Cathodic

Protection
ME 472-061 Corrosion Engineering I
ME, KFUPM
Dr. Zuhair M. Gasem

Dr. Z. Gasem
ME 472-061
KFUPM

References:

ASM Handbook, vol 13, pp. 466-477

Corrosion for Science and Engineering, K.R.
Trethewey and J. Chamberlain, chapter 16
Handbook of Corrosion Engineering, P.R.
Roberge
Cathodic Protection in ARAMCOs Engineering
Encyclopedia

Dr. Z. Gasem
ME 472-061
KFUPM

Anodic and Cathodic Reactions of

Iron in Acids
Acid
Solution

Corrosion Cell on a
Metal Surface

H+

H2
H+

Fe2+

H+

H+

Cathode

Anode
Fe2+

Metal
Electron Flow

H+

H+

Dr. Z. Gasem
ME 472-061
KFUPM

Basic Physics of CP of Iron in Acids

Electrons from an external source are forced to flow into

the structure to be protected resulting in:

Increased cathodic reaction (2H+ + 2e- H2)

Decreased anodic reaction and hence reduced corrosion rate

Electrolyte

H2

H+

H2

H+

H2

H+

H2
H+

H H

H+ H+

H+

H+

H+ H+

H+ H+

H
Fe2+

e e

e e

H+
H+

e ee e e e
e e
e
e
e

Electrons from external source

Dr. Z. Gasem
ME 472-061
KFUPM

Before CP:

Polarization Principle of CP of Iron in Acids

ianode = icathode
= icorr
E = Ecorr

After CP:

icorr = ia
icathode = ic
iapp = ic ia
E = ECP

ECP

Dr. Z. Gasem
ME 472-061
KFUPM

The cathodic reaction for

corrosion of steel and iron
in aerated-water is usually
(O2+2H2O+2e4OH-)
under concentration
polarization.
Before CP:

Polarization Principle of CP of Iron in Water

ianode = icathode = iL
E = Ecorr

After CP:

icorr = ia
icathode = ic = iL
iapp = ic ia
E = ECP

ECP

Dr. Z. Gasem
ME 472-061
KFUPM

Summary of cathodic protection:

Cathodic Protection
CP makes the structures potential more negative which promotes cathodic
reactions and slows anodic reaction
Increases icathode
Decreases ianode
Need to supply iapp = icathode - ianode

Where CP is used?
CP is often applied to coated structures, with the coat providing the
primary form of corrosion protection and the CP system acts as a
supporting protection.
The main applications of CP include:
Buried pipeline
Acids storage tanks
Offshore steel structures such as platforms and oil rigs
Ships
Concrete structures exposed to seawater such as bridges

Dr. Z. Gasem
ME 472-061
KFUPM

CP of Buried Pipelines

Before CP is applied:

Anodes and cathodes are on the same surface of the

pipe
The soil is the electrolyte
Ionic current flow b/w the anode and the cathode in
the external surfaces
Electrons flow in the metal from anode to cathode

Dr. Z. Gasem
ME 472-061
KFUPM

CP of Buried Pipelines

After CP is applied:
The structure to be protected becomes the cathode
The anode is an external electrode:
Amore active metal (sacrificial anode)
An inert anode with impressed DC current (Impressed
current)
The soil is the electrolyte
Ionic current flow b/w the anode and the cathode in the
external surfaces
Electrons flow between the anode and cathode through an
insulated copper wire.
e-

cathode

+ve ions
current in
electrolyte

Sacrificial
anode

Dr. Z. Gasem
ME 472-061
KFUPM

CP of Buried Pipelines

10

Sources of current

Sacrificial anode system

Impressed current system (note the - polarity from the rectifier)

Dr. Z. Gasem
ME 472-061
KFUPM

Electrochemical reaction in sacrificial Anode CP System

Cathodic reactions on the

steel structure:

In aerated wet soil

In aerated wet acidic soil

O2+2H2O+4e- 4OH-

In de-aerated soil or water

O2+4H+ + 4e- 2H2O

In neutral seawater

O2+2H2O+4e- 4OH-

2H2O+2e- 2OH- +H2

Anode reactions

At active anode in
sacrificial anode CP system
(Mg, Al, Zn)

M M+n + ne-

11

Dr. Z. Gasem
ME 472-061
KFUPM

CP of pipelines

Note that cathodic protection

current will only protect external
surfaces on buried structures,
because the anode-electrolytecathode is at external surfaces.
Above ground, structures cannot
be protected by cathodic
protection because the current
discharged from the current
source can not travel through the
atmosphere (no electrolyte).
CP is not usually used to protect
internal surfaces of pipelines
because of difficulty in placing
anodes.
internal surfaces of pipelines can
be protected by: inhibitors,
coatings, or by using a corrosion
resistant alloy.

12

Protection Criteria

Dr. Z. Gasem
ME 472-061
KFUPM

13

How

much current is needed to protect

the pipeline?

Little current will lead to ineffective protection

High current will lead to disbonding of
coatings and hydrogen embrittlement (more
power consumption and higher cost)
Experience show that we should keep the
pipeline potential less than a protection
potential.

Dr. Z. Gasem
ME 472-061
KFUPM

Protection Criteria

14

In less corrosive soil, E< -0.850 mV wrt

Cu/CuSO4 reference electrode
this reference electrode is used because it is
less sensitive to temperature variation (0.318
s. SHE)
In Saudis Aramco, the protection potential
for cross-country pipeline is -1.1 V vs
Cu/CuSO4 (due to highly corrosive soil)
More ve potential means more current
required and more operation cost.

Reference Electrodes

Dr. Z. Gasem
ME 472-061
KFUPM

Common

Cu/CuSO4 in soil

reference electrodes used in CP

CuSO4 + 2e- Cu+SO42E vs. SHE 0.318 V

AgCl in seawater

AgCl + e- Ag + ClE vs. SHE 0.222 V

15

Dr. Z. Gasem
ME 472-061
KFUPM

Potential Protection

Why <-0.850 mV vs.

Cu/CuSO4?
From Pourbaix diagram,
Fe is stable below -0.6 V
vs SHE
Cu/CuSO4 is more +ve
than SHE by 0.318 V
Hence, Fe is stable and
corrosion is minimum if
potential is (-0.6-0.318=
-0.918 V vs Cu/CuSO4)

16

Dr. Z. Gasem
ME 472-061
KFUPM

Potential and Corrosion of Buried Steel

Potential (V vs. Cu/CuSO4)

Corrosion condition

-0.5 to -0.6

Intense corrosion

-0.6 to -0.7

Corrosion

-0.7 to -0.8

Slow corrosion

-0.8 to -0.9

Cathodic protection

-0.9 to -1.1

Overprotection

-1.1 to -1.4

Severe overprotection
(disbonding of coatings,
hydrogen blistering, HE)

17

Dr. Z. Gasem
ME 472-061
KFUPM

NACE Standards for CP

18

Saudi Aramcos Potential

Requirements

Dr. Z. Gasem
ME 472-061
KFUPM

Structure

19

Minimum Required Potentials

Buried Cross-Country Pipelines

-1.10 volts versus CuSO4 electrode.

Buried Plant Piping, Tank

-1.00 volt versus CuSO4 electrode.

Bottom Externals,
Isolated Buried Casings

-850 mV versus CuSO4 electrode.

Water Tank Interiors

-0.90 volts vs. AgCl electrode

Marine structures

-0.90 volt or more negative versus AgCl electrode

Dr. Z. Gasem
ME 472-061
KFUPM

20

Soil is composed mainly of mineral particles (mainly SiO2).

Soil is composed of a mixture of:

Soil Corrosivity

Fine sand (0.02-0.2 mm)

Coarse sand (0.2-2 mm)
Slit (0.002-0.02 mm)
Clay (< 0.002 mm)

The soil particles are covered with thin surface film of moisture with
dissolved salts and gases.
The total volume of soil consists of solid particles and pores filled
with moisture and air.
Soils with a high proportion of sand have very limited storage
capacity for water whereas clays are excellent in retaining water
Air in the pores contains 10-20 times as much CO2 as atmospheric
air.
Soils with high moisture content, high electrical conductivity, high
acidity, and high dissolved salts will be most corrosive.

Soil Corrosivity

Dr. Z. Gasem
ME 472-061
KFUPM

Variables affecting soil corrosivity:

Water is the electrolyte for electrochemical corrosion

reactions
Oxygen: the oxygen concentration decreases with
increasing depth of soil
pH: soils usually have a pH range of 5-8

21

Soil acidity is produced by decomposition of acidic plants,

industrial wastes, and acid rain
Alkaline soils tend to have high sodium, potassium,
magnesium and calcium contents which form calcareous
deposits on buried structures with protective properties
against corrosion.

Chloride level: harmful for metals

sulfate level: harmful for concreter

Dr. Z. Gasem
ME 472-061
KFUPM

Soil Corrosivity

For CP design against

corrosion, the most important
property of a soil in
determining its corrosivity is its
electrical conductivity.
The table shows soil corrosion
severity ratings.
Soil corrosion causes corrosion
in underground petroleum
storage tanks, pipelines, and
water distribution systems.
Soil resistivity is measured by
Wenner 4-pin method

22

Soil
Corrosivit
resistivity y Rating
(ohm cm)
>20,000

Essentially
noncorrosive

10,000 to
20,000

Mildly
corrosive

5,000 to
10,000

Moderately
corrosive

1,000 to
5,000

Corrosive

<1,000

Very
corrosive

Dry sand

Clay with
saline
water
(sabkha)

Soil Corrosivity

Dr. Z. Gasem
ME 472-061
KFUPM

Seawater
Resistivity

Electrolyte

23

Progressively Less
Corrosive
10,000

Resistivity
(ohm-cm)
Mildly Corrosive

Seawater (Gulf)
Raw water
Drinking water

16
200-2000
2000-5000
2,000
1,000
500

Ohm-cm

Moderately Corrosive
Corrosive
Very Corrosive

Dr. Z. Gasem
ME 472-061
KFUPM

Current density required to reach Ecp for steel

in moving and standing seawater and in soil

24

ASM Handbook Vol#13 p.476

Environment

Bare Steel (mA/m2)

Coated steel (mA/m2)

Initial CP Applied
Initial CP
current CP current current

Applied
CP current

Moving
seawater

325375

75-105

32-54

11-16

Stagnant
seawater

160270

45-75

11-32

5-11

soil

43-54

11-16

5.4-11

1.1-0.54

Dr. Z. Gasem
ME 472-061
KFUPM

Current Calculation for Design

Given a coated offshore structure with a

surface area of 5,000 m2, 2/3 is immersed in
seawater, calculate the amount of initial
current and applied current necessary to
cathodically protect the structure.
The initial and applied current density
requirement for coated seawater structures is
35 and 10 mA/m2.
iinitial = 5,000*2/3*35= 116,666 mA = 117 A
iapplied = 5,000*2/3*10 = 33,333 mA = 34 A

25

Dr. Z. Gasem
ME 472-061
KFUPM

Example

Given a 150 m section of 0.75 m diameter steel pipe

coated with fusion bonded epoxy (FBE), calculate the
total amount of current required. Assume that 10% of
the coating was damaged during installation. Assume
that the required current density for FBE coated buried
pipeline is 0.1 mA/m2 while for uncoated steel is 1
mA/m2 .
surface area = DL=354 m2
iinitial = bare area*1 mA/m2 + coated area*0.1 mA/m2

= 354*0.1*1 + 354*0.9*0.1 = 67.3 mA

Note that if the whole pipe is not coated, then the
current requirement would be
= 354*1=354 mA (5 times more than above)

26

Dr. Z. Gasem
ME 472-061
KFUPM

Coatings in CP Systems

27

Bare structures require more current than

coated structures
Economical applications of CP for buried
pipelines applied only for coated pipelines.
Always assume 5-10% of coated area as bare
due to damage during pipe installation.

Dr. Z. Gasem
ME 472-061
KFUPM

Sacrificial Anode CP Systems

a more active metal than steels

can act as a sacrificial anode.
The galvanic series indicate that
Mg, Zn, and Al are more active
than steels.
A number of anodes are
electrically connected to the
steel structure to be protected to
provide the needed current.
The amount of current output is
increased by increasing the
number of anodes.
Usually applied in:

Low current requirement

application
Soil resistivity < 10,000 (.cm)

28

Dr. Z. Gasem
ME 472-061
KFUPM

Advantages of sacrificial CP:

Sacrificial Anode CP Systems

No external power source needed
Ease of installation, low maintenance, low cost
Provides uniform distribution of current

Disadvantages

Limited current and power output

High resistivity environments or large structures
require a large number of anodes
Periodic replacement of anodes

29

Dr. Z. Gasem
ME 472-061
KFUPM

Metal

Galvanic Series in soil and seawater

Volts
(referenced to Cu/CuSo4)

Commercially pure magnesium

Magnesium alloy (6% Al, 3%, Zn, 0.15% Mn)
Zinc
Aluminum alloy (5% Zn)
Commercially pure aluminum
Mild steel (clean and shiny)
Mild steel (rusted)
Cast Iron
Lead
Mild steel in concrete
Copper, brass, bronze
High silicon cast iron
Mill scale on steel
Carbon, graphite, coke

-1.75
-1.6
-1.1
-1.1
-0.8
-0.5 to -0.8
-0.2 to -0.5
-0.5
-0.5
-0.2
-0.2
-0.2
-0.2
+0.3

30

Dr. Z. Gasem
ME 472-061
KFUPM

Sacrificial anodes

In soil, special backfills

are used with sacrificial
anodes to improve anode
efficiency.
Anodes are packaged in
porous bags prefilled with
backfill materials such as
clay. Clay:

absorbs moisture from the

soil and reduce anode
resistance of
anode/electrolyte
distribute the anodic
reaction all over the anode
Increase the life of the
anode

31

Dr. Z. Gasem
ME 472-061
KFUPM

Anodes are packaged in

bags filled with backfill
material
Commercial anodes (

Sacrificial anodes

60 inch in length
4 Kg

Anodes for buried structures (pipes,

tanks):
Pure Mg
Mg alloy (Mg+6Al+3Zn+0.2Mn)
Pure Zn
For marine applications
Al alloy containing 5% Zn is
used
Zn alloy

32

Dr. Z. Gasem
ME 472-061
KFUPM

Soil resistivity ranges from (500-20,000 *cm)

Seawater ranges from ( 10-50 *cm)

Estimate cathodic current requirement which depends on the

environment and the surface area to be protected using either:

For buried steel (NACE standard gives protection potential = -850 mV

vs. Cu/CuSO4 )

Measure resistivity of environment (slide#34):

33

Select Protection Criterion (depends on the environment)

Design of Sacrificial Anode CP

Current requirement table (see slide#24)

Current requirement test (see slide#35)

Select a suitable sacrificial anode and calculate the theoretical

capacity and the driving voltage (slide#37 and 38)
Estimate the number of anodes needed based on groundbed
resistance (slide#41 and 42)
Estimate anode life and replacement period

Dr. Z. Gasem
ME 472-061
KFUPM

Wenner 4-pin Method to Measure Soil Resistivity

34

This method is done by placing four pins at equal distances from each other.
A current is passed through the two outer pins using a power supply.
the voltage across the two inner pins is measured using a voltmeter.
the resistance can be calculated using Ohm's law (Resist = V/I).
Soil resistivity = 191.2*V/I*d (d in feet) ohm-cm,
where R is the soil resistance and d is the pin spacing in feet.

Power
supply
voltmeter

Dr. Z. Gasem
ME 472-061
KFUPM

Current Requirement Test

The current may be increased

gradually until the voltmeters at
positions A and B reaches -0.85 V
with respect to a copper sulfate
reference electrode placed directly
above the pipe. Current
requirement test:

A small DC power system is used

(10 A)
A temporary anode ground bed is
installed
Potential loggers are installed at
selected test locations to monitor
potentials
A current is applied and the
potential is measured
The current that brings the
potential of the whole pipe below
the protective potential is used
the required current for
protection

35

Dr. Z. Gasem
ME 472-061
KFUPM

Sacrificial Anode

Anodes must have:

High driving potential to generate sufficient current

Stable operating potentials over a range of current
outputs (Eanode does not vary a lot with i)
High capacity to deliver current per unit mass
Does not passivate
Theoretical capacity: the total charge in coulombs
produced by the corrosion (dissolution) of a unit
mass of the anode material [units in (A* hr)/Kg].
High Efficiency (efficiency = actual
capacity/theoretical capacity*100)

36

Dr. Z. Gasem
ME 472-061
KFUPM

Calculating the theoretical capacity

37

MW of Mg is 24.3 g/mol, density=1.74 g/cm3

MgMg+2 + 2e- (one mole of Mg produces 2
moles of electrons)
Take 1 Kg of Mg as a basis:

1000g * mole/24.3g=41.2 mole of Mg

# of e- mole= 2*41.2=82.4 moles of e82.4 moles of e- *96500 Coulomb/(mole e)=
795,1600 Coulomb/(Kg of Mg)
795,1600 Coulomb/Kg *1 hr/3600s=2,200 (A.hr)/Kg

Dr. Z. Gasem
ME 472-061
KFUPM

Calculating driving potential

ED = Eanode Ep + Epolar
ED = driving potential
Eanode = anode potential
Ep = protection potential
Epolar = change in potential
of anode due to current
flow (polarization); usually
taken as 0.1 V

ED

38

Driving Potential

Dr. Z. Gasem
ME 472-061
KFUPM

39

Example:

calculate the driving potential for Mg

in soil assuming:

Eanode = -1.75 vs Cu/CuSO4

Ep (buried pipeline cross country) = -1.0 V
Epolar = 0.1 V
ED = -1.75 (-1.0) +0.1 = -0.65 V

Example: calculate the driving potential for Al

alloy (5%Zn) in soil assume Ep = -0.85 V and
Epola=0 and Eanode=-1.1V

ED = -1.1- (-0.85) = -0.25 V

Dr. Z. Gasem
ME 472-061
KFUPM

Sacrificial Anodes

40

Mg

Zn

Al

Theoretical
capacity
Actual
capacity
Efficiency

2200
(A*hr)/Kg
1232

810

2980

780

2640

50-60%

>90%

>90%

potential

-1.75 V (vs -1.1

Cu/CuSO4)

-1.1

Dr. Z. Gasem
ME 472-061
KFUPM

Anode bed (groundbed) resistance

In both systems, the flow of current

is analogous to a simple resistive
circuit.
The highest resistance to current flow
is due to the anode/electrolyte
resistance (Rab)
RS (structure/electrolyte) resistance.
RLW (lead wire) resistance.
Rab = Resistance of
anode/electrolyte; depends on the
anode shape and the resistivity of the
environment.
Rtotal = Ra+RLW+RS
(RS and RLW) can be neglected
Rtotal Rab

41

Electric Circuit
I

Battery
Resistor

R total

Dr. Z. Gasem
ME 472-061
KFUPM

Dwights equation for single

vertical anodes:
Ra = /(2La)*(ln(8La/Da) -1)
(for slender anodes mounted
at least 0.3 m away from the
steel structure)

Anode bed (ground bed) resistance

La= length of anode (cm)

= soil resistivity (.cm)
Da = anode diameter (cm)

Anode current output

i = ED/Ra

42

Rab

Dr. Z. Gasem
ME 472-061
KFUPM

43

Example: Calculate the maximum current output for

zinc anodes (L = 150 cm and D = 15 cm) in sacrificial
anode CP system. Assume very corrosive soil (=1000
*cm)
Calculate the driving potential assuming Epola = 0.1V,
EZn = -1.1 vs Cu/CuSO4, Ep (buried pipeline) = -0.85 V

1.

ED = -1.1 (-0.85)-0.1 = -0.15 V

Calculate the ground bed resistance

2.

3.

Anode bed (ground bed) resistance

Ra = /(2La)*(ln(8La/Da) -1)
Ra = 1000/(2*150)*(ln(8*150/15)-1) = 3.6

Calculate the maximum current output from each

anode
i = ED/Ra = 0.15/3.6 = 0.042 A = 42 mA

Dr. Z. Gasem
ME 472-061
KFUPM

Anodes distribution

Example: suppose you need 1

A to protect a steel structure
by using Zn anodes as in the
previous example.
Each anode provides 0.042 A.
Then, you need to have
1/(0.042) 24 anodes to give
sufficient protection.
Distance of anode to cathode:

Too far: high resistance in the

soil leads to voltage drop
Too short: current distribution
is not uniform
Needs experience (usually less
than a meter)

44

Dr. Z. Gasem
ME 472-061
KFUPM

Design Example

45

Example: design a CP system for a section of coated steel buried pipe

assuming that the current required to shift the pipeline potential to the
EP was approximated by a current requirement test to be 500 mA. Zn
anodes (L=150 cm, D=15 cm) are available. (Density of Zn = 7.14
g/cm3). Assume Zn efficiency is 90% and =1000 *cm.
From the previous example, each Zn anode produces 42 mA. Then,
#anodes = 500/42 = 12 anodes.
Total mass of anodes = 12*vol*density =12*3.14*D2*L/4*7.14 g/cm3=
2270 Kg
Total charge available = efficiency*theoretical capacity*mass=
0.9*810*(A.hr/Kg)*2270 Kg= 1,593,540 (A*hr)
Replacement period = 1,593,540 (A*hr)/0.5A= 189540 hr = 364 years

Dr. Z. Gasem
ME 472-061
KFUPM

Sacrificial Anode CP System

Install 12 anodes evenly

distributed along the
pipeline. Keep each anode
30-100 cm away from the
pipe. The system design
life is indefinite.
Monitoring Sacrificial CP

Measure the potential of

the pipe and make sure it
is -850mV
Monitor the current flow
from each anode at the
junction box

46

Dr. Z. Gasem
ME 472-061
KFUPM

Applications: buried tanks, pipelines, internal protection of heat

exchangers and vessels, ship hulls, marine structures

Anodes

Aluminum
alloy anode
AA-036348

47

Dr. Z. Gasem
ME 472-061
KFUPM

Impressed Current CP (ICCP) System

ICCP is used if:

high current is required

high resistance electrolyte

48

ICCP

Dr. Z. Gasem
ME 472-061
KFUPM

Components of ICCP
system

A transformer: to
reduce the voltage
from high to low
voltage
A rectifier to convert
AC to DC
A current distributor
(junction box)
Anodes with backfills

49

Reactions

Dr. Z. Gasem
ME 472-061
KFUPM

50

The anode potential is set at

high +ve potential and the
following oxidations reactions
become possible:

2H2O O2 + 4H++4e- (in

water or in wet soil)
2Cl-Cl2 + 2e- (in salt or
brackish water)
C+2H2O CO2 + 4H++4e(in graphite anodes)

Reactions at the cathode:

In aerated wet soil

In aerated acidic solution

O2+4H+ + 4e- 2H2O

In neutral seawater

O2+2H2O+4e- 4OH-

O2+2H2O+4e- 4OH-

In de-aerated soil or water

2H2O+2e- 2OH- +H2

Cathode

anode

Dr. Z. Gasem
ME 472-061
KFUPM

Advantages and Disadvantages of

Impressed Current Systems
Advantages

Higher Current and power outputs

Adjustable protection levels (controlled current)
Large areas of protection
Low number of anodes
Can be used to protect poorly coated structure

Disadvantages

Complex equipment and installation costs

Higher maintenance costs
Possible interference problems with foreign
structures
Risk of incorrect polarity connections

51

Dr. Z. Gasem
ME 472-061
KFUPM

An

Components of ICCP
external power source
AC transmission lines
A solar power system

Anodes

are not necessarily more active

than the structure to be protected

Two types of anodes

inert or non-consumable anodes: platinized

anodes (a few micrometers thick coating of
platinum on Ti or Niobium), graphite,
consumable anodes (scrap steel, high-Si Cr cast
iron)

52

Dr. Z. Gasem
ME 472-061
KFUPM

Anodes for ICCP

53

Anodes are used with

carbonaceous backfill
called coke-breeze to:

increases the effective

size of the anode
lowers the anode-toground resistance.
extends the life of the
anode.

Anode
Coke-to-earth
Resistance

Anode to
coke
resistance

Soil

Coke
breeze

Anodes in ICCP

Dr. Z. Gasem
ME 472-061
KFUPM

54

Material

Consumption rate
(Kg/(A*yr)

applications

Platinized niobium
(inert)
Platinized Ti (inert)

8x10-6

Seawater,
concrete,
==

Graphite (inert)

0.1-1

Scrap steel

7-9

Soil,
Potable water
Marine, soil

High Si-cast iron

1-0.25

Marine, soil

8x10-6

Dr. Z. Gasem
ME 472-061
KFUPM

Applications

Ships (with coatings)

Offshore platforms
Buried pipelines (pref
method)
Oil well casing
Concrete Structures
(offshore bridges)

55

Dr. Z. Gasem
ME 472-061
KFUPM

Buried pipelines

56

Well Casing

Dr. Z. Gasem
ME 472-061
KFUPM

Remote
Surface
Anode
Bed

Junction
Box

Producing Zone

Rectifier

Perforations

57

ICCP Design

Dr. Z. Gasem
ME 472-061
KFUPM

1.
2.

Evaluation of electrolyte resistivity

Estimating the current requirement

3.

Selecting anode material and current

distribution

4.
5.
6.

Current requirement test

Current requirements theoretical estimation

Uniform current distribution

Avoid interference (stray current)

Determine the anode bed ground resistance

Determine number of required anodes
Select the power source capacity

58

Dr. Z. Gasem
ME 472-061
KFUPM

1. Electrolyte Resistivity Survey

Measure soil resistivity along the pipeline

The data from a soil resistivity survey along a 6
km section of pipeline is shown below. The
lowest effective soil resistivity points are the
most favorable anode bed locations.

59

Dr. Z. Gasem
ME 472-061
KFUPM

2. Interruption Test for Bare Pipeline in Impressed

Current System

60

In impressed current system for bare structure, the

applied current is high and IR drop can not be
neglected.
Thus, protection Criteria for bare pipeline must check
I*R effect.
The protection criterion for bare steel pipeline uses
interruption test where a negative (cathodic) change in
potential of >300 mV must take place immediately after
potential
CP current is applied.
CP power on

CP Power off
300 mV

time

Dr. Z. Gasem
ME 472-061
KFUPM

3. Current distribution

Variation of electrolyte
resistivity b/w anode
and cathode (largest
current flows along
least resistant path)
Defects in coatings:
current concentrates
at defects

61

Dr. Z. Gasem
ME 472-061
KFUPM

Stray Currents

Stray Currents: currents

flowing in the
electrolyte from
external sources other
than the applied CP.
Sources of stray
currents:

Subway system

Interference with
another CP system

Welding equipment

Electrical power
transmission lines

62

Dr. Z. Gasem
ME 472-061
KFUPM

4. Number of Required
Anodes

N = Y*C*I/W
N =
anodes
Y =
I =
C =
W =

number of impressed current

design life in years
total current required in amperes
anode consumption rate in kg/A-yr
weight of a single anode in kg

63

5. Resistance calculation

Dr. Z. Gasem
ME 472-061
KFUPM

Dwights

anode:

equation for single vertical

Ra = /(2La)*(ln(8La/Da) -1)

group of vertical or horizontal anodes

(buried 6 ft below ground):

Vertical anodes ( Rv = *F/537)

Each anode is 8-12 in in diameter and 10 ft in length
Horizontal anodes (RH = *F/483)
Each anode is 10 ft in length and 6 ft below surface
F is called adjusting factor (F=1 for single anode)

64

Dr. Z. Gasem
ME 472-061
KFUPM

F : Adjusting Factor

65

4. Power Source Selection

Dr. Z. Gasem
ME 472-061
KFUPM

66

The

size of the power source is

determined by:

the amount of current required to protect the

structure (I)
the voltage required to force the current
through the anode ground bed resistance (R)
E=I*R

Dr. Z. Gasem
ME 472-061
KFUPM

Example: Design for ICCP

Design an impressed current system to protect a

buried pipeline coated with fusion bonded
epoxy (FBE) using the following information:

Horizontal anodes 6 ft below ground with 20

ft spacing

Anode material: High silicon-cast iron (

C=0.5 Kg/(A*yr))

Anode dimensions with backfill: 25 cm dia. x

300cm, weight=50 Kg

Pipeline length: 500 m and 115 mm in

diameter

the anode to soil resistance is 0.24

ohm

Neglect cable resisitivity.

Soil resistivity: 2,000 ohm-cm

Required current density is 0.2 mA/m2 for

FBE.

Design life of 20 years

67

Dr. Z. Gasem
ME 472-061
KFUPM

Example: Design for ICCP

68

Current required = surface area * current density

= d L *i= 3.14*0.115*500 *0.2 = 36.1 A
# anodes= Y*I*C/W = 20*36.1*0.5/50 = 7.2 anodes .
Then use 8 anodes.
To calculate the resistance:
RH = *F/483 (for 8 horizontal anodes F=0.184)

= 2000*0.184/483 = 0.76
Total R= 0.76+0.24=1
E = I*R=1*36.1 = 36.1 V
Hence, use a DC power with a minimum current
supply of 40 A and a minimum voltage of 40 V (1600
Watt rating).