Cathodic Protection Guide

Cathodic Protection Guide
Cathodic
Contents
Protection
Introduction
1
History
1
The Principles of Cathodic Protection
page
1
Sacrificial anodes
2
Impressed current
2
Advantages and Uses of Cathodic Protection
2
Pipelines
Storage tanks
Steel pilings
Reinforced concrete
Ships
Offshore structures
This is an update of a DTI publication first issued in 1981. The
new version has been prepared by Eur Ing R. L. Kean of ARK
Corrosion Services and Mr K. G. Davies, Corrosion Engineer,
under contract from NPL for the Department of Trade and
Industry.
Basic Requirements for Cathodic Protection
3
Design Factors
4
Monitoring and Maintenance
6
Sources of advice
7
Further Information
7
Cathodic Protection
Corrosion is an electro-chemical process that involves the
1.0 Introduction
passage of electrical currents on a micro or macro scale. The
This Guide describes the basic principles of cathodic protection,
change from the metallic to the combined form occurs by an
the areas of use, and the general factors to be considered in the
“anodic” reaction:
choice and design of a system. It gives a basic introduction and
→
simple technical data on cathodic protection. Further assistance
M
and information may be gained from organisations listed in
(metal)
M
+
e-
+
(soluble salt)
(electron)
A common example is:
Section 10, various independent or commercial consultants, and
++
→
Fe
product suppliers.
2e-
+
Fe
This reaction produces free electrons, which pass within the
metal to another site on the metal surface (the cathode), where
2.0 History
it is consumed by the cathodic reaction. In acid solutions the
The first reported practical use of cathodic protection is
cathodic reaction is:
generally credited to Sir Humphrey Davy in the 1820s. Davy’s
+
2e-
+
2H
(hydrogen ions
in solution)
advice was sought by the Royal Navy in investigating the
corrosion of copper sheeting used for cladding the hulls of naval
vessels. Davy found that he could preserve copper in seawater
→
H2
(gas)
In neutral solutions the cathodic reaction involves the
by the attachment of small quantities of iron, zinc or tin. The
consumption of oxygen dissolved in the solution:
copper became, as Davy put it, “cathodically protected”. It was
O2
quickly abandoned because by protecting the copper its antifouling properties became retarded, hence reducing the
+
2H2O
+
4e-
4OH(alkali)
→
Corrosion thus occurs at the anode but not at the cathode
streamline of the ships, as they began to collect marine growths.
(unless the metal of the cathode is attacked by alkali).
The most rapid development of cathodic-protection was made in
the United States of America and by 1945, the method was well
established to meet the requirements of the rapidly expanding
2M → 2M
oil and natural gas industry, which wanted to benefit from the
++
+ 4e
-
-
O2 + 2H2O + 4e → 4OH
-
(corrosion)
advantages of using thin-walled steel pipes for underground
transmission.
-
Electron (e ) flow in metal
In the United Kingdom, where low-pressure, thicker-walled castiron pipes were used extensively, very little cathodic protection
was applied until the early 1950s. The increasing use of
Figure 1. Corrosion cell / Bimetallic corrosion
cathodic protection in modern times has arisen, in part, from the
initial success of the method as used from 1952 onwards to
protect about 1000 miles of wartime fuel-line network. The
The anode and cathode in a corrosion process may be on two
method is now well established and is used on a wide variety of
different metals connected together forming a bimetallic couple,
immersed and buried facilities and infrastructure, as well as
or, as with rusting of steel, they may be close together on the
reinforced concrete structures, to provide corrosion control.
same metal surface.
This corrosion process is initially caused by:
Differerence in natural potential in galvanic (bimetallic) couples.
3.0 The Principles of Cathodic Protection
Metallurgical variations in the state of the metal at different
Metal that has been extracted from its primary ore (metal oxides
points on the surface.
or other free radicals) has a natural tendency to revert to that
Local differences in the environment, such as variations in the
state under the action of oxygen and water. This action is called
supply of oxygen at the surface (oxygen rich areas become the
corrosion and the most common example is the rusting of steel.
cathode and oxygen depleted areas become the anode).
1
1
Cathodic Protection
4.0 Advantages and Uses of Cathodic
The principle of cathodic protection is in connecting an external
Protection
anode to the metal to be protected and the passing of an
The main advantage of cathodic protection over other forms of
electrical dc current so that all areas of the metal surface
anti-corrosion treatment is that it is applied simply by
become cathodic and therefore do not corrode. The external
maintaining a dc circuit and its effectiveness may be monitored
anode may be a galvanic anode, where the current is a result of
continuously. Cathodic protection is commonly applied to a
the potential difference between the two metals, or it may be an
coated structure to provide corrosion control to areas where the
impressed current anode, where the current is impressed from
coating may be damaged. It may be applied to existing
an external dc power source. In electro-chemical terms, the
structures to prolong their life.
electrical potential between the metal and the electrolyte
solution with which it is in contact is made more negative, by the
Specifying the use of cathodic protection initially will avoid the
supply of negative charged electrons, to a value at which the
need to provide a “corrosion allowance” to thin sections of
corroding (anodic) reactions are stifled and only cathodic
structures that may be costly to fabricate. It may be used to
reactions can take place. In the discussion that follows it is
afford security where even a small leak cannot be tolerated for
assumed that the metal to be protected is carbon steel, which is
reasons of safety or environment. Cathodic protection can, in
the most common material used in construction. The cathodic
principle, be applied to any metallic structure in contact with a
protection of reinforcing carbon steel in reinforced concrete
bulk electrolyte (including concrete). In practice, its main use is
structures can be applied in a similar manner.
to protect steel structures buried in soil or immersed in water. It
cannot be used to prevent atmospheric corrosion on metals.
Cathodic protection can be achieved in two ways:
However, it can be used to protect atmospherically exposed
- by the use of galvanic (sacrificial) anodes, or
and buried reinforced concrete from corrosion, as the concrete
- by “impressed” current.
itself contains sufficient moisture to act as the electrolyte.
Galvanic anode systems employ reactive metals as auxiliary
Structures that are commonly protected by cathodic protection
anodes that are directly electrically connected to the steel to be
are the exterior surfaces of:
protected. The difference in natural potentials between the
Pipelines
anode and the steel, as indicated by their relative positions in
Ships’ hulls
the electro-chemical series, causes a positive current to flow in
Storage tank bases
the electrolyte, from the anode to the steel. Thus, the whole
Jetties and harbour structures
surface of the steel becomes more negatively charged and
Steel sheet, tubular and foundation pilings
becomes the cathode. The metals commonly used, as
Offshore platforms, floating and sub sea structures
sacrificial anodes are aluminium, zinc and magnesium. These
metals are alloyed to improve the long-term performance and
Cathodic protection is also used to protect the internal surfaces
dissolution characteristics.
of:
Large diameter pipelines
Impressed-current systems employ inert (zero or low
Ship’s tanks (product and ballast)
dissolution) anodes and use an external source of dc power
Storage tanks (oil and water)
(rectified ac) to impress a current from an external anode onto
Water-circulating systems.
the cathode surface.
However, since an internal anode will seldom spread the
protection for a distance of more than two to five pipe-
The connections are similar for the application of cathodic
diameters, the method is not usually practical, or suitable, for
protection to metallic storage tanks, jetties, offshore structures
the protection of small-bore pipework.
and reinforced concrete structures.
2
2
Cathodic Protection
a) Electrical continuity. The resistance of the conductor and
Cathodic protection is applied to control the corrosion of steel
embedded in reinforced concrete structures (bridges, buildings,
structure should be such as to minimise the potential drop
port and harbour structures, etc.) – See Guide in Corrosion
of the return protective currents through the structure.
Control, Corrosion and Protection of Steel in Concrete and it’s
b) Coatings. The provision of a protective/insulating coating
Monitoring.
Cathodic protection can be applied to copper-based alloys in
to the structure will greatly reduce the current demanded
water systems, and, exceptionally, to lead-sheathed cables and
for cathodic protection of the metallic surface. The use of a
to aluminium alloys, where cathodic potentials have to be very
well-applied and suitable coating, increases the effective
carefully controlled.
spread of cathodic protection current. A combination of
applying both a coating and cathodic protection will
normally result in the most practical and economic overall
5.0 Basic Requirements for
Cathodic Protection
protection system. Ideal coatings are those that have a
high electrical resistance, are continuous and will adhere
The essential features of cathodic protection to metals that are
strongly to the surface to be protected. Other desirable
surrounded by a conducting electrolyte, in each of the two types
coating characteristics include; stability in the environment,
of system are as follows:
abrasion resistance, and compatibility with the alkaline
environment created or enhanced by cathodic protection.
a)
A galvanic system requires:
i)
Sacrificial anodes
c) Structure isolation. It is often desirable to limit the spread
ii) Direct welding to the structure or a conductor
of cathodic protection. For pipelines and tanks, this may be
connecting the anode to the structure
achieved by the insertion of monolithic electrical isolation
iii) Secure and minimum resistance connections
joints in the structure. Insulating flange kits are sometimes
between conductor and structure, and between
used though they often require regular maintenance.
conductor and anode.
Polarisation cells that restrict low voltage cathodic
protection dc currents, but allow passage of high voltage ac
b)
An impressed-current system requires:
currents, may be used to isolate low-resistance earthing
i)
systems from a well-coated protected structure.
Inert anodes (clusters of which, connected together
often in a backfill, are called the “groundbed”).
ii) A dc power source.
d) Test facilities. It is important to consider the location of test
iii) Electrically well insulated, minimum resistance and
facilities, test stations, corrosion monitoring coupons,
secure conductors between anodes and power
permanent half cells (reference electrodes), and the
source.
manner that data can be routinely collected or viewed.
iv) Secure and minimum resistance connections
between power source and structure.
6.0 Design Factors
6.1
In both cases, fundamental design decisions must be made to
Initial considerations
Modifications to the structure to incorporate requirements, such
select the type of system and the most suitable type of anode
as those discussed in section 5, are best made at the early
appropriate to that system. Also required, is the determination
design and pre-construction phase of the structure. For
of the size and number of the power sources, or sacrificial
underground structures it may be necessary to visit the
anodes, and their distribution on the structure.
proposed site, or for pipelines the proposed route, to obtain
additional information on low-resistivity areas, availability of
Other requirements that must be met to ensure that cathodic
electric power, and the existence of stray dc current or other
protection is applied in the most economic and reliable manner
possible interaction.
are:
3
3
Cathodic Protection
It is common practice for a survey to be made before design.
The potential values measured on a cathodically protected
This survey is often combined with a study to establish
structure will be dependent on the anodic and cathodic
economic justification for the recommended anti-corrosion
reactions, structural geometry, and internal electrical
proposal while the principal data necessary for design (chemical
resistance. However, the provision of a protective coating will
and physical) are also collected.
have by far the greatest effect on the potential for a given
applied current. The potentials will generally be most negative
If the structure already exists, measurement of existing
at a point nearest to the anode or groundbed and, for pipelines,
structure-to-soil potentials is essential to give valuable
will attenuate towards the natural corrosion potential as the
information as to which areas are anodic and which are
distance from the anode or groundbed increases.
cathodic. In addition, with the application to the structure of
temporary cathodic-protection current, using any convenient dc
An example of potential attenuation is that, in the case of a
source and a temporary anode system (groundbed), a more
power-impressed system, a single cathodic-protection
accurate assessment of current demand and the likely spread of
installation may supply cathodic protection to as much as
protection to the structure may be assessed.
150 km of extremely well coated pipeline, whereas for similarsizes of bare (uncoated) pipelines it may be necessary to have
Design of a cathodic-protection system for a new structure
installations at only 2 km intervals.
should include the calculation of:
Current demand
6.3
Economics of decisions
Resistance to earth of the anodes
At the design stage of a cathodic-protection scheme, a decision
Quantity and location of anodes or anode systems
must be made as to whether the scheme will be a galvanic or
Electrical supply requirements
impressed-current system. In specific circumstances, the use
Test and monitoring facilities.
of both types of systems may be appropriate, but care is
required to avoid interaction between them.
Project specifications and European or national guideline
documents should be consulted.
Galvanic systems have the advantage of being –
a)
simple to install
In the case of onshore pipelines and other structures,
b)
independent of a source of external electric power
negotiation with landowners, public authorities, or other
c)
suitable for localised protection
interested parties, for easements and wayleaves for
d)
less liable to cause interaction on neighbouring
groundbeds, cable routes, transformer-rectifier sites, and
structures.
electricity supplies should also be undertaken at the design
stage.
However, the current output available from the practical size
and weight of galvanic anodes is relatively small and depends
6.2
Potential level and distribution
principally on the electrical resistivity of the electrolyte (local
In practice, the structure-to-electrolyte potentials are measured
environment if buried / submerged / concrete). Thus, galvanic
using a standard half-cell (reference electrode). For example, a
anodes of aluminium and zinc, which have similar driving emfs
common protection criterion used for steel in an aerobic
to steel of approximately 0.5V, are limited to use in electrolytes
electrolyte of nearly neutral pH is a negative value of minus 850
of less than 5 Ohm.m resistivity. The anodes are usually self-
mV. When exposed to sulphate-reducing bacteria, steel would
regulating because their current output is usually less than their
require a more negative potential of minus 950 mV. Both values
maximum output capability and is controlled by the difference in
are with respect to a copper/copper sulphate half-cell. Ideally, to
potential between the two metals. The current from the anodes
attain a high degree of accuracy and in order to minimise
is not normally controllable; thus changes in the structure, such
measurement errors, the half-cell should be very close to the
as the deterioration of a coating, that causes an increase in
surface at which the potential is being measured.
protection current demand, may necessitate the installation of
further sacrificial anodes to maintain protection.
4
4
Cathodic Protection
however, be inspected at periodic intervals to ensure they are
Impressed-current installations have the advantage of being –
a)
b)
c)
capable of supplying continued protection.
able to supply a relatively large current
able to provide of high dc driving voltages (up to 50V).
Any secondary structure residing in the same electrolyte may
Enables it to be used in most types of electrolytes
receive and discharge the cathodic protection direct current by
able to provide a flexible output that may accommodate
acting as an alternative low-resistance path (interaction).
changes in, and additions to, the structure being
Corrosion will be accelerated on the secondary structure at any
protected
point where current is discharged to the electrolyte. This
Generally, however, care must be taken in the design to
phenomenon is called "stray current corrosion".
minimise interaction on other structures and, if no ac supply is
Interaction may occur, for example, on a ship that is moored
available, an alternative power source (solar, diesel, etc.) is
alongside a cathodically protected jetty, or on a pipeline or
required. Impressed current systems require regular
metal-sheathed cable that crosses a cathodically protected
maintenance and monitoring.
pipeline.
Interaction may be minimized by careful design of the cathodic
Generally, galvanic systems have found favour for small well-
protection system. In particular, by design of a scheme to
coated, low current demand, structures or for localised
operate at the lowest possible current density and by
protection. Impressed current schemes are utilised for large
maintaining good separation between the protected structure
complex structures, which may be of bare metal or poorly
and the secondary structure, and between the groundbeds or
coated. However, in North Sea offshore work, it has been found
anodes and the secondary structure.
cost effective to provide galvanic protection to large uncoated
platforms, and similar structures, where the initial cost of coating
It is an advantage of sacrificial-anode schemes that they are
and the cost of maintenance are very high. In addition, the
not prone to creating severe interaction problems and therefore
galvanic anodes offer easy to install robust systems, which
they are popular for protection in congested and complex
being independent of a power source, provide protection
locations.
immediately on “float-out” of the structure.
Methods and procedures are available for overcoming
interaction, and testing should be carried out in the presence of
6.3
Problems to be avoided
interested parties, so that the choice of remedial measures may
There are certain limitations to the use of cathodic protection.
be agreed, if and when the acceptable limit of interaction is
Excessive negative potentials can cause accelerated corrosion
exceeded.
of lead and aluminium structures because of the alkaline
environments created at the cathode. These alkaline conditions
6.4
Types of equipment
may also be detrimental to certain coating systems, and may
Various galvanic anode alloys of magnesium, aluminium or zinc
cause loss of adhesion of the coating. Hydrogen evolution at
are available in a variety of block, rod or wire forms. These
the cathode surface may, on high-strength steels, result in
alloys are cast around steel inserts to enable fixing of the
hydrogen embrittlement of the steel, with subsequent loss of
anode and to maintain electrical continuity and mechanical
strength. On some high strength steels, this may lead to
strength towards the end of the anode life. The insert may be
catastrophic failures. It may also cause disbondment of
directly welded or bolted to the structure to be protected, or
coatings; the coating would then act as an insulating shield to
anodes may be connected to the structure by means of an
the cathodic-protection currents.
insulated lead, usually of copper, as for onshore and offshore
pipelines.
Consideration must also be given to spark hazards created by
the introduction of electric currents into a structure situated in a
Impressed-current groundbeds in soils have traditionally
hazardous area. Generally sacrificial anode systems do not
consisted of high-silicon cast iron. However, mixed metal oxide
cause problems, as they are self-regulating and are often
(MMO) anodes are becoming increasingly popular for all
regarded as systems that can be ‘fit and forget’. They must,
environments because of their good mechanical and electrical
5
5
Cathodic Protection
characteristics and compact size. For seawater applications
Galvanic-anode outputs may also be monitored, as can
and areas where chlorides are present, MMO anodes work well
currents in electrical bonds between structures. Tests to
as do high-silicon cast iron alloyed with chromium. Other
measure interaction are usually conducted annually where
anodes consist of lead alloy and platinum formed in a thin layer
areas are at risk or after adjustments to cathodic-protection
on a titanium or niobium base
current output.
There are many possible sources of dc power; the most popular
Maintenance includes the mechanical maintenance of power-
is the selenium plate or silicon-diode rectifier with transformer
supply equipment and the maintenance of painted surfaces of
unit in conjunction with an existing ac supply or diesel- or gas-
equipment.
engine-driven alternator. For most applications, a constant dc
voltage or constant current systems are used.
It is good practice to inform all owners of cathodic protection
systems and infrastructure in the area of influence of any new
In remote areas, power sources include thermo- electric
cathodic protection systems, or of significant changes to
generators, closed-cycle vapour turbines, and solar or wind
existing systems, so that the effect on these facilities may be
generators. The latter two are used in conjunction with lead-
assessed.
acid or similar storage batteries. The choice is dependent on
power requirements, maintenance capabilities, and
8.0 Sources of Advice
environmental conditions.
Corrosion/Cathodic Protection Consultants – Various listings.
There are also automatic control units available that will adjust
Institute of Corrosion
current output in accordance with potential changes at a half
Corrosion House, Vimy Court, Leighton Buzzard
cell.
Bedfordshire. LU7 1FG
7.0 Monitoring and Maintenance
National Association of Corrosion Engineers (NACE)
Cathodic-protection systems may be monitored effectively by
International
the measurement of structure-to-electrolyte potentials, using a
Houston, Texas, USA
high input impedance voltmeter and suitable half-cell. The
standard practical half-cells are copper/copper sulphate,
Institute of Materials, Minerals and Mining
silver/silver chloride/seawater, silver/silver chloride/ potassium
1 Carlton House Terrace, London. SW1Y 5DB
chloride and zinc.
The Institution of Civil Engineers
Adjustments are made to the cathodic-protection current output
One Great George Street, Westminster, London SW1P 3AA
to ensure that protective potentials are maintained at a
sufficiently negative level as defined by the project specification.
Corrosion Protection Association (Reinforced Concrete)
The level of protection in soils and water is accepted at steel
Association House, 99 West Street, Farnham, Surrey GU9 7EN
potentials of minus 850 mV (wrt Cu/CuSO4) or minus 800 mV
(wrt Ag/AgCl/seawater).
The Society of Operations Engineers
22 Greencoat Place, London. SW1P 1PR
Transformer rectifier outputs may be displayed by telemetry at
central control stations. Many cathodic protection systems are
Galvanisers Association
increasingly being controlled and monitored by remote
6 Wren’s Court, 56 Victoria Road, Sutton Coldfield
computers and modem links. Other communication systems
West Midlands B72 1SY
that enable, for example, pipe-to- soil potentials to be monitored
from a helicopter or light aeroplane, are available.
Paint Research Association
8 Waldegrave Road, Teddington, Middlesex, TW11 8LD
6
6
Cathodic Protection
Pipeline Industries Guild
BS EN 12696
14/15 Belgrave Square, London SW1X 8PS
Part 1 : Atmospherically exposed concrete
Cathodic protection of steel in concrete
BS EN 12954 Cathodic protection of buried or immersed
metallic structures – General principles and application for
pipelines.
9.0 Further Information
The following references provide further information on cathodic
BS EN 13173 Cathodic protection for steel offshore floating
protection. Potential users are recommended to employ
structures.
qualified and experienced specialists to design and undertake
the work. The following handbook provides listings of various
BS EN 13174 Cathodic protection for harbour installations.
manufacturers, suppliers, consultants, and contractors.
The Corrosion Handbook, 1999, (incorporating Corrosion
Prevention Directory), MPI Group, (Inst. of Materials, Inst. of
Corrosion)
Other useful Publications:
J.H. Morgan 'Cathodic Protection' National Association of
Corrosion Engineers (NACE) 1987 2nd Edition.
nd
Peabody’s Control of Pipeline Corrosion. (2
edition, Ed by R
Bianchetti), NACE, Houston, 2000.
Corrosion and corrosion control. H H Uhlig, Wiley, New York,
1985 (3rd edition).
Corrosion. L L Shreir (2 vols), Newnes-Butterworth, 19 (3rd
edition).
Cathodic Protection Criteria - A Literature Survey' National
Association of Corrosion Engineers (NACE) 1989.
W.V. Baeckmann 'Handbook of Cathodic Corrosion Protection',
rd
(3 edition) Gulf Pub., 1997.
Standards
BS 7361 Part 1 1991 'Cathodic Protection Part 1 - Code of
Practice for Land and Marine Applications' British Standards
Institution, U.K.
BS EN 12473 General principles of cathodic protection in sea
water.
BS EN 12474 Cathodic protection for submarine pipelines.
7
7
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