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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