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IP54 Cathodic Protection Rectifier for Pipelines, Ships, Desert and Harsh Environment

IP54 Cathodic Protection Rectifier 

for Pipelines, Ships, Desert and Harsh Environment

1. Switch mode rectifiers for cathodic protection

Cathodic protection (CP) is a technique used to control the corrosion of a metal surface by making it the cathode of an electrochemical cell. A simple method of protection connects the metal to be protected to a more easily corroded "sacrificial metal" to act as the anode. The sacrificial metal then corrodes instead of the protected metal. For structures such as long pipelines, where passive galvanic cathodic protection is not adequate, an external DC electrical power source is used to provide sufficient current.

Cathodic protection systems protect a wide range of metallic structures in various environments. Common applications are: steel water or fuel pipelines and steel storage tanks such as home water heaters; steel pier piles; ship and boat hulls; offshore oil platforms and onshore oil well casings; offshore wind farm foundations and metal reinforcement bars in concrete buildings and structures. Another common application is in galvanized steel, in which a sacrificial coating of zinc on steel parts protects them from rust.

2. Why GERE's switch mode power supplies replace SCR rectifier?
GERE's Switch mode power supplies have many advantages over SCR rectifier, therefore, they are now more and more used for electroplating process to replace SCR rectifier.
The main advantages of GERE pulse plating rectifiers over thyristor rectifiers include but not limited to:

• Low maintenance

• Light weight, small size, in far areas, don't need crane truck, like heavy oil-cooled SCR rectifier which is difficult and expensive.

• Same high reliability as SCR rectifier, long time 7 days 24 hours continuous running

• High conversion efficiency, power saving at least 15% than SCR rectifier.

• Not affected by power fluctuation, 100% output, don't need extra capacity

IGBT rectifier adopts AC-DC-AC-DC topology, 3 phase AC is firstly converted to DC, which has capacitors for energy charging and discharging, it will suppress power fluctuation, so rectifiers don't need bigger capacity than actual use.
SCR rectifier doesn't have energy buffer function, it is affected directly by the grid power fluctuation, so it always keep much extra capacityand increase user's investment cost.

• Pulse output needs less plating time, customer feedback 40% shorter time needed for plating

• Modular design:

  -Rectifier won't break down: in case of one module failed, the rectifier continue working with reduced power

  -Less downtime and easy recovering:plug-in structure, replace module directly, downtime is shorten to minimum, this reduces potential high cost of your plant stop and increase your plant's availability.

  -Current expansion available:thanks to the modular design and supporting parallel connection, if you need more power, you only need to add more modules.

  -Reduce current rating to save power: if you don't need all modules working, you can switch off some modules, rectifier can work at lower rating.

  -Less floor space occupied: the rectifiers can be built on top of each other, making them easy to fit into your plant's design, optimizingfloor space.

  -Easy to install and maintain: each rectifier consists of up to ten modules and naturally two or more stacks can be connected to allow higher currents (40kA) and voltages (200V DC).

  -Separate output or parallel running output available: you can let the rectifier module separate output to connect to more tanks, or parallel connecting to get higher current for one tank.

  -Compact size, modular structure, e.g. air cooling 1000A 12V size only 450*560*300mm, weight is only 58kg. much less size and weight than SCR rectifier, don't need forklift

• Low pollution to grid, power factor 0.93

• Lower costfor the same specification

3. Comparison chart of the rectifiers

4. Main Technical Parameters of the rectifiers

• Input voltage: 3 phase 4 line, 220V, 380V, 415V, 480V

• Input voltage protection range: +/-10%

• Cooling method: Water cooling, forced air cooling, natural cooling

• Power factor: 0.93

• Efficiency: 92% at rated output

• Regulation range: 0-100%

• Duty cycle: 100% continuous running

• Control mode: constant voltage, constant current

• Accuracy: 1%

• Ambient temperature: Max. 40℃

• Elevation: 4000m

5. Advantages of the rectifiers

Convenient use and operation

Module structure

• Easy to move and replacement

• Flexible combination, get different current output

• Compact size, light weight

• Save space, could be installed stacked

• Standard design, short lead time, lower cost

Easy remote control by communication

• DSP digital control support multiple remote control option:

• 0-10V/4-20mA analog signal+dry contacts to be controlled by PLC

• Communication with PLC through RS485, Profibus, Profinet

• We provide remote control box, distance up to 30 meters long

Touch panel operation

• Could set output value accurately

• Could set step length

• Could realize timer function, automatic stop after timing up

• Could set protection parameters on touch panel

• Could save history data for inquiry

• Set local control/remote control

• Set CC/CV mode

Easy and quick fault judge and troubleshooting

• Rectifier provide full protections and self alarm

• DSP realize self fault diagnosis

• Touch panel shows protection type automatically

• Touch panel provide history protection record for inquiry

• Provide detailed troubleshooting guidance with pictures in manual

• User-oriented mechanical design, easy for disassembly to change parts

Look for IP54 Cathodic Protection Rectifier, for Pipelines, Ships, Desert and Harsh Environment, coming from Chengdu General Rectifier Research Institute, is of high precision, high efficiency and reliable performance, which has already been exported to USA, Germany, India, etc and owned good reputation. Customized service is also available if you need.