Cathodic Protection Engineering

-Introduction to the course

-Understanding corrosion

V.S. RAJA
Professor
Department of Metallurgical Engineering and
Materials Science
Indian Institute of Technology Bombay
Mumbai-400076, INDIA
Email: vsraja@iitb.ac.in; rajavs.rajavs@gmail.com
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 Course Content
• Focus is on pipelines
• Principle
• Criteria
• Pipeline corrosion monitoring/ assessment
(surveys)
• Anode ground-bed design
• Anode materials
• Stray current corrosion & control
• Coatings
• Internal corrosion of pipelines
• Anodic protection VS Raja, IIT Bombay 2
 Some important books
1. Bianchetti, R.L., (Eds), Peabody’s control of pipeline Corrosion, 2nd Edition, NACE International, Houston,
2001
2. Morgan, J., Cathodic protection, 2nd Edition, NACE International, Houston, 1993
3. Tagare, D.M., Cathodic protection and control methods, Tagare publication 1972, Bombay
4. Pritula, V.A., Cathodic protection of pipelines and storage tanks, Her majesty's stationary office, London
1954
5. Applegate, L.M., Cathodic protection, McGraw-Hill book, New York,1960
6. Parker, M.E., Peattie, E.G., Pipe line corrosion and cathodic protection, 3rd Edition, Gulf Publishing
company, Houston,1984
7. Berkeley, K.G.C., and Padmanabhan, S., Cathodic protection of reinforced steels in concrete, Butterworths,
London, 1990.
8. Baeckmann, W.V., and Schwenk, W., Handbook of cathodic protection : The theory and practice of
electrochemical corrosion protection techniques, Portcullis Press, UK, 1975
9. IS 8062-2 (2006): Code of practice for cathodic protection of steel structures, Part II: Underground
pipelines [MTD.24: Corrosion protection]
10. https://www.youtube.com/watch?v=Vd8Kvz39msQ&list=PLOzRYVm0a65fl3nMhfMH0FvfpCGiBQDvG
for Aqueous Corrosion and Control
11. Perumal, K.E., and Raja,V.S., Corrosion Failures: Theory, Case Studies and Solutions, John Wiley & Sons,
NJ, 2015, USA VS Raja, IIT Bombay 3
 Contents of this lecture ( Lecture-1)

• Importance of buried structures

• Introduction to corrosion
• Forms of corrosion
• Corrosion control measures

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First cross-country pipeline with CP in India
Nahorkatia in Assam to Barauni in Bihar
12” / 16” dia – 1000 km long
Coating: coal tar with fibre glass inner and outer wrap
Commissioned: 1964

• Hazira-Bijapur-Jagdishpur (HBJ)
• Non-branched 1,750 kilometer
grid was commissioned in 1997.
Now 3,474 km, additional
branches

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 Current Trend

Y-2014, 120 countries : (https://en.wikipedia.org/wiki/Pipeline_transport, 11-11-2020)

Existing: 3,500,000 km of pipeline
Planned: 190,905 km
Y-2015, India (Annual Report 2015-16, Ministry of Petroleum and Natural Gas, Government of India
http://petroleum.nic.in/sites/default/files/AR15-16.pdf, 11-11-2020)

Existing: 15,000 km ( 1000 km in 1964)

Planned : 15,000km
Corrosion Protection, Plant Integrity and Residual Life Assessment

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 Tanks Ship-hull

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Corrosion Basics

Environment
Material
Corrosion

Design

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Corrosion: Deterioration of materials in
presence of a chemical environment leading
to loss in their function.

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 Functional requirements of materials
• Mechanical • Physical
– Strength – Thermal Conductivity
– Ductility – Electrical Resistance
– Toughness – Magnetic
– Wear – Optical
• Dimensional Stability – acoustic
• Wear
• Machinability • Chemical
– Catalytic

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 Exposure to
Corrosive/chemical medium Corrosion Tendency

Metal

Energy
level

Ore

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 Thermodynamics

⮚ Corrosion of metals and alloys involves

oxidation from its metallic state
⮚ Must obey the thermodynamic criteria as any
other processes

Fe+2H2O → Fe (OH)2 +H2 ΔGo = −15.72 kJ/mol

Au +3/2 H2O +3/2 O2 → Au(OH)3 ΔGo = 157 kcal

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Metallic corrosion must at least have two
partial reactions

Fe+2H2O → Fe (OH)2 +H2

Fe → Fe2+ + 2e ( Oxidation)

2H2O + 2e → 2OH- + H2 (Reduction)

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 e-

e-F Fe2+
ee
-

e-F Fe2+
ee
-

e-
F Fe2+
ee
-

F Fe2+
e-

e
Fe Fe2+
e-

Fe
e-

Metal

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 H+

HH
H2 H+

e e
-
F Fe
-
2+

e
Fe Fe 2+
e- e
H+
-

HH
H 2
H+

Metal

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 What are these cathodic reactions?
2H+ + 2e → H2
(Hydrogen reduction reaction)

2H2O+ 2e → H2
(Reduction of water at relatively negative potentials)

O2 + 2H2O+ 4e → 4(OH)-
(Reduction of dissolved O2 in water)

M+ + e → M
(Metal deposition: Cu ions from return condensate)

Mn+ + e → M(n-1)+
(metal reduction: Ferric to ferrous) 16
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Electrochemical Nature of Corrosion
R
Ox
e M+

e M+
Metal Environment
R
Ox

Ox : Electron acceptor (H+, M+, O2 )

R : Reduced species (H2, OH-, M )
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 Various Forms of corrosion
Uniform Corrosion Galvanic Corrosion

Crevice Corrosion Pitting Corrosion

Intergranular Corrosion Selective Leaching

Erosion/Cavitation Stress Corrosion Cracking/Hydrogen

Corrosion Assisted Failures

Microbial Corrosion High Temperature Oxidation

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 b
IGC

HIC
100 μm
SCC

Cavitation

Microbe induced corrosion

Crevice
Corrosion

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Pitting
 Corrosion Control Management
Strategies/Practices
Prevention Methods
⮚ Start at the Design Board
⮚ Cathodic protection ⮚ Fabrication
⮚ Inhibitors ⮚ Commissioning
⮚ Protective coatings ⮚ Operation
⮚ Selecting proper ⮚ Inspection
materials ⮚ Maintenance
⮚ Design ⮚ Education

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Factors affecting service life/performance of
equipment
• Design
• Materials of construction
• Specification
• Fabrication and quality control
• Operation
• Maintenance
• Environmental conditions
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 Summary
• Buried engineering structures are one of the major infrastructures
– Pipelines, storage tanks ( off-shore structures)
• Corrosion, a spontaneous process, is a major cause of failures
– Oxidation of metals and reduction of some species from the
environment
– Several forms of corrosion occur on metallic structures
• Cathodic protection is a dominant method of controlling
corrosion

Email: vsraja@iitb.ac.in; rajavs.rajavs@gmail.com

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