Training Program

Skill Group 15.10

Level 1
Cathodic Protection

Table of Contents

Corrosion Fundamentals and Principles of

Cathodic Protection
Cathodic Protection Hardware
Cathodic Protection Operation and Monitoring
Coatings and Cathodic Protection

Corrosion Fundamentals and Principles

of Cathodic Protection
Contents
Introduction
The Electrochemical Cell
Other Common Corrosion Reactions
Electrode Potentials
Determining the Rates of Corrosion
Corrosion Control Methods
Practical Applications of Cathodic Protection

Reference
Petronas Technical Standards
PTS ( Petronas Technical Standard )
API ( American Petrolium Institution )
AS ( Australian Standard )
BS ( British Standard )
DNV
NACE

Introduction
Metallic corrosion is a general term used to describe all the processes by
which metals and its alloys are degraded by reactions with their environment.
In Oil and Gas production operations, the reactions are primarily
electrochemical.

For iron/steel in sea water :

Anodic Reaction : Fe ----> Fe2+ + 2eCathodic Reaction : O2 + 4e- + 2H2O ---> 4OH-

Electrochemistry
Corrosion Cell
Fe O -H O
2 3 2 X
FeS
FeCO
3

HO
2
+
2H + H2 1/2 O2

++
Fe++ Fe

2 e-

ANODE
Fe

Fe

ELECTRON
FLOW

2e

2OH-

CATHODE

ELECTROLYTE
METAL SURFACE

Other Common Corrosion Reactions

Anodic Oxidation Reaction :
Fe ----> Fe2+ + 2e-

Cathodic Reduction Reactions :

In Near-neutral Solution
O2 + 4H+ + 4e- ---> 2H2O
In Acidic Waters
O2 + 4H+ +4e- ----> 4OHIn Very Acidic Waters
2H+ + 2e- ----> H2

Rust Formation
4Fe(OH)2 + O2 +2H2O ----> 4Fe(OH)3

Electrode Potentials
Definition
Measured potential of an electrode in an electrolyte relative to the potential of a
reference electrode

Measurement of Standard Electrode Potentials

Electrode Potentials
Selected Standard Electrode Potentials

Corrosion Rate Determination

Faraday's Law
Mass of substances dissolved in an electrochemical reaction is proportional to
current flowing in the electrochemical cell

W = MiT
nF
where
W = mass of substances dissolved
M = atomic or molecular weight of substances
i = corrosion current, amps
T = time, s
n = number of electrons per atom involved in the reaction
F = the Faraday = 96500 coulombs / gm equivalent

Corrosion Rate Determination

Based on Electrochemical Technique

Corrosion Rate = Kai
nD
where
K = constant

(for corrosion rate in mpy, micrommeter/yr and mm/yr, the values of K are 0.129,
3.27, and 0.00327, respectively)

a = atomic weight of metal

i = current density, micro amps/cm2
n = number of electrons lost
D = metal density, g/cm2

Corrosion Rate Determination

Based on Metal Loss

Corrosion Rate (mpy) = 534W
DAT
where
W = mass loss, mg
D = density of specimen, g/cm3
A = area of specimen, sq. in
T = time of exposure, in hr

Corrosion Control Methods

C athodic P rotection

Design
Materials Selection
Protective Coatings
Chemical Inhibition

Cathodic Protection - Definition

" Cathodic protection is an electrochemical

technique for controlling corrosion on metallic structures
immersed in an electrolyte, by applying an external DC

current to lower the potential of the structure, to an

extent that the structure becomes cathodic with respect
to an external anode connected to the structure "

Practical Application of Cathodic Protection

Types of Cathodic Protection Systems

Galvanic (sacrificial) anode system
Impressed current system

Practical Application of Cathodic

Protection

Galvanic (Sacrificial) Anode Cathodic Protection System

By appropriate galvanic coupling; Sacrificial Anode Cathodic Protection (SACP) system

Coated Copper Wire

Soil

Current
Tank
Mg Anode

Practical Application of Cathodic Protection

Impressed Current Cathodic Protection System
By an external power supply; Impressed Current Cathodic Protection (ICCP) system

Rectifier

Current

Soil

Current
Tank

Anode

Cathodic Protection Hardware

Contents
Basic Electrical Principles
Equivalent Circuits
Power Sources for Impressed Current Systems
Anodes
Galvanic Anodes
Impressed Current Anodes
Test Points
Transformer Rectifier
Junction Box

Basic Electrical Principles

Ohm's Law
V = IR where V = Voltage (Volts), I = Current (Amps), R = Resistance (ohms)
Electrical Power
P = VI where P = Power (watts), V = Voltage (volts), I = Current (Amps),
R = Resistance (ohms)

Resistivity
p= RA/L where R = resistance (ohms), A = cross-sectional area, L = length
Kirchoff's Law
sum of voltages around a close circuit is zero
sum of currents entering one point in a circuit is equal to the sum of current leaving it

Equivalent Circuits
Equivalent Electrical Circuit of Basic Corrosion Cell

Galvanic Anodes
Pipeline Bracelet Zinc Anodes
PROTECTIVE
COATING REMOVED
BRACELET ZINC ANODE

THERMI
T WELD

BONDING
CABLE

THERMI
T WELD

PROTECTIVE COATING

STEEL CORE

STEEL PIPE

Power Sources for Impressed Current Systems

Types of Power Sources :
Rectifiers
takes AC current and rectifies it to Dc current

Solar cells
convert solar radiation directly to electrical power

Thermoelectric generators
convert heat from a heater system to electricity

Batteries
convert chemical energy to electricity

Anodes
Types of Anodes
galvanic anodes
impressed current anodes

Galvanic Anodes
Typical Environment and Operating Characteristics
Anode
Description

Zinc

Typical
Typical
Environment for
Environment
Cathodic
Resistivity
Protection
(ohm.m)
Application
All water
0.2 to 15

Aluminum

Seawater

0.2 to 4

Magnesium

Potable water

5 to 75

Environment
Resistivity
(ohm.m)

Controlled by
circuit resistance
Controlled by
circuit resistance
Controlled by
circuit resistance

Approximate
Consumption
(kg/A.year)

12
3.5
7

Higher consumption rates may occur at temperatures above 40 o C. Zinc anodes may be unsuitable for use in waters
warmer than 45o C.

Platform Aluminum
Anodes

Galvanic Anodes

Galvanic Anodes
Tank Zinc Anodes

Vessel Zinc Anodes

Test Points
Test Points
a nominated point on a structure for electrical contact
construction ranges from simple electrical termination boxes to galvanized cast steel or
iron boxes on standposts; or proprietary test leads on standposts

Test Points
Installation Location
at regular intervals along buried pipelines
at likely sources or discharge points for stray current
at rail or road crossings, or waterways
at cased crossing
adjacent to insulating joints or at structure termination
close to foreign structures
at connection points for galvanic anodes, or structure cables in impressed current
systems

Test Points

Link
box

Terminal
board

Removable
Link Test
Connectio
n
Test
Post

Ground
level
Anode
Cable

Pipelin
e

Cable connections to
pipeline
Anod
e

Test Points

Transformer Rectifier

Junction Box

Cathodic Protection Operation and Monitoring

Contents
Monitoring Structure Potential
Cathodic Protection Assessment Criteria
Surveys and Audit
Safety
Documentation

Cathodic Protection Operation and Monitoring

Cathodic Protection Monitoring Data
Time
Ambient Conditions

Monitoring Structure Potential

Monitoring Structure Potential

Equipment for Measurement of Structure / Electrolyte Potential
reference cell (copper/copper sulfate, silver/silver chloride, zinc)
voltmeter or recorder or data logger
cables

Monitoring CP Current
Equipment for CP Current Measurement
ammeter or magnetic clamp ammeters
voltmeter or chart recorder or data logger

Monitoring Current
Clamp On Meters

Monitoring Current
Clamp On Meters

Surveys and Audits

Regular Monitoring and Test Data
Data Collected
transformer rectifier (voltage and current) output
potentials at drain points, structure extremities and critical areas (e.g. areas subject to
stray current)
loop resistance to monitor groundbed or anode performance

Surveys and Audits

Potential Testing - When ?
Factors Considered
accessibility of test points
system type
type and location of structure
legislation
interference

Surveys and Audits

Audits
testing on all cathodic protection test point, foreign structure bond and
transformer rectifier or galvanic anode outputs
reevaluation for the structure requirement for CP

Safety
Electrical Hazards
excessive DC voltages at impressed current power supply
excessive voltage gradients in aqueous electrolytes
induced voltages from parallel electric power transmission lines
high voltage transients resulting from lighting strikes

Evolution of Dangerous Gases

hydrogen evolution
chlorine evolution

Documentation
Operating and Maintenance Manual
a description of system and system components
commissioning report
as built drawings
manufacturer documentation
a schedule of all monitoring facilities
protection potential criteria for the system
monitoring schedules and requirements for monitoring equipment
monitoring procedures for each type of monitoring facilities installed
guidelines for safe operation of the CP system

Monitoring and Maintenance Program

Frequency
Sacrificial Anode Cathodic Protection System
six monthly

Impressed Current Cathodic Protection System

weekly
3 monthly

Coatings and Cathodic Protection

Contents
Coating Systems Used

Coating Systems Used

Commonly Used Coating Types :
coal tar and asphalt enamel
wrapping tapes
extruded polyethylene
fusion bonded epoxy
fusion bonded polyethylene
liquid polymeric systems i.e. epoxies and phenolics, coal tar epoxy, polyurethane and
polyesters