File No. 20.1/35.15.

01

GUIDELINES FOR THE DESIGN, INSTALLATION, AND MAINTENANCE OF

ANODES IN COOLING WATER HEAT EXCHANGERS

1.0 SCOPE

These are guidelines for the design, installation, and maintenance of sacrificial anodes in
cooling water heat exchangers. They are meant to protect the channel section of heat
exchangers with cooling water on the tube side.

Designers can use this when designing new exchangers or protecting existing exchangers.
Reliability personnel, such as inspectors can use this to spot problems with anodes systems or
to know when anodes may be needed (Section 7 and flow chart pg. 2). Maintenance
personnel can learn how to avoid past installation mistakes (Section 6 and 7).

Anodes in the channel section are not likely to protect the tubes from corrosion.

2.0 GOALS OF GUIDELINES (What these guidelines can help you do)

Give background on the engineering principles used for determining the number of anodes
required (Section 3).

Decide under what conditions is it appropriate to use anodes (Section 4 and Flow chart Page
1)

Decide how many anodes are needed and where to place them (Section 4 and excel
spreadsheet)

Understand how to change the anode system to reduce the number required (Section 5.0).

Maintain and troubleshoot the anode system (Section 4 and flow chart page 2)

Avoid mistakes of the past (Section 6)

3.0 BACKGROUND: ENGINEERING PRINCIPLES FOR DETERMINING THE

NUMBER OF ANODES REQUIRED
Cooling Water Variables

Current density is a characteristic of the cooling water, which includes the effects of
temperature and aeration (how much oxygen is dissolved in the system). Typical units are
mA/ft2.

Conductivity is how well the cooling water conducts electricity. Units are usually given in
micro mhos/cm. Among other things, chloride content and temperature can affect this
parameter.

Anode Materials Properties

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Two anode properties that measure the anodes performance are anode current capacity and
driving voltage.

Current capacity is a measure of how much charge an anode can put out per pound. It is
usually expressed as Amp*hrs/lb. For example, if an anode must be used at 0.100 Amp for
10,000hrs and the current capacity is 500Amp*hr/lb, then about 2lbs of anode will be
required. The higher the current capacity, the longer the anode tends to last.

Driving voltage is a measure of the difference in electrostatic potential between it and a

standard reference electrode such as the Cu/CuSO4 electrode. The higher the driving voltage,
the more effectively the anode protects the structure.

Specific Anode Materials and Where They Are Appropriate

Magnesium has become the standard for cooling water service, so zinc and aluminum alloys
will not be discussed in much detail here.

Magnesium alloys are the most commonly used anode materials for cooling water service.

Two common alloy compositions are specified in ASTM B843 (See Table I for the different
grades and their properties)

They are especially effective where conductivity is relatively low (<5000micro mhos /cm)

Aluminum alloys perform better than magnesium in high conductivity water.

WARNING: WE DO NOT RECOMMEND ALUMINUM ALLOYS FOR COOLING WATER

SERVICE.

Aluminum by itself does not usually corrode as would be required of an anode, but when
activated with elements such as tin, indium, and mercury they tend to corrode uniformly.

At the Richmond Refinery in both 1998 and 2000, portions of a scale containing aluminum
were found plugging the tubes. When an analysis of the anode was done it was found to be
aluminum and not magnesium as specified. The reason for decomposition of the anode is
unclear.

Zinc alloys are useful in brine type environments

WARNING: ONLY USE BELOW 130F. ABOVE THIS TEMPERATURE, THE GALVANIC
POTENTIAL WILL TEND TO REVERSE AND CAUSE THE STEEL TO CORRODE.

They are most useful where sparking, caused by dropping the anode, cannot be tolerated.

Recommended anode shape and costs

The current locknut design shown in Figure 1 (Appendix A) should be used. Two
companies that supply anodes of this type are HARCO and Farwest. Richmonds supplier is
currently HARCO, a Corrpro company. A supplier that the El Segundo refinery is
considering is Farwest. The prices as of Aug. 2000 are listed in Table II. Other sizes may be
available but only on special order.
TABLE I. TYPICAL PROPERTIES OF ANODE MATERIALS
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Material

Driving Voltage
(V vs. Cu/CuSO4)

Current Capacity
(Amp*hrs/lb)

Density
(g/cm3)

Magnesium Grade M11636B

1.5
450
1.6
Magnesium Grade M15102B
1.7
450
1.6
Aluminum alloys
1.1
900A
2.4
Zinc
1.1
335
6.6
A: This is for the most common indium activated grade at ambient temperatures. This value
changes at elevated temperatures. Consult CRTC for temperature dependence.
B: ASTM B843
TABLE II. ANODE SIZES AND PRICES FOR ASTM B843 GRADE M11636

Supplier

Harco
Harco
Harco
Farwest
4.0

Shape

Dimensions, inches Weight Potential Cost, $

vs.
Cu/CuSO4
Cylindrical 5 diameter, 2 thick
3
1.5
12
Square block
8X8, 2 thick
7.5
1.5
36
Square block
8X8, 4 thick
15
1.5
69
Square block
8X8, 4 thick
15
1.5
70

Cost /lb.

4.00
4.80
4.60
4.67

TOOLS FOR DESIGNING ANODE SYSTEMS

4.1 Basic Procedure

Use the flow chart in Appendix B or the table below to make the decision step-by-step for
installing anodes. There are links to the flow chart in the step column. To return to this
document simply press ALT+LEFT ARROW.
Fill in the shaded boxes in Figure 2 (Appendix A) and enter this data into the size.xls
spreadsheet to determine the size and the number required. Steps involved in using this
spreadsheet and a description of the terms used are given in Table IV.

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STEP
1
2

3
4

7
8

10

11

TABLE III. DESCRIPTION OF STEPS FOR FLOW CHART

TYPE
ACTION
COMMENTS
DETERMINE IF ANODES ARE APPROPRIATE
Decision Decide whether excessive channel
repairs due to corrosion are required.
Decision Decide whether the tube corrosion
Acceptable rates are: carbon steel,
rate is acceptable.
5mpy; admiralty brass, 0.3mpy. For
other materials consult CRTC or a
materials engineer. Even though the
tubes are not being protected, tube
corrosion rate is an indication of
cooling water service severity.
Decision Decide whether the outlet fluid
Corrosion is more likely to occur in
temperature exceeds 120F
excess of this temperature.
Decision Use anodes if reclaimed water is
Experience at the Richmond refinery
used.
has shown that cooling water heat
exchanger channels tend to require
more maintenance when reclaimed
water is used. The exact reasons for
this are not clear, but may be due to
the corrosiveness of an occasional
slug of biocide like chlorine or
bromine that the city uses to de-nitrify
the water.
End point Anodes not required.
Although not required, anodes have
been found to be cost effective in
most cooling water services.
Decision Consult a materials engineer if the
It may indicate that the coating quality
channel is already internally coated,
is poor and that anodes might not be
but corrosion problems still exist.
the solution to the problem.
Task
Determine the appropriate size and
number of anodes using size.xls
Task
Make a drawing showing where
This should prevent poor distribution
anodes should be place and place the of flow into the tubes
anodes at least 5 tube diameters
away from the tubesheet and out of
the direct flow path from the inlet
nozzle to the tube inlets.
Decision Decide whether the required number The number can be especially high if
of anodes could realistically fit in
magnesium is used with high
your exchanger.
conductivity (>5000micromhos/cm)
water.
Task
If size.xls requires an unreasonable
It is better to have some anodes than
number of anodes, install as many
to have none at all. NOTE: The
anodes as possible or consider
anodes may be consumed sooner than
coating the channel.
desired
Proper coating can reduce the number
End point From...Cannot fit anodes
of anodes required. NOTE: With
Describe the problem to your
mixed metallurgys, coatings should
materials engineer or CRTC and
only be used when anode replacement
include:
system is reliable. If the anodes fail,
1. Completed size.xls worksheet.
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2. Criteria for deciding to install

anodes (e.g. Steps 1-4).

severe corrosion of the channel could

result at coating defects.

...Channel internally coated

Describe for the materials engineer
what is the tube/shell metallurgy

12

13

14

15

16

17

18
19
20

21

Decision

...Personnel Approval
If you still believe anodes are
needed, but the appropriate
personnel do not approve, provide
the following to the materials
engineer:
1. Reason for disapproval
2. Contact information for person
who does not approve.
Depending on the problem, the
materials engineer might be able to
suggest an alternative (e.g. coating)
Determine whether the appropriate
personnel approve of installing
anodes.

The appropriate personnel are the

materials engineer, whoever is
responsible for cooling water
chemistry (e.g. NALCO), and your
immediate supervisor.

End point Install anodes per engineering

drawings.
TROUBLESHOOTING AND MAINTENACE OF ANODES, Page 2 of flow chart
Task
Inspect anodes when the channel is
opened to determine if the anodes
need to be replaced because of either
damage or deterioration.
Decision Decide whether the majority of
If so, all anodes should be replaced,
anodes are at or below half size.
because size.xls is intended for anodes
to be fully effective until they reach
quarter size.
Decision Inspect to see whether one or two
If so, this could suggest that only a
anodes appear to be much smaller
few anodes are bearing the electrical
than the others are.
load.
Decision Decide if anodes have severe
They may have defects (e.g. from
localized corrosion
casting) that might cause large pieces
to spall off and plug exchanger tubes.
End point Continue to use anode until the
anodes design life is exceeded.
End point Replace all the anodes, their design
life will be exceeded soon.
End point Replace the anodes in this chamber
and send the anodes removed to your
materials engineer for analysis. Be
sure to provide a picture or sketch of
the anode layout in the channel.
End point Replace anodes that have defects
Anodes such as these should be
that are 1/8 or greater in size.
replaced, and the remnants should be
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sent to your materials engineer for

analysis to determine the quality.

TABLE IV. DESCRIPTION OF ANODE SIZING SPREADSHEET AND WORKSHEET

STEP
ACTION
COMMENTS
ANODES
1
Enter the current
Most suppliers will not quote a current capacity. If
Current
capacity in Amp*hr/lb.
magnesium is purchased to the composition
Capacity
requirements of ASTM B843 then use the data in Table
(Amp*hr/lb)
I.
Enter the driving
ASTM B843 M11636 is about 1.5V vs. the Cu/CuSO4.
2
voltage.
Anode
If you are quoted a driving voltage with respect to some
driving
other reference use Table V to determine the Cu/CuSO4
voltage vs.
equivalent.
Cu/CuSO4
(V)
3
Enter the weight of the
The densities of some cast products can vary, so input
Anode
anode.
the weight and dimensions independent of one another.
weight (lbs.)
4
Enter the OD of the
For a square-shaped cross-section, enter one of the sides
Anode
anode.
instead.
diameter (in)
Enter the height of a
5
cylindrical anode or the
Anode
thickness of a square
thickness
anode.
(in)
6
Enter the OD of the
Core
steel pipe core in the
diameter (in) anode.
CHANNEL
7
Enter the channel
The surface area attributed to the partition plates and
Channel
length, assuming that the baffles is accounted for in Steps 9 and 10.
Length (in) channel is shaped like a
cylinder.
Enter the channel inside The surface area attributed to the partition plates and
8
baffles is accounted for in Steps 9 and 10. The inside
diameter, assuming that
Channel
diameter should be used because it is the surface area of
the channel is shaped
Diameter
the channel that we are concerned about protecting.
like a cylinder.
(in)
9
Enter the number of
A baffle is a plate other than the partition plate that
Number of additional baffles.
separates a portion of the channel (See Figure 3).
additional
baffles
10
Enter the number of
A chamber is defined as the volume within the channel
Number of chambers.
enclosed by channel walls, baffles, and/or a partition
chambers
plate.
Enter the chamber type. The type can be either end (e), half (h), or middle (m)
11
as shown in Figure 3.
Category of
largest
chamber
(h,m,e)
12
Enter the A
The A dimension is the base of the largest chamber in
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Largest
chamber
base, A (in)
13
Largest
chamber
wall to end,
B (in)

dimension shown in
Figure 3.

the channel (Figure 3).

The B dimension is from one end of the largest

Enter the B
chamber to the nearest end of the channel (Figure 3).
dimension shown in
Figure 3 only if the
largest chamber is in the
middle of the channel.
COOLING WATER
14
Enter the expected
Typically, the Richmond Refinerys cooling water is
Conductivity conductivity of the
between 4000 and 8000 micro mhos/cm.
(micro
cooling waters, after
mhos/cm)
consulting your NALCO
rep.
ASSUMPTIONS
15
Enter the expected
If coating quality is considered:
Coating
coating efficiency.
Good--assume a coating efficiency of 0.9
efficiency
Poorassume a coating efficiency of 0.1
If there is no coating, assume 0.
16
The design life is how
This can be changed to coincide with
Design Life long the anodes should
turnaround/shutdown cycles.
(years)
last before replacement
is necessary.
A bare steel structure is considered cathodically
17
Do not modify.
protected if it is at a potential of 850mV (Cu/Cu/SO4).
Structure
Potential vs.
Cu/CuSO4
(V)
A current density of 20mA/ft2 is assumed for hot, well18
Do not modify.
aerated water such as cooling tower water. Lower
Current
current densities exist for lower temperatures and less
Density
aeration.
(mA/ft2)
REPORT
19
This line contains the total number of anodes required for the entire heat
Minimum
exchanger.
number of
Some anodes are better than none, so if the number required seems
anodes total:
unreasonably large, fit as many anodes in the exchanger as you can, and consult
with your local materials engineer.
You may want to consider coating the channel or follow the recommendations
in section 5.0.
20
This line contains the minimum number of anodes required in the largest
Min. anodes
chamber.
in largest
The absolute minimum number that you should put in each chamber is 1
chamber:
because if an anode were a light bulb, only the areas that were illuminated
would be protected.
21
This line tells you whether you should change the size of your anode.
Comments: At the bottom of the CALCULATIONS section you will find, in bold print, the
number of anodes required by weight (w) and by current (c). These will be
referred to as the W and C requirements respectively.
If line 21 says increase the size of your anode and recalculate then the
weight requirement is much greater than the current requirement. This means
that the channel might be fully protected with fewer anodes (the C requirement)
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but that the anode would consume faster than designed.

If line 21 says decrease the size of your anode and recalculate then the
current requirement is much greater than the weight requirement. The number
of anodes must meet the C requirement.
If it says anodes optimized that means that there is only a 10% difference
between the W and the C requirements, or if the difference is less than 1
anode.
Fewer anodes may be required if you follow the instructions in Section 5.0.

5.0. Suggestions For Changing The Number Of Anodes Required

At the bottom of the CALCULATIONS section you will find, in red print, the number of
anodes required by weight (w) and by current (c). These will be referred to as the W and C
requirements respectively.
The W requirement can be lowered by:
increasing the current capacity or the coating efficiency
decreasing the current density, un-coated surface area of the channel, or the design life.
The C requirement can be lowered by:
increasing the driving voltage, or the coating efficiency
decreasing the conductivity of the water, the un-coated surface area of the channel, or the
design life

TABLE V. CONVERSION FACTORS FOR REFERENCE ELECTRODES.

If the reference cell is
then addto it to get the Cu/CuSO4
potential.
Cu/CuSO4
+0.00
Standard hydrogen
-0.318
Mercury-Mercurous Sulfate
-0.297
Silver-Silver Chloride
+0.096
Saturated Calomel Electrode (SCE)
+0.077
6.0

Installation Procedure

1. Be sure that the following are available: grit blasting and stud welding equipment, anode
accessories (stud, rubber washer, hex nut, lock washer, flat washer).
2. Grit blast metal surface of partition plate until bare metal is showing. If the partition plate is
not cleaned of rust, dirt, or scale, the stud will not make good electrical contact with the
anode, hindering weldability and potentially preventing the anode from functioning.
3. Lightly scribe marks into the partition plate where the studs are to be attached.
4. Place rubber washer down around stud.
5. Place anode on top of washer such that stud fits through the core of the anode. Anode should
not come in direct contact with the partition plate (See section 7).
6. Tighten nut on stud such that a tight seal is formed between the anode, washer, and partition
plate
7.0 AVOID REPEATING PAST MISTAKES: READ REGARDLESS OF
INSTALLATION PRACTICE
7.1 Electrical Contact
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The anode must make electrical contact with the stud.

Be sure that the anode is bolted down securely and that the mating surfaces between the nut
and anode are clean. Dirt, oil, etc. can prevent good electrical contact between these surfaces.
Be sure that neither the anode nor the threads of the stud are painted or coated in anyway.
The anode must corrode to protect the heat exchanger.

7.2 Miscellaneous

If in the future both aluminum and magnesium anodes are purchased, purchase aluminum in
square shapes and magnesium in cylindrical shapes to avoid mistaking one for the other. It is
difficult to distinguish between the two materials because they have similar weights and
appearance. Stamps in the cast material can be difficult to read.

Note the rubber washer/plastic spacer detail in Figure 1. From experience, we find that anode
corrosion products can build up under the anode and break off chunks of it if this spacer is
not used. The spacer also promotes uniform decay of the anode by preventing corrosion at
the channel interface.

Do not use modified anode configurations without checking with your local materials
engineer or CRTC.

Do not screw the magnesium anode into the threaded stud as this will cause preferential
corrosion at the threads and could potentially lead to heat exchanger plugging.

8.0 REFERENCES

Corrosion Prevention Manual Sections 1100, 1600, and 1700.

ASTM B843
Steve Turnipseed (sptu@chevron.com)
Corrosion Prevention and Metallurgy manual, specification CPM-LCL-5001-A
CRTC File: 75.16.187: Jack, B.L. and Rosenthal, L.M.. Minimizing Corrosion and Fouling
in Cooling Water Systems: Technical Development Interim Report.

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APPENDIX A.

Figure 1. Exchanger Anode Detail.

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STEP INPUTS
ANODE

CALCULATIONS
Channel surface area (ft2)

1 Current Capacity (Amp*hr/lb)

Resistivity of electrolyte
(Ohm*cm)

2 Driving voltage vs. Cu/CuSO4 (V)

3 Anode weight (lbs)
4 Anode diameter (in)
5 Anode thickness (in)
6 Core diameter (in)

Resisitivity basis
Current requirement (mA)
Total weight of anodes required (lbs)
rr (cm)
Driving voltage (V)
Resistance (ohms)
IAC (mA)
Surface area of largest chamber (ft2)

CHANNEL
7 Channel Length (in)
8 Channel Diameter (in)
9 Number of additional baffles
10 Number of chambers
11 Category of largest chamber (h,m,e)
12 Largest chamber base, A (in)
13 Largest chamber wall to end, B (in)

alpha
beta
gamma
r (in)

COOLING WATER (typical)

14 Conductivity (micro mhos/cm)

number of anodes by weight

number of anodes by current
number of anodes in largest chamber

ASSUMPTIONS
15 Coating efficiency
16 Design Life (years)
17 Structure Potential vs. Cu/CuSO4 (V)
18 Current Density (mA/ft2)

0.85
20

m
h
e part I
e part II

W
C
L

Difference between requirements

Sum of the two requirements
Absolute value of the percent difference
anode density (lb/in3) assumes round

REPORT
19 Minimum number of anodes total:
20 Min. anodes in largest chamber:
21 Comments:

Figure 2. Anode sizing worksheet.

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Additional Baffles

A
h

Partition plate
Figure 3. Anode dimensions.

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