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 [email protected]
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