This project is an extension of EC-08-12, documented in the final report PR405-213601-R04 Validation of Digital Twins for Monitoring, Optimization, and Compliance of CP Systems, with the aim of further improving the accuracy of digital twin computer models for CP compliance of pipelines by performing dedicated field tests such that the predicted IR-free (or polarized) potentials better align with the measured values at test stations.
The initial project demonstrated that digital twin technology results in an accuracy of approximately 90% in calculated IR-free potentials for 6 out of 9 pipelines...
The initial project demonstrated that digital twin technology results in an accuracy of approximately 90% in calculated IR-free potentials for 6 out of 9 pipelines of the simulated cases. This means that in 90% of the test stations the simulated IR-free does not deviate more than 10% from the measured value. Technology acceptance might require higher accuracy of the digital twin, which in turn requires more field data. After validating the potentials at the test stations, the computer models predict the ON and IR-free potential in between test stations, and compute current density and corrosion rates on coating defects.
This document addresses the field tests and simulation results for three industrial cases. The CP currents, soil properties, coupon data and coating survey based on the alternating current attenuation (ACCA) method were recommended to increase knowledge on the pipeline and cathodic protection (CP) conditions and ultimately to enhance the accuracy of the model.
This document aims to demonstrate how digital twin computer models endorse corrosion and integrity programs with semi-quantitative corrosion assessments. It helps improve external corrosion direct assessment (ECDA) programs by defining technologies and pipeline sections for additional field tests. Digital twin computer models bridge CP surveys with the ILI inspections by converting potentials into corrosion growth rates with a spatial resolution at joint level.
The work supports pipeline operators, integrity engineers, and corrosion specialists in the practical application of digital twin modeling for cathodic protection (CP) compliance and external corrosion management.