Cathodic protection
History of CP
• First Cathodic protection was used by Sir.
Humphrey Davy for Copper Cladding of
ship Man of War, Samarang
• Described by Sir Davy as an obscure
branch of Electrochemistry, CP still
remains difficult to understand / analyze
by analytical models.
Preambles
• Design: Tailor Made with reference to
construction , environment etc.
• Monitor, Maintain and upgrade safe,
reliable and effective protection
continuously throughout the design life
• Experience: reliable basis for future design
/ Engg and operation.
Corrosion
Corrosion is defined as the degradation of a
metallic materials because of an electrochemical
reaction between the metallic materials and its
environment.
In Nature, Metals exist as ores, Which may
be oxides, carbonates or Sulphides and metals
have natural tendency to revert to its original
“ore” state.
Basic Corrosion Cell
• Consider two iron (Fe) electrodes suspended in
dilute solution of common salt. The electrode
that is polarized positive is the anode and the
electrode that is polarized negative is the
cathode.
At the anode, the metal gets oxidized
Fe –> Fe++ + 2e-
At the cathode, oxygen will be reduced to form
negative ions.
½ O2 + H2O+ 2e- -> 2(OH)-
Galvanic Corrosion Cell
• To understand the working of a galvanic
cell, it is important to take a look at the
electrochemical series.
• The electrochemical series is a tabulation
of various elements and is indicative of the
extent of their electrochemical activity.
Electrochemical Series
• Mg - 2.38 V
• Al -1.67 V
• Zn -0.76 V
• Fe -0.44 V
• Ni -0.23 V
• Pb -0.13 V
• H 0.00
• Cu 0.35 V
• Ag 0.80 V
• Au 0.80V
Galvanic Series in sea water
Base end
• Magnesium
• Zinc
• Aluminium
• Steel
• Cast iron
• Lead
• Brass
• Copper
• Silver
• Gold
Noble end
Old steel in contact with new
steel
-0.4V -0.65V -0.35V
+V- +V- +V-
Old pipe New pipe Old pipe
Cathodic Area Anodic Area Cathodic Area
Corrosion cell due to different
soils
A C A C A C A
TYPES OF CP SYSTEM
• GALVENIC (Sacrificial) ANODE
SYSTEM
• IMPRESSED CURRENT SYSTEM
Sacrificial CP System
Current
Sacrificial Anode Pipeline
Advantages of Galvanic anode systems
• Low susceptibility to damage by outside
influences
• Low maintenance costs throughout the design life
• Do no require an outside source of energy such
as commercial power
• Fewer system components
• Well suited to the protection of electrically
isolated/segmented structures (such as
mechanically joined pipe sections) in which each
component is provided with its own galvanic
anode
• Low potential operation-seldom produces
significant corrosive interference (stray current)
on other structures.
Limitations of Galvanic
anode systems
• Electrical potential available is limited
• Subject to seasonal variations affecting
operation
• In acid environment, the anode materials are
directly attacked by the acid and the life and
efficiency are extremely low.
• Maximum services life is dependent on the
quantity of anode material
• Chemistry of the electrolyte (soil) and
temperature may have and undesirable
effect on the anode half cell potential
Impressed Current CP
System
+ DC Power -
Source
Current
Impressed current Anode Pipeline
Criteria for protection.
To verify the efficacy of a CP system for
buried steel structure.
It has to meet one or more criteria as set out
in NACE-RP 01-69.
• A cathodic potential of at least 850mv with
the CP applied.
• A negative polarized potential of at least
850mv relative to a CSE.
• A minimum of 100mv of cathodic
polarization between the structure surface
and a stable reference electrode.
Advantages of Impressed
Current Systems
• The electrical potential available through
the power supply can be fully adjustable
from very low values to quite high values
• The power is limited only by the source
• A wide variety of materials are available for
impressed current anodes
• Many impressed current anode materials
have very low consumption rates and can
provide high output with limited size
• Electronic methods of control and
monitoring are possible.
Limitations of Impressed
Current Systems
• Impressed Current Systems require
an outside source of energy
• Regular maintenance is essential
• Operation of the anode at relatively
high potentials may cause
interference current on other
structures.
GALVANIC CP IS APPLIED
FOR
• WELL COATED PIPELINE
• SHORT PIPELINE
• STROAGE TANK
• HOT SPOTS
FACTORS AFFECTING
DESIGN
• NATURE OF ENVIRONMENT
• NATURE OF COATING
• POLARISATION LEVEL
• LINEAR ELECTRICAL RESISTANCE
• EXTENT OF NEIGHBOURING
STRUCTURE
• AVAILABIILITY OF POWER
• STRAY CURRENTS
Steps in designing CP
installation Sacrificial
System
1. Establish soil resistivity
2. Estimate current requirement
3. Electrical continuity of structure
4. Consider requirement for electrical isolation
5. Select suitable Anode material
6. Calculate total mass of metal for required life
7. Select individual anode shape to satisfy current
requirement
8. Check the total anode weight determine by (6)
satisfy requirement of (7)
9. Consider facilities for monitoring performance
10. Proper project drawing & specifications
Steps in designing CP
installation Impressed
1. Current
Establish soil resistivity
2. Estimates total current requirement
3. Establish electrical continuity of structure
4. Consider requirement for electrical isolation
5. Consider the no. & disposition of anode/ground bed
6. Select suitable anode material
7. Calculate Anode/ground bed size, shape, configrn
8. Calculate circuit resistance & system DC Volts
9. Design the DC wiring system for the most economical cable
size & total IR drop in the circuit.
10. Select rectifier voltage & current output
11. Design electrical circuit, fittings & switchgear
12. Select location of CP test stations
13. Consider facilities required for control monitoring
14. Proper project drawing & specifications
ADVANTAGES OF GOOD
COATING FOR CP
• REQUIRED LOW CURRENT DENSITY
• LOW POWER CONSUMPTION
• LOW WEAR OF ANODES
• LARGER SPACING BETWEEN CP
STATION
• INTERFERENCE PROBLEMS ARE
MINIMISED
Coating & Cathodic
Protection
Total Cost
Cost
Coating
Cathodic
Protection
0% 100 %
CURRENT REQUIREMENTS FOR STEEL
ENVIRONMENT CURRENT DENSITY IN
mA/m2
WELL-AERATED NEUTRAL SOIL 21.5 – 32.3
DRY, WELL-AERATED SOIL 5.4 – 16.1
WET, SOIL, MODERATE/SEVERE 26.9 – 64.6
CONDITIONS
HIGHLY ACID SOIL 53.8 – 161.4
STATIONARY FRESH WATER 53.8
MOVING FRESH WATER 53.8 – 64.6
WELL COATED PIPELINE IN 0.01
SOILS
Protective current
requirement
2Io = 2 D J L
Io = Protective current from one side of the CP Station
D = Diameter of the pipeline (m).
J = Protective current density (A/m2).
L = One side Spread of protection (m)
Pipeline Spread of
protection
8 UL
2L =
D J R'
L = Spread of protection in m
UL = Potential difference between drain point & at
end (x = L).
D = Diameter of the pipeline (m).
J = Protective current density (A/m2).
R' = Resistance of the pipe (ohm/m).
Choice of Sacrificial Anodes for
Earth Application
Anode Anode Anode Kg/A -
material corrosion potential year
potential mV difference
mV (anode –
850 mV)
Zinc -1100 -250 12
Magnesiu - 1600 -750 8
m
CALCULATION OF ANODE LIFE
A Galvanic Anode useful life can be calculated when the
following parameters are known:
• Anode output current I (A)
• Anode weight m (kg)
• Efficiency E (%)
• Capacity C (Ah/kg)
The lifetime L in hours can be calculated from
E.C.m
L= ------------ (hours)
I
CP HEALTH MONITORING SURVEY
• EFFECTIVENESS OF CP SYSTYEM
Close Interval Potential Survey
• CORROSION PROTECTIVE COATING
Pearson Survey
CAT Survey
DCVG Survey
Recommendations
• GOVT OF INDIA (MOP&NG – OISD)
CPL survey once in 5 year or
whenever inadequate CP is observed
which ever is earlier.
Pearson survey , DCVG survey, CAT
survey to elaborate the coating defects
as and when required.
Continuous Potential Logging (CPL)
• Pipe to soil potential is only criteria
used for determination of corrosion
activities/condition & effectiveness of
corrosion protective coating &
cathodic protection
• CPL survey is an essential survey.
PEARSON SURVEY
To find out
• the location & depth of pipeline.
• Exact locations of coating defects.
• Location of electric contacts.
Current attenuation test (CAT) survey
To find out
• To find out the location & depth of
pipeline.
• Exact locations of coating defects.
This is a user friendly & modernized
version of Pearson Survey
Direct current voltage Gradient
DCVG survey
To find out
• the location of Electric contacts.
may be by exp. Operator.
• locations of coating defects.
THANK
YOU
