Essay on Cathodic Protection System for

LPG Underground Tank

Prepared by: Hussain Abdullah Al Khumairi

Trainee Mechanical Engineer At Al Shaikh Factory and Company for Cathodic Protection
Introduction: LPG Underground Tank corrode due to an electrochemical reaction between the tank and the surrounding soil.
The process of corrosion occurs due to small voltage differences on the steel surface that result in the -flow of DC current from
one location to another. Where current flows from the tank into the soil corrosion occurs. This location is called the anode in a
corrosion circuit. Where current flows from the soil to the tank, no corrosion occurs. The progress of corrosion is determined by
the amount of current flowing between the anode and the cathode and whether the locations of the anode/ cathode remain
constant over time. Corrosion rates are generally higher in wet soil environments since the conductivity of the soil promotes
the -ow of DC current in the corrosion circuit.

Concept of SACP: Sacrificial systems work by creating a galvanic connection between two different metals. The most common
anode material is magnesium, which when coupled to steel results in DC current -ow from the magnesium to the steel. The open
circuit potential of steel is about -0.50 volts referenced to a copper sulfate electrode, while the open circuit potential of
magnesium is about -1.55V to -1.80V. By connecting the two metals together, the difference of 1 to 1.25V volts results in
current -flow to the tank that overcomes the natural corrosion cells that exist on the tank. With this current available to the tank,
no corrosion occurs.

fig 1: Galvanic cell fig 2: Schematic of SACP System

Assembly of Pre-packed Mg Anode:

1. Cut the required length of cable.
2. Braze the cable with the insert.
3. Seal the brazing joints by using 2-part epoxy.
4. Prepare the backfill mixture.
5. Ratio: Bentonite - 25% + Gypsum - 70% + NaSO4 - 5%.
6. Fill the mixture up to ¼ length of the bag.
7. Place the Bare Anode at the center.
fig 3: Anode Bar
8. Fill the remaining portion with the backfill mixture.

fig 4: schematic of Pre -Packed Mg Anode fig 5: Pre-Packed Mg Anode

Procedures of Connection:
The connection of the negative cable and the monitoring on the LPG tank recommended to use threaded stud on the any
accessible metallic connection point to the for sure connection point must be with a moisture-proof material.

1. Making hole on the external plate of the LPF Tank as shown in figure 6.

2. Using threaded stud to fasten it on the hole and connected the cable lug.

3. coating all connection points with moisture-proof material as shown in figure 7.

fig 6: Preparing Hole fig 7: Coating Connection Point

Procedures of Installation Pre-packed Mg Anode:

1. Soak the Pre-packed anode in water, at least 4 hours before the installation, see figure 8.
2. Take the open circuit potential with respect to the CSE.
3. Measure LPG tank to soil potential with respect to the CSE.
4. Anode shall be installed vertically as shown in figure 9.

fig 8: Soaking the Pre-packed anode. fig 9: Installation Pre-Packed Mg Anode

5. Tank area shall be backfilled with native soil, free of stones and rocks.
6. Measure the open circuit potential of the anode after being buried in soil and pouring sufficient water.
7. Connect the negative cable with the anodes tail cables.
8. Measure the potential of the LPG Tank with respect to CSE after connection.

fig 10: Design of CP system of LPG Tank

Analysis of Results:
Table 1: Field Records Reading (mV) Condition as per NACE Status

V Neural (mV) -650 NA Acceptable

V Open Circuit (mV) for 20
-1714 to -1650 -1.600 to -1750 Acceptable
Anodes

V Polarized (mV) -1257 -950 to -1180 Acceptable

Continuity (Ω) 0.4 1.00 Ω ˃ Acceptable

Note: All measurements with respect to Cu/CuSO 4

V Neutral: LPG Tank to soil potential measurements (before connecting negative cable to anode tail).

V open circuit: Open circuit potential of Mg anode (before connecting negative cable to anode tail).

V polarized: LPG Tank to soil potential measurements after connecting the negative cable to the anode tail cable.

Continuity: Resistance between negative cable and monitoring cable which are connected to the LPG Tank.

Note: If the area is backfilled with soil, direct connection between negative cable and anodes tail cables must be done as
temporary connection till the junction box installed to avoid present of corrosion.

Isolation: Any pipelines or earthing connected to the structure shall be isolated by using IF kits and PCRs respectively.
Installation of Permanent Reference Electrode:
The Cu/Cu SO4 permanent reference electrode should be installed at the depth of half from the height LPG tank.

Problem Faced: Client request to backfilling the LPG Tank area urgently where we are facing problem to get reference
electrode due to problem with supply chain.

Solution: First we take instrument wire which is to be connected to the reference electrode, through conduit to junction box
after that install PVC pipe and take the cable through it then backfilling the area see figure 11.

fig 11: Installation of Reference Electrode