Cathodic Protection USE OF D.C.

CURRENT FROM AN EXTERNAL SOURCE TO

OPPOSE THE DISCHARGE OF CORROSION CURRENT FROM ANODIC AREAS OF THE STRUCTURE.

A TECHNIQUE TO CONTROL THE CORROSION OF A

METAL SURFACE BY MAKING THAT SURFACE THE CATHODE OF AN ELECTROCHEMICAL CELL NACE RP 0169

A MEANS OF RENDERING THE METAL IMMUNE FROM

CORROSION ATTACK BY CAUSING THE DIRECT CURRENT TO FLOW FROM ITS ELECTROLYTIC ENVIRONMENT INTO THE ENTIRE METAL SURFACE BS 7631 PART 1.

CATHODIC PROTECTION- DEFINATIONS

ANODE : THE ELECTRODE THROUGH WHICH CATHODIC PROTECTION DIRECT CURRENT ENTERS THE ELECTROLYTE.
CATHODE : THE ELECTRODE THROUGH WHICH THE DIRECT CURRENT LEAVES AN ELECTROLYTE.

CATHODIC PROTECTION- DEFINATIONS

ELECTROLYTE : A LIQUID OR LIQUID COMPONENT IN COMPOSITE MATERIAL LIKE SOIL , IN WHICH ELECTRIC CURRENT FLOW BY MOVEMENT OF IONS. GROUNDBED ; SYSTEM OF BURIED OR SUBMERGED ANODES CONNECTED TO POSITIVE TERMINAL.

CATHODIC PROTECTION- DEFINATIONS

PROTECTION STRUCTURE : A STRUCTURE TO WHICH CATHODIC PROTECTION IS APPLIED

PROTECTION CURRENT : THE CURRENT MADE TO FLOW INTO A METALLIC STRUCTURE FROM ELECTROLYTE IN ORDER TO PROTECT METALLIC STRUCTURE

CATHODIC PROTECTION- DEFINATIONS

REFERENCE CELL : AN ELECTRODE THAT SERVES AS BASIS OF COMPARISON IN THE MEASUREMENT OF OTHER ELECTRODE POTENTIALS.

ELECTROCHEMICAL THEORY

ELECTROLYTE

+ IONS

ANODE

CATHODE

ELECTROCHEMICAL THEORY
AT ANODE

Fe
IRON
AT CATHODE

Fe++
FERROUS ION

2eELECTRONS

2e-

+ 2 H+

= 2H
HYDROGEN ATOMS

= H2
HYDROGEN MOLECULE

ELECTRONS HYDROGEN IONS

H2 O
WATER

+ 2 eELECTRON

= O2
OXYGEN ATOMS

= 2(OH)HYDROXYL IONS

HOW DOES CATHODIC PROTECTION STOP CORROSION ?

DIRECT CURRENT IS FORCED TO FLOW FROM AN EXTERNAL SOURCE TO THE PIPELINE. THE FLOW OF THIS CURRENT IS SO ADJUSTED TO OVERPOWER CORROSION CURRENT DISCHARGING FROM ALL ANODIC AREAS THEREBY PROVIDING COMPLETE PROTECTION.

How do we know that the entire buried pipeline has become a CATHODE ?

VARIOUS STANDARDS HAVE BEEN FRAMED AFTER YEARS OF RESEARCH AND PRACTICE MOST UNIVERSALLY ACCEPTED - NACE STANDARDS NATIONAL ASSOCIATION OF CORROSION ENGINEERS USA

CRITERIA OF C.P. FOR STEEL STRUCTURES

1. A negative (cathodic) potential of at least 850 mV with the cathodic protection applied, measured w.r.t. Cu/CuSO4 reference electrode. Voltage drops other than those across the structure to electrolyte boundary must be considered for valid interpretation of this voltage measurement. 2. A negative voltage shift of at least 300 mV as measured between the structure surface and a saturated Cu/CuSO4 reference electrode contacting the electrolyte. 3. A minimum negative polarization voltage shift of 100 mV measured between the structure surface and a Cu/CuSO4 half cell. This polarization voltage shift is to be determined by interrupting the protective current and measuring the polarisation decay.

SPECIAL CONDITIONS

IN THE PRESENCE OF SULFIDES, BACTERIA, ELEVATED TEMPERATURES, ACID ENVIRONMENTS AND DISSIMILAR METALS, THE CRITERIA OF 0.85 V MAY NOT BE SUFFICIENT. WHEN A PIPELINE IS ENCASED IN CONCRETE OR BURIED IN DRY OR AERATED HIGH RESISTIVITY SOIL, VALUES LESS NEGATIVE THAN 0.85 V MAY BE SUFFICIENT.

PRECAUTIONS :

USE OF EXCESSIVE POLARISED POTENTIALS ON EXTERNALLY COATED PIPELINES SHOULD BE AVOIDED TO MINIMIZE CATHODIC DISBONDMENT OF THE COATING. POLARISED POTENTIALS THAT RESULT IN EXCESSIVE GENERATION OF HYDROGEN SHOULD BE AVOIDED ON ALL METALS.

HAZARDS OF OVER-PROTECTION :

CATHODIC DISBONDMENT : DESTRUCTION OF ADHESION BETWEEN THE COATING AND THE COATED SURFACE IS CAUSED DUE TO EVOLUTION OF HIGH AMOUNT OF HYDROGEN.

Cathodic Protection Techniques

Galvanic Anode System Impressed Current System

GALVANIC ANODE
A METAL WHICH, BECAUSE OF ITS RELATIVE POSITION IN THE GALVANIC SERIES, PROVIDES PROTECTION TO METAL/METALS THAT ARE MORE NOBLE IN THE SERIES, WHEN COUPLED WITH AN ELECTROLYTE.

Galvanic Anode System

NO POWER SOURCE IS NEEDED

Lead Wire

OBJECT TO BE PROTECTED

Galvanic Anode
Protective Current

Essential Comonents of a Galvanic Anode System

ANODE GROUND BED

Choice of Galvanic Anode Material

1. MAGNESIUM 2. ZINC OTHER MATERIALS ALUMINIUM & ALLOYS

PREPACKAGED ANODE

GALVANIC ANODES SELECTION CRITERIA

CURRENT OUTPUT OR CAPACITY DRIVING POTENTIAL ANODIC POLARISATION BEHAVIOUR

Performance of Aluminium, Magnesium and Zinc Alloy Anodes

ANODE MATERIAL ALUMINIUM Mg. ALLOY 50 ZINC ALLOY 95

CURRENT EFFICIENCY (%) (APPROX.) CURRENT CAPACITY (Amp.-HR/Kg.) OPEN CIRCUIT POTENTIAL (V)

90

2,600

1,100

780

-1.05

-1.5

-1.1

ZINC

GENERALLY USED FOR THE PROTECTION OF PIPELINES, WHERE THE EFFECTS OF BURIAL ALONG WITH THE HIGH DUTY COATING TEND TO GIVE LOW ANODE CURRENT DENSITIES. HIGH EFFICIENCY NEGLIGIBLE RATE OF SELF CORROSION/INTER GRANULAR CORROSION LOW CURRENT OUTPUT DRIVING VOLTAGE DIMINISHES WITH INCREASING TEMPERATURE VIRTUALLY INEFFECTIVE AT TEMPERATURES OF ABOUT 60O C.

ALUMINIUM

PURE ALUMINIUM CANNOT BE USED AS AN ANODE AS IT PASSIVATES. ALUMINIUM ALLOY ANODES HAVE BEEN DEVELOPED LIKE GALVALUM I, GALVALUM III, ALANODE ETC.

HIGH CAPACITIES CAPABLE OF OPERATING AT HIGH TEMPERATURES UPTO 100O C. ALLOY COMPOSITIONS RELATIVELY TOLERANT OF TRACE IMPURITIES OFFER AN ECONOMIC SOLUTION TO SEA WATER PROTECTION.

MAGNESIUM

DISSOLVES VIGOROUSLY IN SEA WATER USE RESTRICTED ONLY TO SOIL APPLICATIONS OR ESTUARINE WATERS (HIGH RESISTIVITY) HIGH RATE OF INTERGRANULAR CORROSION ESPECIALLY IN LOW RESISTIVITY SOILS HIGH CURRENT OUTPUT LOW CURRENT OUTPUT EFFICIENCY

ADVANTAGES OF GALVANIC ANODE SYSTEM

EASY TO DESIGN, INSTALL AND MAINTAIN HIGH RELIABILITY LOW MAINTENANCE COST SELF REGULATED CURRENT OUTPUT HENCE LOW RISK OF OVERPROTECTION AND HYDROGEN EMBRITTLEMENT ECONOMICAL FOR SMALLER STRUCTURES

TYPICAL APPLICATIONS

SMALL PIPELINES WITH GOOD COATING OFF SHORE PLATFORM JACKETS HARBOR FACILITIES, STEEL PILE JETTIES ETC. PLANT FACILITIES & EQUIPMENT, SEA WATER INTAKE SCREENS, CONDENSERS, HEAT EXCHANGERS VESSELS

LIMITATIONS :

LOW DRIVING VOLTAGE ANODES NEED TO BE FITTED CLOSE TO THE STRUCTURE OR ON THE STRUCTURE ITSELF WHICH MAY INCREASE THE BURDEN ON THE STRUCTURE. ANODES NEED TO BE DISTRIBUTED ALL OVER DUE TO LIMITED COVERAGE DESIGN LIMITATIONS POOR PERFORMANCE DUE TO PASSIVATION.

IMPRESSED CURRENT
DIRECT CURRENT SUPPLIED BY A CATHODIC PROTECTION SYSTEM UTILIZING AN EXTERNAL POWER SOURCE

IMPRESSED CURRENT SYSTEM

EXTERNAL POWER SOURCE

OBJECT TO BE PROTECTED

PROTECTIVE CURRENT ANODE

BASIC CATHODIC PROTECTION INSTALLATION

BURIED EARTH CONNECTION (GROUND BED) CONDUCTORS INTERCONNECTING PIPELINE, CURRENT SOURCE AND GROUNDBED

+
SHADED AREA OF PIPELINE DENOTES ANODIC AREAS EXISTING PRIOR TO APPLICATION OF CATHODIC PROTECTION x x

SOURCE OF DIRECT CURRENT ELECTRICITY

x PROTECTED PIPELINE

ESSENTIAL COMPONENTS

ANODE/ ANODE GROUNDBED D.C. POWER SOURCE REFERENCE CELLS BACKFILL MATERIAL TEST STATIONS

Impressed Current Anodes Material Requirements

Chemical resistance to low pH environments Low Passive current, breakdown potential to be well above oxygen evolution potential Low oxygen & chloring overvoltage to reduce power consumption Wide temperature range operation Good castability and mechanical strength Good resistance to abrasion Good current discharge capability good conductivity even in passive state Resistant to localised corrosion such as pitting and Intergranular corrosion

Choice of Impressed Current Anode Material

Scrap Steel Silicon Iron Artificial Graphite Lead Lead Platinum Platinized Titanium Platinized Niobium

Impressed current anode materials and their properties

Material Mixed Metal Oxide Anodes High Silicon Iron Steel Iron Lead-platinum Graphite
Consumption

(Kg./Amp-yr) 8 x 10-6 Marine env. / high purity liquids 0.25 1.0 Potable waters and soil 6.8 9.1 Normal Soil Approx. 9.5 0.09 0.1 1.0 Normal Soil

Recommended Uses

Marine evironments Normal Soil

CHOICE OF EXTERNAL POWER SOURCE

TRANSFORMER RECTIFIER UNIT

CCVT SOLAR CELLS

WIND POWERED GENERATORS

FUEL CELLS

Selection of type of T/R Unit

Depends on Site conditions Facilities available for operation & maintainence System Requirements If Power Supply unreliable T/R unit used alongwith standby alternative source

REFERENCE ELECTRODES
A REVERSIBLE ELECTRODE WITH A POTENTIAL THAT MAY BE CONSIDERED CONSTANT UNDER SIMILAR CONDITIONS OF MEASUREMENT.

HALF CELL METAL DIPPED INTO AN ELECTROLYTE. IN ORDER TO MEASURE ITS POTENTIAL, IT MUST BE CONNECTED TO ANOTHER HALF CELL WHOSE POTENTIAL IS ALREADY KNOWN.

Electrochemical Series
Electrode K Mg Zn Fe H Cu Ag Pt Potential of Standard Electrode at 25o C (V) -2.92 -2.34 -0.76 -0.44 0 0.34 0.80 1.2

COPPER COPPER SULPHATE REFERENCE CELL

MOST COMMONLY USED HALF CELL FOR C.P. APPLICATIONS.

CONSISTS OF AN ELECTRODE OF ELECTROLYTIC COPPER IN A SATURATED SOLUTION OF COPPER SULPHATE.

Limitations of Cu/CuSO4 half cell

Capacity decreased with time by formation of copper sulphate crystals and copper oxide on the metal. Thus the cell needs to be cleaned after 2-3 months to restore current carrying capacity. Copper sulphate, when leaked into the electrolyte, forms small copper cathodes which can enhance corrosion of the structure. Copper sulphate can easily be contaminated, though potential does not alter significantly, it is susceptible to polarisation and hence unsuitable for prolonged use in sea.

Silver Silver Chloride Reference Cell

Ag wire coated with silver chloride so that both Ag and AgCl are in contact with a chloride ion electrolyte. The potential of the half cell will depend on the chloride concentration. Generally used for Sea Water applications or also for Marsy Areas in cross country pipelines.

BACKFILL MATERIALS
PURPOSE 1. Increase effective anode to obtain lower resistance to earth. 2. Reduces entrapment of gas generated by anodic reactions by providing venting and an increased surface area. 3. Helps in reducing the electroosmotic effect COMMON BACKFILL MATERIALS Coal Coke Calcined Petroleum Coke Natural or Manufactured graphite

Test stations for potential, current, or resistance measurements provided at sufficient locations to facilitate C.P. testing.

Test Stations

Pipe casing installations Metallic structure crossings Isolating joints Waterway crossings Road/Rail/Bridge crossings Galvanic anode installations Valve stations Stray current areas Rectifier installations

Cable to Pipe Connections

Cable to pipe connection should be mechanically strong and electrically conductive.

Thermit Welding Process Soldering PIN BRAZING Mechanical Means

Particular attention to avoid :

Damaging or penetrating pipe Sensitising or altering of pipe properties Weakening the cable Damaging internal or external pipe coatings Creating hazardous conditions in explosive environments

Cable to Pipe connection by mechanical means least desirable since such a connection may

Loosen Become highly resistant Loose electrical continuity

THERMIT CONNECTION KIT

ANODE JUNCTION BOX

ADVANTAGES OF IMPRESSED CURRENT SYSTEM

FREE FROM LIMITATIONS OF GALVANIC SYSTEM. NO LIMITATION OF DRIVING VOLTAGE. VOLTAGE & CURRENT BOTH CAN BE VARIED. VOLTAGE - UPTO 50 V CURRENT - LESS THAN 10 Amp TO SEVERAL HUNDRED Amp SYSTEM EXTREMELY FLEXIBLE EASY TO MAINTAIN AND RESURVEY

Comparison of Galvanic Anode System v/s Impressed Current System

Galvanic Anode
No external power reqd. Fixed driving voltage Limited current Suitable for low resistivity electrolytes Frequent monitoring and maintenance not required Create minimum interference problems

Impressed Current
Requires external power Voltage can be varied Current can be varied Can be designed for almost all current/life requirements Regular monitoring and maintenance required Interference problems must be considered

Galvanic Anode
Remote Monitoring and control is impossible

Impressed Current
Can be designed for remote monitoring and control

Measurement of instant off Can be designed for potentials difficult measurement of instantoff/on potentials Suitable for off-shore Usually not recommended platforms/structures, for such applications. internal surface of pipelines/water boxes, small boats etc. and temporary protection of cross-country pipelines

EFFECTIVENESS OF CATHODIC PROTECTION IN STOPPING DEVELOPMENT OF LEAKS

160 140 120 100 80 60 40 20 0 1930 1935 1940 1943 1945 1950 1955 1960 1965

C.P. APPLIED
CUMULATIVE LEAKS

YEARS

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