Review On Cathodic Protection System Modelling: December 2017
Review On Cathodic Protection System Modelling: December 2017
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Abstract: Cathodic protection is most frequently used technique for protection of underground or underwater metallic infrastructures from
corrosion. Design of the cathodic protection system implies determination of the electric potential and current density distribution on the
electrode surfaces. These values must meet criterions defined by relevant standards. For the calculation of the electrical potential and current
density distribution, different analytical and numerical methods can be used. In this paper, a review of the methods that are used for calculate
of the cathodic protection system parameters is given. Also, due to frequent use, a mathematical model based on the boundary element
method for the calculation of the cathodic protection system parameters is presented in more detail. Presented mathematical model was
used for calculation of the cathodic protection system parameters of one geometry simple example.
Keywords: Cathodic protection system, current density distribution, electric potential, boundary conditions
Sažetak: Katodna zaštita je najčešće korištena tehnika za zaštitu podzemnih i podmorskih metalnih instalacija od korozije. Projektiran-
je sistema katodne zaštite podrazumjeva određivanje raspodjele električnog potencijala i gustoće struje na elektrodnim površinama.
Ove vrijednosti moraju zadovoljiti kriterije definirane relevantnim standardima. Za proračun raspodjele električnog potencijala i gustoće
zaštitne struje, različite analitičke i numerčke metode mogu biti korištene. U ovom radu je dat pregled metoda koje se koriste za proračun
navedenih parametara sistema katodne zaštite. Također, zbog česte upotrebe, detaljnije je predstavljen matematički model baziran na
metodi graničnih elemenata za proračun parametara sistema katodne zaštite. Predstavljeni matematički model je iskorišten za proračun
parametara jednog geometrijski jednostavnog sistema katodne zaštite.
Ključne riječi: Sistem katodne zaštite, raspodjela gustoće zaštitne struje, električni potencijal, granični uslovi
20% of the world's metallurgical production (production are used [14], [16], [17]. To date, a number of analytical
of metal from their ore) is only used to compensate for models and models based on numerical methods used
loss of lost metal in the corrosion process [7]. for calculations when designing and applying cathodic
protection systems have been developed.
Previous research has shown that the greatest percent-
age of damage caused by corrosion can be prevented by
The purpose of cathodic protection system modelling is to
the use of modern protection techniques. The metal can
determine the distribution of electrical potential and pro-
be protected from corrosion by using different methods.
However, technical practice has shown that one of the tection current density on the electrode surfaces as well
most effective methods of protecting metallic structures as at the corresponding points in/on electrolyte (usually at
from corrosion is the application of the cathodic protection the points where the reference electrode is set for the pur-
system in combination with passive protection (insulating pose of verifying the measured values) [7], [14], [16]. The
coatings based on polymers or concrete) [2], [7] – [13]. The calculation of electric potential and current density distri-
cost of installing the cathodic protection system is approx. bution comes down to solving the well-known Laplace
0.1 - 1% of the total investment value of the object being partial differential equation. Also, the correct calculation of
protected. the parameters of the cathodic protection system implies
the definition of the appropriate boundary conditions at
The application of the cathodic protection system to un- the overall boundary of the calculation domain. Bound-
derground metal pipelines results in extending the pro-
ary conditions in the cathodic protection system are
tected object’s life span for 10 to 25 years, depending on
most commonly defined through analytical expressions
the chosen solution of the cathodic protection system [2].
for functional relationships between the protection cur-
Modelling of corrosive processes implies the definition of rent density and the electrical potential on the electrodes
the simplest possible mathematical model with the invari- surfaces [18] – [20]. The establishment of boundary con-
ability of the basic characteristics of the electrochemical ditions on electrode surfaces in cathodic protection sys-
system. Practical engineering calculations can simplify tems is based on the physical and analytical definitions of
the mathematical model, depending on the level of the electrochemical mechanisms of electrode reactions. The
required accuracy of the calculation. In case of complex total anodic and cathodic current density is the result of
geometries of the system, calculation method can be electrochemical reactions, which occur simultaneously on
simplified only in cases of objects with a high degree of the electrodes surfaces. Partial electrochemical reactions
symmetry, which can be adequately modelled as one-di- occurring simultaneously on the electrode surfaces result
mensional or two-dimensional problems [7].
in a nonlinear relationship between the electrical potential
and the current density i.e. nonlinear polarization charac-
The design of the complex geometry objects installed in
different corrosive aggressive environments (electrolytes) teristics as boundary conditions.
results in the introduction of more sophisticated scientif-
ic methods of calculating the parameters of the cathod- 1.1. Analytical models
ic protection system. The development of underground
metal infrastructure increases the need for application of Analytical models used in designing of the cathodic pro-
cathodic protection systems [14]. More intensive applica- tection system can generally be divided into two types.
tion of cathodic protection systems results in the devel- The first type is based on basic principles of electrical engi-
opment of numerical methods for solving the distribution neering [9], [21] - Ohm's law and Kirchhoff's laws. In such
of electric potential and current density of these systems. models, anodes and protected objects are equivalented
by a combination of appropriate DC voltages sources and
Defining the spatial distribution of cathode protection resistors, while electrolytes resistance and resistance of
currents density is a preliminary assumption for the opti- the connecting wires are represented by resistors. These
mal design of electrochemical protection of underground
types of models are very simple for application, since only
metallic structures. The cathodic protection system must
basic laws of electrical engineering are applied. On the
be designed to ensure the highest possible homogenous
distribution of the protection current density on the sur- other hand, this type of models has a number of disad-
face of the protected object [15]. vantages, consisting in the fact that by representing the
electrodes simply by resistors, the current density at all
points on the electrode surface is obtained as a constant.
This is a rough approximation of most real cases of ca-
1. LITERATURE REVIEW ON CATHODIC PROTECTION
MODELLING METHODS thodically protected objects. Also, polarization effects of
the cathodic protection system cannot be taken into ac-
For the purpose of determining the relevant parameters of count with simple elements such as linear resistors. By
the cathodic protection system parameters, mathematical introducing nonlinear (variable) resistors, which represent
models based on calculation of distribution of electrical the polarization resistance of the electrodes, the previous
potential and current density on the electrode surfaces model can be improved [22], [23]. However, the deter-
Volume 11 January/December 2017 83
mination of the value of these nonlinear resistors is only discretization of the entire domain (electrolyte) considered
possible for linearized polarization characteristics, which as a semi-infinite domain and due to a large difference in
make this model unacceptable for modelling realistic ca- the subdomain dimensions (electrolyte as a semi-infinite
thodic protection systems. subdomain and, for example, the pipeline wall thickness).
This results in a large number of finite elements and there-
Second type of analytical models is based on calculat- fore a large number of algebraic equations, and conse-
ing the stationary current field by solving Laplace partial quently requires a long time for calculation.
differential equation (LPD) using analytical methods such
as variable separation, obtaining solutions in the form of 1.2.3. Boundary element method (BEM)
infinite series, superposition method, confident mapping
method, etc. The application of this approach is limited One of the most efficient methods for solving problems
to simpler geometries with high the degree of symmetry in the field of application of cathodic protection systems
such as cathodic protection of the inner wall of the well, is the boundary element method (BEM). The basic ad-
assuming that the working point of the cathodic protec- vantage of this method is that discretization is required
tion system is on the linear part of polarization character- only at the boundary of the domain of interest and there
istics [14], [23]. is no need for discretization of infinite boundaries [30] –
[32]. For the modelling of the cathodic protection system
of underground or underwater metallic installations using
1.2. Numerical models the boundary element method, Laplace's partial differ-
ential equation (LPD), which is valid for the considered
1.2.1. Finite difference method (FDM) domain (electrolyte), is transformed into the integral field
equation that only treats the boundary surfaces [33]. The
In the early seventies of the last century, the finite different discretization of this equation as well as the application of
method was used to solve the problem of the distribu- boundary conditions leads to the formation of the system
tion of electrical potential and the current density of the of algebraic equations that need to be solved. For non-
cathodic protection system [24]. This method requires linear boundary conditions, such as the case of cathod-
discretization of the entire domain of interest with a net- ic protection system modelling, the system of equations
work. Solutions are located in network nodes. Although is nonlinear, and it is necessary to use iterative methods
by using this method results with satisfactory accuracy such as the Newton - Raphson method [3], [34] – [38].
are obtained, it is very rarely used when modelling realistic
cathodic protection systems because of the need for dis- As the most suitable method for calculating the param-
cretization of the entire domain. The disadvantages that eters of the cathodic protection system of underground
have eliminated this method from this field are long time metallic installations, this method has been improved
needed for calculations, especially in the case of complex during the last three decades through hybridization with
underground structures that need to be modelled in 3D other mathematical methods. As such, it has been used
space. Long time needed for calculation is caused by a for specific calculations in the application of the cathodic
large number of nodes required for calculation. protection system. Below are some interesting applica-
tions of these types of methods for specific calculations in
1.2.2. Finite element method (FEM) the application of the cathodic protection system:
The finite element method is one of the most frequently - for the analysis of the impact of the horizontal layered
used numerical methods in science and engineering. It soil on the level of polarization of the protected pipe-
is characterized by robustness, modularity and multidis- lines by the cathodic protection system as well as
ciplinary. In the finite element method, the entire domain the wells. Two approaches based on the boundary
of interest is divided into the volumetric elements of the element method were proposed. The first approach,
finite dimensions. For each finite element, a set of algebra- called the MRBEM (Multi Region Boundary Element
ic equations is written, by solving those yields the distri- Method), where all boundaries between neighbour-
bution of fields within each finite element. Unlike the finite ing soil layers are to be discretized by the network
difference method, the finite element method is algorith- of boundary elements [19], [39], [40] as well as the
mic and relatively simple to program for general equations MLBEM (Multi-Layer Boundary Element Method) in
of electromagnetic fields [14], [16]. As with the modelling which the layered soil is treated by applying the ap-
of most engineering problems, the finite element meth- propriate Green's functions [19], [30], [35], [38], [40],
od has been found to be applied in the field of cathodic [41];
protection systems [25] – [29]. However, this method has
one disadvantage when modelling the cathodic protec- - to determine the optimal anode location and output
tion system of underground pipelines due to the need for current of the cathodic protection systems of under-
84 B&H Electrical Engineering Bosanskohercegovačka elektrotehnika
ground pipeline or the ship’s hull, many authors used surface domains, so it is suitable for calculating distribu-
a hybrid method based on the boundary element tion of electric potential in the electrolyte. On the other
method for the calculation of the distribution of elec- hand, the finite element method is suitable for solving
tric potential and optimization methods such as gra- stationary current field of bounded domains; therefore it can
dient method, Gauss - Newton method, a simulated be applied for the field calculation within the electrodes. The
annealing method [42], a genetic algorithm [43], or potential difference on the electrode/electrolyte interface is
a combination of optimization methods [44], [45] for calculated using the hybrid boundary element/finite element
optimization of location and output current of anode; method, as described in literature [7], [14], [53], [55] – [59].
Although the boundary element method is one of the The distribution of electric potential in electrolyte and on
most frequently used methods for the modelling of the electrode surface of cathodic protection system, under
cathodic protection system, it does not give satisfactory assumption that electrolyte is homogeneous and iso-
results in the case of very long electrode surfaces such as tropic, is defined by the Laplace partial differential (LPD)
long underground pipelines protected by a cathodic pro- equation for the static current field [8]:
tection system. The reason for this lies in the fact that this
method treats the electrode systems as equipotential, i.e.
− ∇(γ ⋅ ∇ϕ ) = 0 (1)
does not take into account the potential drop caused by
the resistance of the material from which the electrodes
where: γ electric conductivity of electrolyte in which ca-
are made. To overcome this problem, hybrid boundary el-
thodic protection system is placed, φ electric potential, a
ement/finite element method is proposed in literature [7],
symbol ∇ is Nabla operator.
[14]. The boundary element method is suitable for solving
stationary current field problem in infinite and semi-sub-
Volume 11 January/December 2017 85
By solving the previous partial differential equations (1), significantly different form in comparison to the remaining
the value of the electric potential at any point within do- two functional relationships. The reason for this lies in the
main of interest can be determined. It is well known that fact that the electrochemical reaction of oxygen reduction
the LPD equation (1) have infinite solutions. Therefore, is concentration controlled and subject to diffusion laws,
to obtain a unique solution, it is necessary to solve the while the remaining two electrochemical reactions are ac-
LPD along with the appropriate boundary conditions. The tively controlled and their functional dependencies can be
boundary that needs to be take into account when mod- described by the Butler-Volmer equation.
elling cathodic protection systems are the anode/elec-
trolyte boundary and cathode/electrolyte boundary [63]. Different electrochemical reactions take place on different
The boundary conditions applied at these boundaries electrodes. For anodic surfaces, it is characteristic that
are called polarization characteristics and they take into an electrochemical reaction occurs simultaneously are
account the electrochemical reactions that take place on anode metal dissolution and oxygen reduction. The total
the electrode (anode and cathode) surfaces. Polarization value of the polarization current density of galvanic anode
characteristics represent functional relationships between surface is defined by following equation [65]:
the current density and the electrical potential of the elec-
trode surfaces [64]. Due to the nature of the electrochem- ϕ −ϕ A
j A = jO2 ⋅ 10 β A − 1
ical reactions, these functional relationships are nonlinear.
The mathematical form of these functional relationships (3)
depends primarily on the number and type of partial elec-
trochemical reactions occurring simultaneously on the where φA is the corrosive potential of the galvanic anode,
electrode surfaces. Partial electrochemical reactions oc- and βA is the Tafel's coefficient (slope) of the galvanic
curring at the same time on the cathode surface are metal anode.
dissolution, oxygen reduction and hydrogen separation.
Therefore, the total value of the polarization current den- Previous equation (3) is suitable for the galvanic anode
sity of the cathode current can be represented by the fol- cathodic protection system modelling. In case of the im-
lowing equation [31], [59]: pressed current cathodic protection system boundary
condition on the impressed current anode surface have
ϕ −ϕ F e (
− ϕ −ϕ H
2
) the following form [14]:
βF e βH2
j c = j 0, F e ⋅ 10 − j lim,O2 − j 0, H 2 ⋅ 10
(2) ϕ − ∆U r −ϕ A
j A = jO2 ⋅ 10 β A − 1
where jc is total current densities for cathode surface, jc,Fe (4)
current density corresponding to the metal dissolution re-
action, jlim,O is the limiting current density of oxygen reduc- where ΔUr is the voltage added by the rectifier.
2
tion jH2 is current density corresponding to the reaction of
hydrogen separation, φ is potential difference of interface
metal/electrolyte φFe, and φH2 are equilibrium potentials of 3. DIRECT BOUNDARY ELEMENT METHOD
corresponding electrochemical reactions and βFe, and βH2
are Tafel's slopes (coefficient) of metal dissolution and hy- The direct boundary element method used for the calcu-
drogen separation, respectively. lation of the electrical potential and current density dis-
tribution is based on solving the integral equation of the
static current field. The integral equation of the static field
From the previous equation (2) it is noticeable that the var-
can be obtained by applying Green’s symmetric identity to
ious electrochemical reactions do not result in the same the Laplace partial differential equation (1). Integral equa-
form of functional relationship between the electric poten- tion of the static current field has the following form [59],
tial and the partial current density. It can be noticed that [66], [67]:
the functional relationship between partial current densi-
ty and electrical potential characteristic for reactions of
the metal dissolution and hydrogen separation have the
c(q )ϕ (q ) + ∫ ϕ ( p ) ⋅ (n ⋅ ∇G ( p, q )) dΓ = ∫ G ( p, q ) ⋅ (n ⋅ ∇ϕ ( p )) dΓ
same form but the opposite sign. The reason is that the Γ Γ (5)
electrochemical reaction of metal dissolution is an anode
reaction and according to the electrochemical convention where q is observation point, p is field source point, c(q) is
there is a positive sign while the electrochemical reaction constant, φ(q) is the electric potential of the observation
of hydrogen separation is a cathode reaction and to the point q, φ(p) is the potential of the field source point p,
electrochemical convention has a negative sign. It is also G(p,q) is the Green’s function, Γ is the boundary of the
noticeable that the functional relationship that represents
domain and n is normal unit vector.
the electrochemical reaction of oxygen reduction in has
86 B&H Electrical Engineering Bosanskohercegovačka elektrotehnika
In order to calculate the normal component of the current integral equations of each element has the same form.
density on the electrode surfaces, the Ohms law needs be After the application of the collocation point method, the
introduced, as follows [54] ,[59], [68]: coordinate transformation from global coordinate system
to the local coordinate system and the Gaussian - Legen-
j( p) dre numerical integration on each boundary element, the
n ⋅ ∇ϕ ( p ) = −
γ (6) current density and the electric potential at the each point
of all the boundary elements can be obtained by solving
where j(p) is normal component of the current density of the following matrix equation [14], [63], [68], [71]:
field source point p.
H cc H ca − 1 ϕ c Gc c Gc a
H j
− 1 ⋅ ϕ a = Ga c Ga a ⋅ c
By incorporating the Ohm's law (6) into the integral equa-
ac H aa
tion of the static current field (5), an integral field equation is j
obtained that is suitable for the calculation of current densi- 0 0 0 ϕ ∞ Ac Aa a
(10)
ty and electrical potential distribution on the electrode sur-
faces of the cathodic protection system, as follows: where [H] and [G] matrix coefficients, {φc, φa, φ∞}T vector
1 of unknown electric potentials of electrode surfaces and
c(q )ϕ (q ) + ∫ ϕ ( p ) ⋅ (n ⋅ ∇G ( p, q )) dΓ = − ∫ G ( p, q ) ⋅ j ( p ) dΓ {jc, ja}T vector of current density. Indexes in the previous
γ
Γ Γ (7) equation c and a denote the cathode and anode surfaces,
respectively.
The previous integral equation of the static current field
(7) is suitable for solving bounded problems such as the
Since the elements of the current density vector are given by
calculation of the current density and electric potential
functional relationships between the current density and the
distribution of the inner wall of the pipeline or tanks. In or-
electrical potential, which are nonlinear, the matrix equation
der to calculate the parameters of the cathodic protection
(10) is nonlinear. Therefore, to solve nonlinear matrix systems
systems of metallic installations that are placed in infinite
it is necessary to use iterative techniques such as Gauss's
and semi-infinite domains, such as soil and sea water, the
method, Gauss - Seidel method or Newton - Raphson
Gaussian boundary condition for infinite boundaries must
method [21,72,73,74]. For the solution of the nonlinear ma-
be satisfied [16], [25], [52], [59], [63], [69], [70]:
trix equation (10), Newton - Raphson 's method was used
in this paper.
∫ j( p ) dΓ = 0 (8)
Γ
3.1. Iterative Newton - Raphson method
This boundary condition can simply be met by imposing a
constant potential at the infinite bound φ∞ which is added The Newton - Raphson's iterative method, proposed in
to the right side of the integral field equation (7). Therefore, the papers [49], [50], [51], [52], was used in this paper to
integral field equation for the modelling the cathodic pro- solve the nonlinear matrix equation (10). The first step of
tection systems placed in infinite and semi-infinite domain the Newton - Raphson's iterative method is the expansion
can be written in the following form [14], [25], [49], [50], of the current density vector into Taylor series. Then the
[53], [54], [59], [68]: current density vector in each iteration can be determined
by applying the following equation:
1
c(q )ϕ (q ) + ϕ ( p ) ⋅ (n ⋅ ∇G ( p, q )) dΓ = −
∫ G ( p , q ) ⋅ j ( p ) dΓ + ϕ ∞
∫
γ (9)
Γ Γ
{ j}n = { j}n−1 + ∂j {∆ϕ}n
∂ϕ n −1
(11)
By introducing a constant potential at the infinite bound-
where n denotes the current iteration, n - 1 previous it-
ary φ∞ in equation (7) provides a conservative flow of cur-
eration, [∂j/∂φ] is Jacobian's matrix and {Δφ} is vector of
rent between anode and cathode surface [16].
electric potential increments between the two adjacent
iterations. The vector of electric potential increments be-
In the procedure of calculating the current density and
tween two adjacent iterations can be calculated by using
electrical potential distribution on the electrode surfaces
the following equation [68,71]:
of the cathodic protection system using a direct boundary
element method, the boundary surfaces must be discret-
ized to a certain number of boundary elements. After the ϕ c ϕ c
discretization of the boundary surfaces, equations (8) and {∆ϕ}n = ϕ a − ϕ a
(9) are solved over each boundary element. Boundary sur- ϕ ϕ
∞ n ∞ n −1
(12)
faces are usually discretized to the boundary elements of
the same geometric shape and thus the solution of the
Volume 11 January/December 2017 87
By adding the equations (11) and (12) in to the matrix tivity of γ = 0.01 S/cm. The system consists of a cylindri-
equation (10), the following matrix equation is obtained cal protected object (cathode) of radius rc = 500 cm and
[49] – [52], [63]: a cylindrical galvanic anode radius ra = 25 cm. Distance
between centres of anode and cathode is d = 625 cm.
Polarization characteristics parameters of anodic and ca-
[H ] − [G ] ∂j ⋅ {∆ϕ } = [G ]{ j} − [H ]{ϕ }
n n −1 n −1 thodic surfaces are given in Table I.
∂ϕ S n −1 (13)
Table I: Parameters of polarization characteristics [14], [31]
From the previous matrix equation (13), a vector of electric Parameter Value
potential increments can be determined between nth and j0Fe 1.0 (µA/cm2)
(n-1)th iterations. Further, by using equations (11) and (12), φFe -700 (mV) vs. CSE
a vector of the current density and the vector of electrical βFe 60 (mV/dec)
potentials of all the boundary elements in the nth iteration
jlimO 1.1 (µA/cm2)
can be determined. The iterative cycle is repeated until 2
jH 1.0 (µA/cm2)
convergence is achieved i.e. until all elements of electric 2
potential increments vector is less than the set value (suf- φH -800 (mV) vs. CSE
2
ficiently close or equal to zero) [49] – [52], [68], [71]. βH 120 (mV/dec)
2
jO 1.0(µA/cm2)
2
In order to start the iterative cycle, it is necessary to guess φa -1100 (mV) vs. CSE
the initial value of electric potential on all points of the βa 60 (mV/dec)
electrode surfaces. Since the performance of Newton -
Raphson's iterative methods depends on the initial guess,
Below are given results of the calculation of the electrical po-
it is necessary to consider the choice of initial point on the
tential and current density distribution on the electrode sur-
polarization characteristics. In this paper the initial value
faces of the analysed cathodic protection system. Due to the
of the electrical potential of all the points on the electrode
existence of symmetry on both analysed electrode surfaces,
surfaces was calculated from the functional relationships
it is sufficient to give the distribution of the electrical potential
defined by equations (2) and (3) under assumption that
and current density in the range 0° to 180°. Figures 2 and 3
there is no current flow in the system.
show the distribution of electrical potential and current densi-
ty on the surface of the protected object (cathodes).
Since matrix [H] and [G] are full matrix, calculation of the
equation (13) can be time consuming. Therefore, to accel-
erate the calculation of equation (13), the GMRES iterative
method was used [68], [71].
4. BENCHMARK EXAMPLE
90°
0° d 0°
180° ra 180°
Anode
270° rc
Electrolyte
270° Cathode
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