surface resistivity of coating is assumed as 500, 1000, 5000, 10000 and 50000 Ω∙m2, shown as Fig. 9.
The potential and current density distribution of interference pipeline is simulated with above values
for surface resistivity of coating and anode current. All other parameters remained unchanged. The
results are shown in Fig. 10.

6
EPPCT 2020 IOP Publishing
IOP Conf. Series: Earth and Environmental Science 474 (2020) 052089 doi:10.1088/1755-1315/474/5/052089

Figure 9. The electrode potential of protected pipeline with varied surface resistivity of coating and
anode current
The results indicate that both the potential and the current density of interference pipeline change
significantly with different surface resistivities of coating. When surface resistivity of coating is very
lager, the potential of interference pipeline is near to Ecorr and the current density is almost zero. With
decreasing of surface resistivity, the potential and the current density of interference pipeline become
very uneven. The potential is more positive near the intersection, and more negative at the each end of
the pipeline, while current density is also more positive near the intersection, and more negative at the
each end of the pipeline. That means that the corrosion on pipelines is more severe when surface
resistivity of coating become smaller.

Figure 10. Effect of the surface resistivity of coating. a Potential distribution. b Stray current density
distribution

4. Conclusions
The numerical simulation based on BEM is used to investigate factors affecting SCC on interference
pipeline crossing the pipelines with ICCP. Numerical simulations based on BEM are a powerful aid to
investigate potential and current density distribution of buried pipelines suffering SCC. Based on our
simulation, the potential and current density distribution of the pipeline changes a lot when the
pipeline is crossed by the pipelines with ICCP. The section of pipeline near the intersection has
positive potential offset, and suffer the SCC, while each ends of pipeline far away from the
intersection have a negative potential offset, and are protected by stray current.
The variation of the pipeline crossing angle and crossing distance has almost no influence on the
potential and the current density distribution of the interference pipeline. That the location of anode is
moved farther from pipelines hardly affect interference pipeline, but moving nearer to crossing, on the
potential and the current density distribution of the interference pipeline are affected significantly.
Upon increasing the anode output current, the soil resistivity, or decreasing surface resistivity of

7
EPPCT 2020 IOP Publishing
IOP Conf. Series: Earth and Environmental Science 474 (2020) 052089 doi:10.1088/1755-1315/474/5/052089

coating, the electrode potential of the interference pipeline becomes very uneven, and the corrosion
potential of the pipeline near the intersection has a larger positive offset that causes worse corrosion on
pipeline.

Acknowledgments
Supported by the grants from the national key R & D Program "Research on important technical
standards of use and management of special equipment in use" (2017YFF0207100).

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