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The Problem
When two dissimilar metals are connected in an electrolyte such as seawater, a corrosion cell is formed in which one metal becomes an anode and suffers corrosion, while the other metal becomes the cathode and remains preserved. Current flows through the electrolyte from the anode to the cathode, resulting in electrolytic corrosion. Anodic and cathodic areas exist on the surface of all steel structures due to slight variations in material composition, local stresses, differences in coating condition and the availability of oxygen. Ships' hulls, cargo tanks and submerged fixed structures are all vulnerable to corrosion (details).

The Solution
Cathodic protection works within this natural process to help put you in control of what corrodes and what does not. The principle of cathodic protection involves the introduction of a metal that is more electro-negative than the existing anodic and cathodic areas. This additional metal becomes the anode and will corrode while providing current to the metal it is protecting, thereby overcoming the local anodic areas and making them cathodic. This time-tested solution utilizes a material such as zinc or aluminum, which will sacrifice itself in protecting the cathode.
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Zinc anodes are cast from 99.995% purity ingot, to US Mil Spec A-18001K, and will yield 780 ampere hours per kilogram. Aluminum anodes are cast from a special mercury-free alloy, yielding 2700 ampere hours per kilogram, resulting in longer life, higher output and lighter weight (for easier installation).

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http://www.wilsonwalton.com/cathodic.htm

Wilson Walton International manufactures sacrificial zinc and aluminum anodes in its own U.S. foundry for superior quality, reliability and value. In the case of ship hulls, the optimal solution includes Wilson Walton's Aquamatic III Impressed Current Cathodic Protection (ICCP) system.

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Wilson Walton | Corrosion Examples

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Ship Hulls
On a ship's hull in seawater, corrosion forms on what might appear to be a uniform surface. Since corrosion results in metal loss, uncoated plates will experience deterioration and wastage. Where an imperfect coating exists, corrosion will take the form of accelerated pitting at the location of the bare spots. In the absence of protection, corrosion will cause:
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Hull roughening Loss of speed Increased fuel consumption

Anodic areas on submerged steel must be eliminated in order to obtain optimum ship performance. Protection with the best and most expensive coatings alone is not enough because paint becomes damaged. It is also prone to breakdown unless it is carefully applied under favorable atmospheric conditions on correctly prepared surfaces. Corrosion can be particularly severe when it occurs at breaks in a coated surface where deep pitting may develop rapidly. Once pitting is initiated, it can be exceedingly difficult to contain. Having commenced at the bare areas, corrosion spreads under adjacent sound paint, accelerating the breakdown of the coating as a whole.

Ship Cargo Tanks

The corrosion pattern is different in the cargo tanks of crude oil carriers where cargos are alternated with seawater ballast. In this environment, corrosion takes the form of pitting on horizontal surfaces
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Wilson Walton | Corrosion Examples

such as the inner bottom shell plating, the upper surfaces of stringer platforms and the face plates of longitudinal and traverse members. It also occurs in other places where water may be present beneath oil cargos and during void periods.

Fixed Structures
Oftentimes, a steel structure (e.g., oil platform or pipeline) submerged in seawater is in contact with mud or deposits which may be conducive to the growth of sulphate-reducing bacteria. A particularly aggressive type of environment results in which paints are prone to breakdown. Steel pilings below the seabed level and buried pipelines are susceptible to this form of attack making cathodic protection essential. Return to the Principles of Cathodic Protection.

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