A CONDENSED DISCUSSION OF

CATHODIC PROTECTION REQUIREMENTS

FOR A TYPICAL
GENERATING STATION

Prepared By

Revision 0
Elizabeth J. Smith
January 5, 1983

Revision 1.0
Bryan Louque
August 21, 2000
 Contents

1.0 Introduction...................................................................................................... 1-1

2.0 How Corrosion Occurs .....................................................................................2-1

3.0 Typical Corrosion Cells ....................................................................................3-1

3.1 Dissimilar Metal Corrosion Cells .......................................................... 3-1
3.2 Dissimilar Environment Corrosion Cells ...............................................3-3
3.3 Differential Aeration Corrosion Cells....................................................3-4
3.4 Bacteriological Corrosion Cells.............................................................3-4

4.0 Cathodic Protection--How It Works..................................................................4-1

5.0 Designing the Cathodic Protection System........................................................5-1

5.1 Analysis of the Requirements................................................................5-1
5.2 Selection of the Optimum System .........................................................5-1
5.2.1 Essential Features ................................................................ 5-1
5.2.2 Desirable Features ...............................................................5-2
5.3 Selection and Arrangement of the Specific Components........................5-2
5.3.1 Sacrificial Anode Systems ...................................................5-2
5.3.2 Impressed Current Systems..................................................5-2
5.4 Avoiding Overprotection and Stray Current ..........................................5-2

6.0 Preferred Methods of Corrosion Control...........................................................6-1

6.1 Underground Cast Iron and Ductile Iron Pipe........................................6-1
6.2 Underground Carbon Steel Pipe ............................................................6-1
6.3 Underground Prestressed Concrete Cylinder Pipe (PCCP).....................6-2
6.4 Underground Copper or Stainless Steel Pipe .........................................6-2
6.5 Underground Aluminum Pipe................................................................6-2
6.6 Underground Steel Tanks......................................................................6-2
6.7 On-Grade Steel Tanks ...........................................................................6-2
6.8 Inside Surfaces of Steel Tanks...............................................................6-3
6.9 Condenser Water...................................................................................6-3
6.10 Traveling Screens .................................................................................6-4
6.11 Supplementary Methods of Protection...................................................6-4

082100 TC-1
 Contents (Continued)

7.0 Maintenance of the Cathodic Protection Systems ..............................................7-1

7.1 Outline of Routine Performance Testing Procedures .............................7-1
7.2 Black & Veatch Services.......................................................................7-1

8.0 Basic Design Philosophy Recommendations.....................................................8-1

8.1 Connection of Pipe to Main Ground Grid ..............................................8-1
8.2 Soil Resistivity Measurements ..............................................................8-1
8.3 Multiple Bond Wires at Pipe Joints .......................................................8-2
8.4 Contact Between Ferrous Pipe and Reinforcing Steel............................8-2
8.5 Condenser Water Box Protection...........................................................8-2

9.0 Summary..........................................................................................................9-1

Appendix A Process Map of Design, Construction, and Testing Activities

Appendix B Typical Cathodic Protection Details

Tables

Table 3-1 Practical Galvanic Series.......................................................................3-2

082100 TC-2
 1.0 Introduction

The Electric Power Research Institute (EPRI) has estimated the cost assigned to
corrosion in the electric power industry to be 0.24 percent of the gross national product
(GNP). This is equivalent to more than 17 billion dollars annually expressed in 1998
dollars. Of these costs, EPRI estimates that 15 percent, or 2.5 billion dollars, could have
been avoided by application of available technology such as equipment design, material
selection, protective coatings and linings, inhibitors and cathodic protection. Experience
has demonstrated that installation and maintenance of effective cathodic protection
systems can mitigate corrosion, increase remaining useful life and significantly reduce
these costs for all underground, on-grade and submerged metallic structures subject to
corrosion.
This discussion provides a brief introduction into the methods for control of
corrosion as recommended by Black & Veatch for installations at generating stations with
emphasis on corrosion control by cathodic protection. In-depth design recommendations
will not be provided, since there are numerous conditions which may cause corrosion and
the method of control appropriate for each situation must be considered on an individual
basis.

082100 1-1
 2.0 How Corrosion Occurs

Corrosion of metallic structures is primarily electrochemical (galvanic) in nature.

There are four conditions which must exist for electrochemical corrosion to occur. These
conditions are as follows.
• There must be an anode.
• There must be a cathode.
• There must be a metallic path electrically connecting the anode and
cathode. (Normally, this will be the structure itself.)
• The anode and cathode must be exposed to an electrically conductive
electrolyte, such as soil moisture, or water, surrounding a buried or
submerged structure.
Wherever these conditions exist, a corrosion cell may be formed. An electric
current will flow between the anode and cathode and corrosion of the anode will result.
The amount of corrosion will be directly proportional to the amount of current flowing
from the anode. Therefore, the rate of corrosion will vary proportionately with the
relative cathode/anode surface area ratio, the magnitude of the cathode/anode potential
difference and inversely with the value of the electrolyte resistivity. The figure below
illustrates the relationship between the corrosion rate of a ferrous metal and it's
environment.

INCREASE DECREASE DECREASE INCREASE

C
O R T
R E E
R S M
O I P
S S E
I T p R
O I H A
N V T
I U
R T R
A Y E
T
E

DECREASE INCREASE INCREASE DECREASE

082100 2-1
Although seldom used in buried or submerged service, amphoteric materials such as lead
and aluminum may not react according to the relationships illustrated in the above figure.
Another common form of corrosion is stray current corrosion, frequently refered
to as man made corrosion. Stray current corrosion may occur at generating stations using
impressed current cathodic protection systems and on underground metallic structures
which are buried in areas where stray direct currents flow through the earth. Stray
current corrosion occurs when stray direct currents are picked up from the electrolyte by
a metallic structure which is so located that it is a preferential path for the stray current
but has no metallic connection to provide a path back to the source of the stray current.
The stray current will protect the metallic conducting structure to which it has strayed at
its pickup locations, but unless appropriate protective measures are taken, corrosion will
occur at the locations where it leaves that structure and reenters the electrolyte to return
to its source.
Stray current can also be generated by improper welding operations in a
generating station. Welding machines grounded to a structure allow the welding current
to return to the welding machine through the structure. Welding current discharge from
the structure, into an electrolyte will cause severe corrosion of the structure at the current
discharge point.

082100 2-2
 3.0 Typical Corrosion Cells

Several types of corrosion cells are frequently encountered at generating stations.

Four of the most common types are described here.

3.1 Dissimilar Metal Corrosion Cells

Different metals are frequently combined into a single system where both metals
are in contact with the electrolyte. This combination will result in corrosion of the anodic
metal, the surface of which will experience metal loss. Some typical examples of
dissimilar metal corrosion cells in generating stations are as follows:.

Anodic Metal Cathodic Metal

Buried Structures
Carbon steel pipe Copper pipe
New steel pipe Older steel pipe
Coated steel pipe Concrete encased steel pipe
On-Grade Structures
Steel tank bottom Copper grounding conductors
Above Grade Vessels and Piping
Carbon steel water piping Copper water piping
Carbon steel water boxes Titanium tubes and tube sheets
Carbon steel tube sheets Stainless steel tubes

The practical galvanic series indicates the relationship of the natural potential
(voltage) of several common metals installed in neutral soils and water. This table
indicates which material will experience metal loss (anode) and which will receive
protection (cathode) when any two dissimilar metals are coupled in such a manner that a
corrosion cell is formed. A practical galvanic series is shown below in Table 3-1.

082100 3-1
 Table 3-1
Practical Galvanic Series

Metal Volts*
Commercially pure magnesium -1.75 Anodic (most active)
Zinc -1.1
Aluminum alloy (5 percent zinc) -1.05
Carbon steel -0.2 to -0.8
Cast iron -0.5
Stainless Steel
Carbon steel in concrete -0.2
Copper, brass, bronze -0.2
Mill scale on steel -0.2
Titanium +0.3 Cathodic (least active)

*Typical potential normally observed in neutral soils and water, measured with respect
to a copper sulfate reference electrode.

082100 3-2
The following figure illustrates the galvanic series of some commercial metals and alloys
in seawater:

Magnesium
Aluminum
Steel
Cast Iron
Chromium Stainless Steel 13% Cr (Active)
Ni-Resist (High Ni cast iron)
18-8 Stainless Steel (Active)
18-8 Mo Stainless Steel (Active)
Tin ACTIVE OR ANODIC
Copper PASSIVE OR CATHODIC
CuproNickels (60-90Cu-40-10Ni)
Monel (70Ni-30Cu)
Inconel (80Ni-18Cr-18Mo) (Passive)
Chromium Stainless Steel 11-30% Cr (Passive)
18-8 Stainless Steel (Passive)
18-8 Mo Stainless Steel (Passive)
Hastelloy C (62Ni-13Cr-7Fe)
Titanium
Platinum

3.2 Dissimilar Environment Corrosion Cells

The natural potential of a structure in one type of electrolyte is usually different
from the natural potential of the same structure in a different type of electrolyte. Thus, a
pipe passing through two types of soil may experience severe corrosion in one area and
no corrosion in another. For example, a pipe which passes through clay into a sandy
loam will tend to experience corrosion in the clay area, since the natural potential of the
pipe metal to the clay is more negative than the natural potential of the pipe metal to the
sandy loam.
Another typical example of a dissimilar environment corrosion cell is a section of
underground pipe partially encased in concrete and partially surrounded by soil. The
segment of the pipe surrounded by soil will be anodic to that segment encased in

082100 3-3
concrete. Therefore, the pipe surrounded with soil will corrode, with the most severe
corrosion occurring at the soil-concrete interface where the current flow between the
anode and the cathode will be greatest.

3.3 Differential Aeration Corrosion Cells

Differential aeration corrosion cells are created when the oxygen concentration
varies between locations on the surface of a metallic structure immersed in an electrolyte.
The poorly aerated (oxygen deficient) areas on the structure surface will be anodic to
those areas which are well aerated (oxygen rich). Therefore, the poorly aerated areas will
corrode. The corrosion will be most severe at the interface between the well aerated
areas and the poorly aerated areas. Examples of where this type of corrosion cell will
occur are listed:
• On-grade storage tanks. The base plate nearest the center of the tank
bottom has less access to oxygen compared to the base plate near tank
perimeter. The base plate near the center of the tank will be anodic to base
plate with unrestricted access to the air near the perimeter.
• Piping soil/air interface. The pipe nearest the bottom elevation of the pipe
trench has less access to oxygen compared to the pipe near the soil/air
interface. The pipe at lower elevations in the soil will be anodic to pipe
with unrestricted access to the air near grade elevation.
• Underground storage tanks. The underside of underground storage tanks
have less access to oxygen compared to tank surfaces at higher elevations
in the tank pit. The tank surfaces at lower elevations in the soil will be
anodic to tank surfaces with less restricted access to the air at higher
elevations.

3.4 Microbiological Corrosion Cells

Micro-organisms may cause changes in the electrolyte surrounding a structure
such that corrosion will occur. The corrosion process results from the metabolic
processes of anaerobic micro-organisms in locations where an oxygen deficient
environment can be maintained. Such locations most frequently occur in aqueous
environments, bogs and water saturated soils. Examples of conditions producing this
type of corrosion cell are as follows:
• Sludge or sediment build-up in vessels or piping.
• Use of organic waste and rubble for piping backfill.
• Installation in swampy or similar soil which is contaminated.

082100 3-4
 4.0 Cathodic Protection--How It Works

Cathodic protection accomplishes reduction or prevention of corrosion of a metal

surface by making it cathodic, for example, by the use of sacrificial anodes or impressed
currents.
The surface to be protected is made entirely cathodic by creating a corrosion cell
consisting of that surface and an electrically connected structure more anodic than any
part of the surface being protected. The anodic part of the corrosion cell thus created will
be either sacrificial anodes or the anodes of an impressed current system.
Sacrificial anodes, typically magnesium, zinc, or aluminum alloy, are used where
protective current and driving potential requirements are relatively small. The natural
potential (voltage) difference between the sacrificial anodes and the protected surface
produces the DC current flow required to make the protected structure cathodic.
An impressed current system is typically used where either the protective current
requirements or driving potential requirements make such a system cost effective. An
impressed current system consists of a rectifier, impressed current anodes, and
interconnecting electrical conductors. The rectifier is energized from the station auxiliary
electrical system converting the alternating current supply to direct current for cathodic
protection. The function of the impressed current anodes is to introduce the cathodic
protection current into the electrolyte. The impressed current anodes are of a material
such as graphite, high silicon cast iron, platinum-clad titanium or niobium and mixed
metal oxide clad titanium. These anode materials are used because of their low
consumption rate when discharging current. Although the impressed current anodes are
of a material naturally more cathodic than carbon steel, the biasing effect of the rectifier
assures that the impressed current anodes will be anodic to the protected structure.
Performance tests are necessary to evaluate the effectiveness of a cathodic
protection system. Therefore, monitoring and measurement facilities are an integral part
of most cathodic protection systems. Test stations provide a direct connection to buried
or submerged structure to accomplish the following:
• Measure adjacent structure-to-electrolyte potentials to determine if the
structure has achieved and is maintaining a sufficiently negative potential
to assure protection.
• Measure anode current outputs to determine if each anode is functioning
properly or is becoming depleted and needs to be replaced and to project
anode life expectancy.
• Check insulated flanges to determine if each such flange is properly
insulated.

082100 4-1
 • Check electrical continuity to determine if the structure being protected
contains any deleterious electrical discontinuities.

082100 4-2
 5.0 Designing the Cathodic Protection System

The stages of development for design of a cathodic protection system include the
following:
• Analysis of the requirements.
• Selection of the optimum system.
• Selection and arrangement of the specific components.
• Preparation of the drawings and specifications.

5.1 Analysis of the Requirements

Typical factors which must be considered for each structure to be protected
include the following:
• Contractual requirements
• Materials of construction.
• Resistivity (conductivity) of the interfacing medium.
• Surface area.
• Configuration.
• Coating.
• Accessibility.
• Shielding.
• Location in relation to other metallic structures.
• Presence of sources of stray current.

5.2 Selection of the Optimum System

The cathodic protection system selected should be the simplest and most
cost-effective system considering the following factors.

5.2.1 Essential Features

The following features are essential to an optimum cathodic protection system:
• Adequate protective current and driving potential capacities.
• Acceptability of projected service life.
• Freedom from uncontrollable stray current effects.
• Capability of being constructed in the available space.

082100 5-1
5.2.2 Desirable Features
The following features, while not essential, are extremely desirable if they can be
achieved without compromising the performance of a cathodic protection system:
• Maintainability.
• Cost-effectiveness.
• Simplicity.

5.3 Selection and Arrangement of the Specific Components

Following the analysis of the requirements and selection of the optimum cathodic
protection system, the design requirements may be calculated. These calculations
determine the following information for the type of system selected.

5.3.1 Sacrificial Anode Systems

The following information must be determined by calculation for a sacrificial
anode system:
• Quantity of anodes required.
• Size, weight, and material of the anodes.
• Life expectancy of the anodes.
• Current requirement from each anode.
• Location of each anode for maximum effectiveness.

5.3.2 Impressed Current Systems

The following information must be determined by calculation for an impressed
current system:
• DC amperage and voltage rating of the rectifier.
• Quantity of anodes required.
• Resistance of the ground bed to earth/water.
• Required cable size.
• Total anode circuit resistance to earth/water.
• Location of the rectifier and anode bed.

5.4 Avoiding Overprotection and Stray Current

In the design of a cathodic protection system, the designer must be careful not to
design either inherent overprotection or uncontrollable stray current into the system.

082100 5-2
 Providing more current to a structure than is required for its protection is a
problem primarily associated with impressed current cathodic protection systems. The
effects of overprotection, as it is commonly called, include the following:
• Disbonding or failure of protective coatings and linings.
• Hydrogen embrittlement of pre-tensioned or alloyed steel. This
phenomena is most often observed in the catastrophic failure of pre-
stressed concrete cylinder pipe (PCCP) and duplex stainless steel
structural members.
• Hydriding of titanium components in condenser or heat exchanger tubes
and tubesheets.
• Excessive scaling in scale sensitive applications such as condenser water
boxes.
As discussed previously, stray currents can result in electrolytic corrosion of
underground metallic structures. Whether the stray current originates with an impressed
current cathodic protection system designed by Black & Veatch or from some source
with which we are not involved, the effects must be controlled. Control consists of
providing a path back to the source of the stray current such that the current does not
reenter the earth directly from the surface of the structure which is involuntarily receiving
the stray current. The stray current return path may be a metallic bond between the
structures or it may be one or more sacrificial anodes installed as part of the affected
structure for drainage of the stray current.
Black & Veatch encourages the Owners, for whom we design impressed current
cathodic protection systems, to cooperate with the Owners of foreign structures in the
vicinity so that damage to the foreign structures will not occur as a result of stray current
from the Black & Veatch designed systems.

082100 5-3
 6.0 Preferred Methods of Corrosion Control

As stated in the Introduction, the design criteria which affect cathodic protection
are numerous, and frequently there are several effective solutions to each problem.
Identification of the best solution requires knowledge, experience, and good judgment.
The following sections describe the principal features of the corrosion control methods
usually recommended by Black & Veatch for several frequently encountered corrosion
problems.

6.1 Underground Cast Iron and Ductile Iron Pipe

All pipe should be encased in a polyethylene sleeve in accordance with AWWA
C105 and provided electrical isolation provided at the following locations:
• At transition points between iron pipe and any other type of metallic pipe
routed below grade.
• At transition points to existing iron pipe.
• At locations where the iron pipe transitions aboveground at water storage
tanks.
• At locations where iron pipe enters or exits a structure's foundation.

6.2 Underground Carbon Steel Pipe

All pipe should be factory coated, and electrical isolation should be installed at
the following locations:
• At transition points between the carbon steel pipe and any other type of
metallic pipe.
• At transition points to existing carbon steel pipe.
• At locations where the carbon steel pipe transitions aboveground.
Cathodic protection should be provided by either sacrificial anodes or an
impressed current cathodic protection system. Field test stations should be installed at
regular intervals along the piping and at each underground electrical isolation joint.
A bonding station and pipe lead wires should be installed at each location where
the carbon steel pipe transverses another pipe if either pipeline is protected by an
impressed current cathodic protection system. The lead wires from the carbon steel pipe
may be connected to the lead wires from the foreign pipeline in a bonding station, in
order to control stray current between the two pipes.

082100 6-1
6.3 Underground Prestressed Concrete Cylinder Pipe (PCCP)
Bond wires should be installed across all joints and the pipe should be encased in
a polyethylene sleeve wherever the pipe is in an area where stray currents may be present.

6.4 Underground Copper or Stainless Steel Pipe

The pipe should be cleaned, primed, and wrapped with polyethylene tape or
acceptable equal bonded insulating tape. Cathodic protection, as described previously for
carbon steel pipe, should be provided.

6.5 Underground Aluminum Pipe

The installation of aluminum underground is not recommended. In the absence of
cathodic protection or in the presence of excessive cathodic protection, the service life of
underground aluminum is unsatisfactory. Cathodic protection creates an alkaline
environment around a protected aluminum structure. Even if cathodic protection is
appropriately applied, aluminum will corrode rapidly in the alkaline environment
whenever the cathodic protection is out of service.

6.6 Underground Steel Tanks

Carbon steel underground steel tanks should be procured with an STI-P3
corrosion control system. Corrosion control regulations governing the operation of
underground steel tanks can be established by federal, state and local agencies. Verify
that STI-P3 underground steel tanks satisfy requirements for corrosion control prescribed
by the governing regulatory agency.

6.7 On-Grade Steel Tanks

On-grade steel tanks may be constructed directly on the following bases:
• Sand
• Concrete
• Asphalt
All on-grade tanks, with the exception of water tanks, installed on the sand or soil base
materials should be cathodically protected with an impressed current system.
On-grade steel water tanks installed on sand bases are typically grounded with
copper rods and a dedicated grounding ring. Black & Veatch recommends that a
cathodic isolator be installed to isolate the dedicated tank grounding system from the
plant main ground grid in the absence of fault conditions. Sacrificial anodes should be

082100 6-2
installed at each tank grounding pad. The sacrificial anode will provide neutralizing
current to the ground rod-to-tank bottom corrosion cell that will develop. The anode
attached to the copper ground rod will sacrifice itself to both the steel tank base plate and
the copper ground rod to prevent corrosion of the tank bottom.
On-grade tanks installed on concrete pads or asphalt bases shall not be
cathodically protected, as the concrete or asphalt material will effectively shield the steel
surface from the protective effect of the cathodic protection system. Tanks requiring
cathodic protection, such as fuel oil tanks, should not utilize asphalt, concrete, oiled sand
or oil impregnated materials in the foundation.

6.8 Inside Surfaces of Steel Tanks

Tanks containing liquids such as fuel oil with entrained salt water should be
cathodically protected with zinc anodes welded to the inside bottom of the tank. The zinc
will be sacrificial to the steel and prevent corrosion.

6.9 Condenser Water Boxes

Sacrificial anodes or mounting bosses for future installation of anodes are
recommended for installation inside fresh water condenser water boxes. If corrosion
cannot be controlled with sacrificial anodes, an impressed current system may be used.
An impressed current system will provide effective protection for the water boxes and
tubesheets. An impressed current cathodic protection system and permanent reference
electrodes for monitoring the water box-to-water potential is typically recommended for
each water box.
The following figure may be used to determine the condenser cathodic protection
requirements based on circulating water type and physical characteristics from the
condenser to be protected.

START

Less Than 0.25” Similar

Fresh Sea
Past Tubesheet Metals Coated
Tube Tube/ Water Water Circulating Water
Protrusion Tubsheet Box Water

More Than 0.25” Dissimilar Bare

Past Tubesheet Metals

Impressed
Galvanic
Current
CP System
CP System

082100 6-3
Black & Veatch recommends the interior surfaces of the water box wall be cleaned and
coated with a good quality coating. Refer to Black & Veatch Technical Guide, Coating
System Data Sheets, for information on selection and application of condenser waterbox
coating systems.
Some tube/tubesheet materials are sensitive to hydrogen embrittlement or
hydriding in the presence of excessive levels of cathodic protection. These materials
have a history of acceptable performance under impressed current cathodic protection so
long as the cathodic protection system is properly designed, installed and operated.
Special care must be taken when certain combinations of tube and tubesheet materials are
involved (e.g., hydrogen embrittlement of duplex stainless steel materials or hydriding of
titanium tube/tubesheet material is reportedly possible).

6.10 Traveling Screens

Cathodic protection is not required for traveling screens in fresh water. Properly
coated structure frames and screens of corrosion-resistant materials will ordinarily
provide adequate service.
In a salt water environment, all metal surfaces of the traveling screen, racks and
guides, except those fabricated with stainless steel, should be cleaned and coated with a
good quality coating. This coating will aid in the prevention of corrosion to those parts
of the screen which are out of the water and exposed to the salt water in the splash zone.
Refer to Black & Veatch Technical Guide, Coating System Data Sheets, for information
on selection and application of travelling screen coating systems.
A cathodic protection system should be provided and should consist of an
impressed current system using anodes and reference electrodes installed in each screen
intake bay in an evenly distributed pattern.

6.11 Supplementary Methods of Protection

Material selection, coating, encasement, joint bonding and insulated flanges or
any combination thereof, are supplementary methods of protection which may be used in
conjunction with, or in place of, cathodic protection.

6.12 Alternate Corrosion Control Methods

Chemical treatment is an important corrosion control method normally used in
closed cycle cooling water systems, steam systems and other water systems.

082100 6-4
 7.0 Maintenance of the Cathodic Protection Systems

Owners are often unfamiliar with the benefits of proper maintenance of cathodic
protection systems. An arrangement for direct communication between a knowledgeable
representative of the Owner and the Black & Veatch materials application section should
be made, on each project where cathodic protection will be provided, to discuss
maintenance procedures.
The Owner should be made aware of the capabilities and limitations of each
cathodic protection system and should be provided with basic information on how to
recognize problems as they occur.

7.1 Outline of Routine Performance Testing Procedures

The Owner should be provided with an outline of the recommended procedures
for routine performance testing of each cathodic protection system. Included in the
performance testing outline should be a recommended testing schedule.

7.2 Black & Veatch Services

The Owner should be advised that Black & Veatch is capable of performing many
of the recommended routine tests and to correctly interpret the results of such tests.
Black & Veatch will recommend remedial measures when test results indicate their
necessity and, if retained to do so, will oversee modifications and perform tests to verify
that any cathodic protection system deficiencies have been corrected.

082100 7-1
 8.0 Basic Design Philosophy Recommendations

The following are the recommendations of the materials application section

concerning the basic design philosophy of cathodic protection for generating stations.

8.1 Connection of Pipe to Main Ground Grid

Should the underground piping network at a generating station be physically
connected to the main ground grid, or should it be totally isolated?
Electrical isolation of underground piping from the ground grid is preferred;
however, the underground piping network has been connected to the ground grid on some
projects at the request of the client.
Underground ferrous metals (such as steel, ductile iron, and cast iron) will be
anodic to the copper ground grid if they are connected together. To avoid accelerated
corrosion of the ferrous metal, it is necessary to provide sufficient protective current to
raise the potential of all metal surfaces to the same level relative to the surrounding soil.
Although design variations make a meaningful cost analysis impractical, direct
connection of underground piping to the station grid may be expected to increase the total
cost of a cathodic protection system for underground station piping by an order of
magnitude. The actual cost will vary depending on the size of the project, the amount of
underground ferrous pipe, and the resistivity of the soil surrounding the pipe and ground
grid.
The alternatives for cathodic protection of underground station piping (listed in
order of preference) are as follows:
• Cathodically protect the underground ferrous pipe and structures with
sacrificial anodes and electrically isolate the buried, protected structures
from the ground grid, the building steel, the reinforcing steel, and the
aboveground piping.
• Install an impressed current system that will be sufficient to protect the
underground ferrous pipe, structures, ground grid, building steel, and
reinforcing steel. Insulated flanges are not required.

8.2 Soil Resistivity Measurements

Field measurements of soil resistivity using the Wenner Four-Electrode Method
should be performed by Black & Veatch in accordance with ASTM G57.
Soil resistivity data obtained during site geological surveys should obtain
adequate information for cathodic protection system design.

082100 8-1
8.3 Multiple Bond Wires at Pipe Joints
Should one or two bond wires be installed across each pipe joint for electrical
continuity?
If electrical continuity is to be achieved along a section of slip-fitted pipe, a wire
is exothermally welded across the joint. If the exothermal weld at either end is
improperly made, continuity will be interrupted resulting in loss of protection for a
portion of pipe. The possibility of a single inferior weld will increase with the length of
pipe and the subsequent number of welds. Black & Veatch recommends the installation
of two parallel bond wires across each such joint. If the Owner's decision is to use one
bond wire instead of two, the contractor must maintain strict quality control during the
exothermal welding process and backfilling of the pipe trench.

8.4 Contact Between Ferrous Pipe and Reinforcing Steel

When a relatively small area of an underground ferrous pipe is encased in
concrete, such as where it enters a building, is it important to prevent contact between
the ferrous pipe and the reinforcing steel in the concrete?
The natural potential of reinforcing steel in concrete is approximately the same as
that of copper, therefore, when ferrous pipe is attached to the reinforcing rods, a
dissimilar metals corrosion cell will exist and the ferrous pipe will corrode. Even when
the underground ferrous pipe is intentionally connected into the main copper ground grid,
as previously discussed, it is essential that the contractor avoid any direct contact between
the reinforcing steel and the pipe.

8.5 Condenser Water Box Protection

What is Black & Veatch's basic cathodic protection design for condenser water
boxes?
The basic cathodic protection design for condenser water boxes depends largely
upon the type of metals used for the tubes, tube sheets, and water box walls, and whether
the water inside the water box is fresh water or salt water.
The following steps may be used as a basic guide for the preliminary cathodic
protection design. By observing the installation order, the desired level of protection may
be provided while avoiding costly and perhaps damaging overprotection.

8.5.1 Galvanic Anode Application

• Install anode mounting bosses inside of the water box wall as close to the
tube sheet face as practical, typically 18" from the tubesheet.

082100 8-2
8.5.2 Impressed Current Anode Application
• Design and install an impresseed current system using mixed metal oxide
or platinized titanium probe-type anodes and an automatic potential
control rectifier.
• Install permanent reference electrodes to measure the degree of protection
achieved.
• Adjust the rectifier so that the protective current will be sufficient to
control corrosion but not in excess to cause hydrogen embrittlement or
hydriding of tube/tubesheet.
• Monitor and adjust the system on a routine basis.

082100 8-3
 9.0 Summary

Developments in corrosion control technology, since the early 1800s, have

provided feasible and cost-effective methods for limiting, and in some cases eliminating,
the corrosion of most underground and submerged metallic pipe and structures. With the
cost of materials and installation constantly increasing, the design of effective cathodic
protection systems is becoming a recognized necessity for both new and existing
installations of materials which are subject to galvanic and electrolytic corrosion.
The fact that corrosion is affected by numerous variables, makes the design of an
effective cathodic protection system unique. In some situations, the cost of effective
long-term cathodic protection may prohibit its use or, continuing maintenance may
necessitate periodic inspection and adjustment which the Owner may not desire or be
prepared to perform. For this reason, it is important that the cathodic protection designer,
the mechanical and structural engineers, and the Owner all work together with regard to
material selection, component arrangement, installation procedures, and collection of test
data to develop a coordinated system which will provide acceptable service at the lowest
cost.

082100 9-1
 Appendix A
Process Map of
Design, Construction, and Testing Activities

082100 A-1
 Appendix A
Process Map of
Design, Construction, and Testing Activities

Design Design Data Design Field Services

Requirements • Soil resistivity • CP system type • Resident
• Review scope • Water • Anode Develop engineering
documents: resistivity selection Construction • System testing
contract, SDS, • Vendor • Quantity of Drawings and
PDM, schedule equipment data anodes commissioning
• Review code • Underground • Rectifier • Provide as-
and standard utilities data capacity Issue built drawings
requirements • P&ID's • Anode spacing Construction
• Pipeline list • Equipment Documents
• Plant interface
arrangements requirements Develop
• Piping detail Procurement
drawings & Installation
• Foundation Specifications
drawings

082100 A-2
 Appendix B
Typical Cathodic Protection Details

082100 B-1
 Appendix B
Typical Cathodic Protection Details

List of Typical Cathodic Protection Details

Cathodic Protection - Underground Pipe

Cathodic Protection - Water Storage Tanks

Cathodic Protection - Insulated Fitting Details

Cathodic Protection - Fuel Oil Storage Tanks

Cathodic Protection - Condenser (Impressed Current Anode)

Cathodic Protection - Condenser Sacrificial Anode and Mounting Stud Arrangement

082100 B-2