1

Cathodic Protection

Idea of Cathodic Protection

Cathodic protection controls corrosion by making the whole

metal surface a cathode of an electrochemical cell

2
 Cathodic Protection
Cathodic Protection Principle

Sea Water
a) Without Cathodic Protection
Fe2+
Steel pipe wall corrodes freely O2 + 2H2O 4OH-

Both anodic & cathodic reactions e - e- Pipe Wall

occur
Pipe Inside

b) With Cathodic Protection

Anodic reaction stops Sea Water

Cathodic reaction continues O2 + 2H2O 4OH-

External Supply of e - e- e - e - e - e- e- e - e - Pipe Wall

Electrons
Pipe Inside

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 Cathodic Protection

Principles of Cathodic Protection

The CP electric circuit Electronic movement in

conductor wire
involves Two halves:
e-
Electronic movement I
Ionic migration External supply of
electrons
The portion of structure
surface that is included
in the CP electric circuit, Icp protective current
( Umbrella ) +ve
i.e. which sees the
umbrella, is ONLY under Ionic migration in
cathodic protection electrolyte

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 Cathodic Protection

Polarization of a Structure

Native
Potentials -.5 -.6 -.65 -.6 -.7 -.58

-.58 -.6 -.65 -.6 -.7 -.58

-.6 -.6 -.65 -.6 -.7 -.6

-.65 -.65 -.65 -.65 -.7 -.65

Corrosion
-.7 -.7 -.7 -.7 -.7 -.7
Mitigated
5
 Cathodic Protection
However, it is recognized that a coating, no matter how good or
how well applied, is never perfect.

Therefore, the corrosion protection afforded by a coating must

be supplemented with cathodic protection in order to achieve
complete mitigation of corrosion.

Coating being the 1st line of defense, whereas CP the 2nd line.

 Fortunately, coatings and CP work very well together.

 The CP current protects the metal ONLY at coating defects:

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 Cathodic Protection

Application of CP Systems

On-Shore

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 Cathodic Protection

Application of CP Systems Off-Shore

Jackets
Piles

Vessels

Subsea Pipelines

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 Cathodic Protection

Types of CP Systems

According to the source of external supply of electrons, there

are two types of CP systems:

1- Sacrificial anode system

2 - Impressed current system

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 Cathodic Protection

Types of CP Systems

 A galvanic cell: is an electrochemical cell in which a

“spontaneous” reaction occurs to produce electricity.

 An electrolytic cell: is an electrochemical cell in which

electricity is used to bring about a chemical reaction that
does not occur spontaneously.

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 Cathodic Protection
1- Sacrificial anode system
Magnesium ACTIVE
Zinc
Aluminum
Iron

Simplified Galvanic
Lead
Tin
Nickel (Active)

Series
Brass
Copper
Nickel (Passive)
410 Stainless
Titanium
304 Stainless
Silver
Gold
Platinum NOBLE
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 Cathodic Protection

 Arrangement of a Sacrificial CP System

Anode e- Fe

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 Cathodic Protection

Common Sacrificial Anodes

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 Cathodic Protection

Common Sacrificial Anodes

Anode Recommended Electrolyte

Magnesium (Mg) Soils & hot water

Zinc (Zn) Soils & fresh / sea water

Aluminum (Al) Sea waters

At temp. > 600 C : Al & Zn oxidize leading to Reverse Polarity

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 Cathodic Protection

Common Sacrificial Anodes

Indium is added to aluminum to avoid

its oxidation up to 900C

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 Cathodic Protection

Generalization :
Aqueous media with low resistivity, All anodes are
preferred, e.g. seawater
Mg anodes are used in higher resistivity aqueous
media, e.g. wetted soils.
Water electric resistivity can be calculated using this
formula :

0.7
Rw = X 1,000,000 ohm.cm
TDS (ppm)

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 Cathodic Protection

Prepackaged Sacrificial Anode

 For soil applications: prepackaged Mg & Zn anodes

 Backfill:

75% GYPSUM
20% BENTONITE
5% SODIUM SULPHATE

 Completely surround the anode with the backfill mixture

within a cotton bag.
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 Cathodic Protection

Prepackaged Sacrificial Anode

For soil applications: prepackaged Mg & Zn anodes

Role of Backfill:
• provides a reduced contact resistance to
earth,

• provides a uniform environment

surrounding the anode,

• retains moisture around the anode so

keeping the anode in wet environment.

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 Cathodic Protection

Main types and shapes of Al & Zn anodes:

Bracelet

Segmented Bracelet

Segmented Bracelet Sacrificial Anode

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 Cathodic Protection

Main types and shapes of Al & Zn anodes:

Bracelet
Half-Shell Bracelet

Welded Tapered Bolted

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 Cathodic Protection

Main types and shapes of Al & Zn anodes:

Spherical

Recommended for internal protection of tanks and vessels

whose stream is rich in sludge, sand, asphaltenes, etc.

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 Cathodic Protection

Ribbon Anodes ( Zinc / Magnesium )

Soil Surface
Extruded Zinc Anodes

Trench
Pipeline

Connection
Mg Between Pipeline
and Zn Ribbons
Every 300 m
Zn Ribbons
approx.
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 Cathodic Protection

Applications of sacrificial cathodic protection system:

 Buried / sub sea pipelines

 Buried piping

 Platforms & rigs

 Marine piles

 Tank internals

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 Cathodic Protection

Sacrificial anodes for

underground piping

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 Cathodic Protection

Sacrificial Anodes for

Platform Jackets

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Cathodic Protection

Bracelet anode FLUSH with

concrete coating
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 Cathodic Protection

Tan
Sacrificial Anode Cathodic k
Protection for External Side
of Tank Bottom
Sacrificial
Anode +
Backfill
CP
Curren
t
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 Cathodic Protection

Typical CP of a buried
pipeline with prepackaged
sacrificial anodes

Junction
Box 1.5m min

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 Cathodic Protection

Sacrificial anodes for vessel internals

Mist Eliminator

Sacrificial Anode
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 Cathodic Protection

Sacrificial anodes for tank internals

Coal Tar onto Anode surface

facing Tank’s shell 30
 Cathodic Protection

Sacrificial Anodes for Ship Hulls

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 Cathodic Protection

Galvanization ……hot-dip galvanizing

Galvanizing - the act of coating steel with zinc.

 The article is immersed in a bath of

molten zinc at between 435-455 0C.

 During galvanizing, the zinc

metallurgically bonds to the steel,
creating a series of highly abrasion-
resistant zinc-iron alloy layers,
commonly topped by a layer of
impact-resistant pure zinc.

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 Cathodic Protection

2- Impressed current system

DC source

Ground bed
I

Drain Point

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 Cathodic Protection

Basics of Impressed current system

Steel nails fixed to The steel nails immersed Results:

dry battery terminals in saline water 1- The nail at +ve
terminal Corrodes
2- The nail at –ve
terminal remains
Uncorroded
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 Cathodic Protection

e-
I

Drain Point

Drain Point:
Location of negative cable connection to the structure to be protected.
It is the ENTRY POINT of electrons, or the Current drain.
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 Cathodic Protection

Transformer Rectifier (T/R)

(+) (+)

0V 0V

(-) (-)

Alternating Current Direct Current

Input Output

Rectifier

Transformer
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 Cathodic Protection

Transformer Rectifiers (T/R)

• AC input
Voltage, Single/ three phase, Frequency

• DC maximum output Amp, Volt

• Air Cooled: with Sun-shade

Oil Cooled: with Thermometer &
Level indicator

• Location: according to area classification

• Explosion proof (hazardous area)
• Non-explosion proof (non-hazardous area)
 Cathodic Protection

Transformer Rectifiers

T/R on a Concrete Slab

T/R with sun-shade
Explosion-proof
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 Cathodic Protection
Fe - Si Anodes

 Are the most common impressed current anodes

 Are used in soil, water or sea water

 Come in two grades; FeSi and FeSiCr for sea water applications

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 Cathodic Protection
Fe - Si Anodes
 Cable connection to anode shall be handled with great care.
 Anode Caps seal and protect the critical connection between the lead wire
and anode.
 The tight fitting, heat-shrinkable anode cap provides moisture proofs and
electrically insulates the end of the anode at
the lead wire exit point.

Heat-
shrinkable
anode cap

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Reduces instances of stray current interference
due to
Cathodic Protection
proximity of anodes to foreign structures

Non Consumable Impressed Current Anodes:

This type of anodes supports other anodic reactions
on their surfaces.

In environments where water and chloride ions are

present, chlorine evolution or oxidation of water are
possible.
 Anodic reaction in sea water (Chlorine evolution)
-
2Cl- Cl2 (gas) + 2e
 Anodic reaction in fresh water (Water oxidation)

-
H2O O2 + 4H+ + 4e 2
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 Cathodic Protection
Non Consumable Impressed Current Anodes:

Example
Due to the high currents involved in many
seawater systems it is not uncommon to
use impressed current systems.
Impressed current systems use anodes of
a type that are not easily dissolved into
metallic ions, but rather sustain an
alternative anodic reaction, oxidization of -
the dissolved chloride ions. Non Consumable
-
2Cl- Cl2 (gas) + 2e

While the cathodic reaction is the reduction -

of dissolved oxygen

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 Cathodic Protection

Non Consumable Impressed Current Anodes:

Mixed Metal Oxide (MMO) Anodes

• MMO is an electrically conductive coating

that is applied onto a Titanium substrate.
• MMO coating activates the titanium and
enables it to function as an anode.
• The coating has an extremely low
consumption rate (milligrams per year).
As a result, the metal dimensions remain
nearly constant during the design life of
the anode.
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 Cathodic Protection

Non Consumable Impressed Current Anodes:

Mixed Metal Oxide (MMO) Anodes

Titanium
Copper Core

MMO Coating Rods

MMO coated anodes have excellent chemical stability,

consequently do not contaminate the electrolyte. 44
 Cathodic Protection

Non Consumable Impressed Current Anodes:

Titanium Anodes

45
 Cathodic Protection
Non Consumable Impressed Current Anodes:

)-(
T/R
Anodefle
x )+(

Linear Anode

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 Cathodic Protection
Non Consumable Impressed Current Anodes:

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 Cathodic Protection
Non Consumable Impressed current anodes:

Platinized Anodes

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 Cathodic Protection
Non Consumable Impressed current anodes:

Graphite Anodes

Disadvantages:

• Low operating current densities

• Inferior mechanical strength, highly brittle

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Definition of Groundbed:Cathodic Protection
One or more anodes installed below the earth's surface for the
purpose of supplying cathodic protection.
Types of ground beds:

• Deep-well GB
• Horizontal shallow GB
• Distributed (Close) Anodes
 SHALLOW GROUNDBED
One or more anodes installed either vertically or horizontally at a
nominal depth of less than 15 m (50 ft) for the purpose of supplying
cathodic protection.

 DEEP-WELL GROUNDBED
One or more anodes installed vertically at a nominal depth of 15 m (50
ft) or more below the earth's surface in a drilled hole for the purpose of
supplying cathodic protection.
 Cathodic Protection
 Groundbed Location should be determined early in the
design stage because its location may affect the choice
of groundbed type.

 The following factors should be considered when

choosing a groundbed location:

• Soil Resistivity
• Soil Moisture
• Interference with other Structures
• Availability of Power Supply
• Accessibility: accessible to construction vehicles for
groundbed installation, testing, and repairs.
• Vandalism or other Damage
• Availability of Right of Way (ROW)
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 Cathodic Protection

Deep-well GB:
For high resistivity soils

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 Cathodic Protection
Deep-well ground beds
Gas Vent Tube

 This is a common problem in deep

groundbeds and in tightly packed soils.

 It occurs because gas (e.g., oxygen or

chlorine) generated by the anodic reaction
cannot permeate away from the anode.

 The gas increases the anode to earth

resistance, thus reducing the rectifier
current output.

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 Cathodic Protection
Deep-well ground beds
Gas Vent Tube

 Vent tube has openings (SLOTS) placed in a

strategic pattern to allow 360º venting ability
without a loss of pipe strength.

 Vertical / circumferential slits placed with precision

cutting wire. With proper installation, the tube will
vent throughout the life of the deep groundbed.

 In addition to venting, the vent tube can also be

utilized as a watering system for injecting water
should the groundbed require it in case of drying
out.

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 Cathodic Protection

Horizontal Shallow Groundbed

 Depth: 3-5 m
 Application: low resistivity soils
 To be equipped with vent tube

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 Cathodic Protection
Carbonaceous Backfill
“conductive backfill”

The carbonaceous backfill

improves anode performance
because it provides an
electronic path for current flow.

Therefore,

Resistivity, Particle Size, and Specific Gravity (or

Bulk Density) are important backfill properties.

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 Cathodic Protection
Carbonaceous Backfill

57
 Cathodic Protection
Typical Properties of Carbonaceous Backfill

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 Cathodic Protection

Typical Impressed Current System Arrangement

Ground Bed
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 Cathodic Protection

Cathodic Protection Criteria

Pourbaix diagram showing the theoretical

Schematic showing pipe-to-
conditions of iron in water and dilute
soil potential measurement
aqueous solutions.
 Cathodic Protection
Fe-to-Soil Potential in
Potential vs Description
Low Resistivity Soils
Cu/CuSO4
showing the degree of mV
corrosion Intense Corrosion
500-
600- Free Corrosion
700- Some Protection
800- Zone
Zoneof
ofCathodic
Cathodic
Protection
Protection
The value – 850 mV 900- Some Over-Protection
is the CP criterion for 1000- Increased Over-Protection
protecting steel in
aggressive soils, i.e. Sever
SeverOver-Protection
1100-
Over-Protection
the steel structure Problems
acts as a CATHODE 1200- Problems
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 Cathodic Protection

Cathodic Protection Criteria

V vs. CSE

Time

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 Cathodic Protection

Potential criteria for cathodic protection of some

metals and alloys at 25º C

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Temperature effects the potential of the
reference

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 Cathodic Protection
Cathodic protection monitoring

Potential Measurement

Structure/Soil (Electrolyte) Potential is measure by means of a

reference electrode :

Copper / Copper Sulfate ……. Soil

Silver / Silver Chloride ……. Sea Water

Environment Criteria Reference electrode

Soil )V( 0.85 - Copper/copper

sulphate
Sea water )V( 0.80 - Silver/silver chloride 65
 Cathodic Protection
Copper / Copper Sulfate
reference electrode Portable
Type

Pointed tip

Flat tip
 In order to measure the structure – to – soil potential, the CSE must
become part of the soil
 This is fulfilled by inter-mixing of the CSE content with the soil
content due to diffusion down a concentration gradient
 Cathodic Protection

 Mixing of the RE content with the soil water, makes the RE part of the soil.
 Hence, the measured potential is the pipe potential with respect to the soil.
Cathodic Protection
 Cathodic Protection
Typical Arrangement for Pipe – to – Soil Measurement

CSE

Icp umbrella

Icp umbrella
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 Cathodic Protection

Soil Resistivity vs Recommended CP System

Mean Soil Resistivity

Possible Method of Protection Rating of Soil
(Ohm.cm)
CP not necessary with uniform soils not corrosive 25,000 - 100,000
CP may become necessary: impressed
hardly corrosive 10,000 - 25,000
current
impressed current slightly corrosive 5,000 - 10,000
moderately
Mg-anodes / impressed current 2,000 - 5,000
corrosive
Mg-anodes / impressed current highly corrosive 1,000 - 2,000
very highly
impressed current / Mg & Zn anodes under 1,000
corrosive

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 Cathodic Protection
Basic Cathodic Protection Calculations
CP Current Requirement

CD= i x A x CBDF

CD : Current Demand (A)

i : Design Current Density (A/m2)
A : Surface Area (m2)
CBDF : Coating Break-down Factor %
Current Rating : (1.5 times final CD)

Temperature (°C) 50 Initial Average Final

2
Current Density (mA/m ) 5 CBDF (%) 0.01 2 3
2
Design Density (mA/m ) 7.5 Current Demad (A) 0.0 5.7 8.6
Pipeline Length (km) 30
Pipeline Diameter (inch) 16 Current Rating (A) 13
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 Cathodic Protection

CP Current density with respect to different environment.

Environment Current density (mA/m2)

Soil (50 – 500 Ω.cm) 20 – 40

Soil (500 – 1500 Ω.cm) 10 – 20
Soil (1500 – 5000 Ω.cm) 5 – 10
Soil (over 5000 Ω.cm) 5
Fresh water 10 – 30
Moving fresh water 30 – 65
Brackish water 50 – 100
Sea-mud zone 20 – 30 72
 Cathodic Protection
Typical Coating Breakdown Values

Coating type breakdown %

Initial Mean Final
Thick coating 1≤ 5 10

Epoxy coal tar 2≤ 5-10 10-20

Fusion bonded epoxy 1-2 5-10 5-20

Polypropylene (25 yrs) 0.5 2 5

Polyethylene (25 yrs) 0.5 1 3

Coating quality and electrical leakage resistance can

73
reduce the current demand to a large extend
 Cathodic Protection

Anodes Weight & Quantity Requirement

# of Anodes Required

Wt = Weight per anode (kg) Wt = 27.2 kg

CR = Consumption rate (kg/amp-year) CR = 0.34 kg/A-yr
DL = Desired life (years) DL = 20 yrs
Current = Current required (amps) Current = 5.70 A
UF = Utilization factor UF = 0.60
# anodes = 3.00
# of Anodes Required Based on Current Discharge

* from anode manufacturer data

MD = Maximum discharge per anode (amps) MD = 1.50 A
Current = Current required (amps) Current = 5.70 A
# anodes = 4.00

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Basis of Design Plan Sheet Data for Cathodic Protection

75
Design Criteria List for Cathodic Protection (Example)

76
Design Process for Cathodic Protection

77
retrofitted
Cathodic Protection Analysis for Existing Water Tank

78
79
80
Cathodic Protection Analysis for Existing Pipeline

81
Cathodic Protection Analysis for Existing Pipeline

82
Advantages and Disadvantages of Deep Anode
Ground beds

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 Specification and Drawing Development
 Rectifier Sizing
• Transformer rectifiers are sized based on the amount of
protective current necessary to protect the structure and
the resistance of the cathodic protection circuit.
• The following are steps for sizing the transformer rectifier:
 Determine protective current required

 Calculate soil resistivity at the depth of anode installation

84
 Rectifier Sizing
 Calculate anode to earth resistance using Dwight's
Equation for single vertical anode resistance to earth:

 Where:
• ρ = Anode groundbed resistivity, ohm-cm
• L = Anode length, ft
• d = Diameter of anode, ft
• RGB = Resistance of single vertical rod (anode) to earth

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 Rectifier Sizing
 Calculate resistance of remaining components within the
cathodic protection circuit:
a. Positive and negative header cable resistances, RHC
b. Anode lead wire resistances, RLW
c. Structure to earth resistance, RSE
d. Resistance of all connections (generally approximated
as 10% of items described in a, b, and c), RCON
 Total circuit resistance (RT) is equal to the summation of
all resistances:

86
 Rectifier Sizing
6. Once circuit resistance is known, calculate voltage
requirements in accordance with Ohm’s law:

7. Use the measured current requirement and calculated

voltage requirement to properly size the rectifier.
8. The input power requirements of a transformer
rectifier depend on what is available at its location.
The rectifier can be specified for a variety of input AC
voltages (120V, 208V, 240V, and 460V) and can be either
1- or 3-phase.
87
 STRUCTURE-TO-ELECTROLYTE TESTING
 Question No. 1
 Most Navy and Air Force Manuals and other literature show a test
setup with the meter positive lead connected to the reference cell
and the negative lead to the pipeline (or other structure).
 (a) When I setup the equipment as shown in the manuals, the
meter displays a positive reading, yet the criteria calls for a reading
more negative than -0.85 Volts (-850 millivolts). Is something
wrong with the CP system?
 (b) I notice that the contractor connects the meter opposite to that
shown in the manuals (negative to the reference cell and positive to
the structure), or sets it up one way this time and the other way
another time. Is there something wrong with this setup?
88
Answer:
In most DC electrical measurement circuits, the meter negative lead is connected to a reference
point such as a power supply negative or equipment ground. CP testing is no different, and the
reference point, which is the reference cell, should normally be connected to the meter negative
lead. However, most manuals show the reference cell connected to the meter positive lead and
this is explained by going back in time to the days before digital meters and analog meters with
polarity switches. Most old analog meters (d'Arsonval meters with the needle pointer) had only a
positive scale (0 to +XXXX Volts), and Structure-to-electrolyte (S/E) potentials are normally
negative. Therefore, in order to read negative S/E readings, the positive and negative
connections to the meter had to be switched (positive lead connected to the reference cell,
negative lead to the structure), and the test reading read as a positive number, but recorded as
a negative number. This has been the method generally followed to this day, and can be very
confusing to someone not experienced in conducting these tests.
Modern digital meters and analog meters with the polarity switch set to negative will allow
reading negative numbers even though the reference cell is connected to the negative lead. The
industry is now starting to move more toward this test setup.

89
Zinc to Copper Sulfate Reference Cell Conversion Chart

90
Impressed current cathodic protection system for
submersible downhole pumping assembly

91
Impressed current cathodic protection system
for submersible downhole pumping assembly

92
If an earthing system is required, it shall be made compatible with the
cathodic protection system.
When allowed by regulations, this may be achieved by installing suitably
rated d.c. decoupling devices in the earthing circuit. Local earthing
using zinc or galvanized earth electrodes directly connected to the
pipeline may be used, but there can still be future adverse effects on
the cathodic protection.
These adverse effects on cathodic protection effectiveness are due to
one or both of the following:
— the resistance of local earth, with respect to remote earth, can be
much lower than the resistance of coating defects, which results in
reduced CP current at the coating defect;
— zinc or galvanized steel potential can drift with time towards less
negative potentials.
93