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Advance Electronic Systems (AES) is a leading innovator in Cathodic Protection (CP) engineering, dedicated to combating corrosion in critical infrastructure across India and beyond. As pioneers in the manufacturing of CP equipment and machinery in India, AES has been at the forefront of developing and implementing advanced CP solutions for over decades. Our expertise spans the oil and gas, power, water utilities, and infrastructure sectors, providing comprehensive services from design and installation to maintenance and monitoring.
This detailed document explores the principles, applications, equipment, and research and development in CP engineering at AES. With a scientific foundation, we emphasize electrochemical processes, material science, and engineering innovations to ensure the longevity and integrity of metallic structures such as pipelines, storage tanks, and marine installations. Our turn-key approach includes front-end engineering design (FEED) surveys, system configuration, material procurement, and rigorous testing, adhering to international standards like NACE and ISO.
AES's commitment to excellence has resulted in numerous successful projects, reducing corrosion-related costs and enhancing safety.
Founded in the industrial heartland of India, AES has grown from an electronics specialist to a pioneer in corrosion prevention technologies. We were among the first in India to indigenously develop CP systems, addressing the unique challenges posed by the country's diverse soil conditions, humid climates, and aggressive environments that accelerate corrosion.
Our history includes key milestones such as the introduction of impressed current cathodic protection (ICCP) systems tailored for Indian pipelines in the 1990s, collaborations with major public sector undertakings like Indian Oil Corporation, and the establishment of state-of-the-art manufacturing facilities for CP equipment. As a high-tech, research-based company, AES focuses on providing solutions for on-shore and off-shore applications, including cross-country pipelines, jetties, platforms, and underground piping.
In a nation where corrosion inflicts significant economic losses, AES's pioneering efforts have fostered self-reliance by reducing import dependency. We undertake turn-key EPC (Engineering, Procurement, and Construction) projects, encompassing corrosion monitoring, CP implementation, and electrical automation systems. Our team of electrical and chemical engineers ensures that every project is grounded in scientific principles, from FEED surveys to final commissioning.
Cathodic protection is an electrochemical technique that controls corrosion by making the protected metal structure the cathode in an electrochemical cell, thereby suppressing anodic dissolution. The core principle relies on the corrosion process, where metals like steel oxidize in the presence of electrolytes.
ρ = 2πaR
where a = electrode spacing, R = resistance
AES specializes in both galvanic and impressed current CP systems, selected based on structure size, environment, and economic factors.
Ideal for smaller structures or low-resistivity environments. Anodes are connected directly to the structure, providing protection via natural potential difference. Common applications include well casings and storage tanks. AES manufactures high-purity magnesium anodes with efficiencies up to 50%, designed for Indian soil conditions.
Suited for large-scale applications like pipelines. External DC power from rectifiers drives current through anodes. AES's ICCP systems include auto-potential control for dynamic adjustment, preventing under- or over-protection.
Combining both for optimized performance in variable conditions, such as coastal areas with fluctuating salinity.
AES's manufacturing facility produces high-quality CP equipment, engineered for reliability and performance.
Oil- or air-cooled units with SCR technology, outputs up to 100V/200A, efficiency >85%. Features include remote monitoring via IoT.
Sacrificial (Mg, Al-Zn-In) and impressed (MMO-Ti, high-silicon iron). Consumption rates optimized using electrochemical testing.
Permanent Cu/CuSO4 or Ag/AgCl types for accurate potential measurements, with stability ±5mV.
For surveys and adjustments, including close-interval potential surveys (CIPS).
Fluoropolymer-insulated for harsh environments.
AES's R&D division drives innovation in CP engineering, investing in advanced materials and technologies. Our team of electrical and chemical engineers collaborates with institutions to develop solutions for emerging challenges.
AES's CP solutions protect diverse infrastructure:
A 100 km pipeline project for a major oil company involved ICCP with deep well anodes, achieving uniform protection verified by CIPS, reducing corrosion by 95%.
Marine structure protection using galvanic anodes in coastal India, extending service life beyond 50 years.
Continuing applications, CP is vital for buried metallic materials, providing corrosion control through electrochemical means. In power utilities, we protect metal wires via CP to prevent degradation.
Integrity management for a refinery complex, integrating CP with monitoring for proactive maintenance.
AES is committed to sustainable CP advancements, including eco-friendly anodes and AI-driven systems. Future R&D will focus on resolving debates in CP mechanisms, like those clarified in recent studies.
In conclusion, AES's expertise in CP engineering positions us as leaders in India, delivering scientifically robust solutions for corrosion challenges.