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Corrosion Webinar Series - CP System Testing
Corrosion Webinar Series - CP System Testing
MST
Your Friendly TSC Corrosion Staff:
Jessica Torrey
Ph.D. Materials Science & Engineering
jtorrey@usbr.gov
303-445-2376
Daryl Little
Ph.D. Materials Science & Engineering
dlittle@usbr.gov
303-445-2384
Lee Sears
Ph.D. Materials Science & Engineering
lsears@usbr.gov
303-445-2392
protection system for buried -0.65 V -0.7 V -0.60 V -0.65 V -0.7 V -0.60 V
Polarization
involves a good bonded coating
and cathodic protection. -0.65 V -0.7 V -0.65 V -0.65 V -0.7 V -0.65 V
Corrosion
Mitigated
*adapted from NACE CP2 Manual
Galvanic Anode CP System
• Also known as Sacrificial
Anode Cathodic Protection
Test Station
• This system provides a
cathodic current by galvanic
corrosion or by sacrificing
one material to prevent
Electrical corrosion of the other
Continuity Sacrificial
Bonds Anode material
Rectifier
• A direct current power source
Test Station forces current to discharge
Junction Box from anodes, through the
electrolyte, an onto the
structure to be protected
Electrical
Continuity
Bonds • Both the structure and the
Anodes anode must be in contact with
the electrolyte
Protected Structure
Impressed Current CP System
Graphite Anodes Anodes:
• Graphite, High-Si Cast Iron, Mixed Metal Oxide,
Platinum, etc.
High-Si Cast Iron Anode • Anodes Normally Connected Through Calibrated
Shunts in Junction Box
• Installed via Linear or Deep Anode Ground Beds
Applications: Angostura Dam Radial Gates, May 2004
• Pipelines
• Reinforced Concrete
• Pumping Plant Pump Sumps
• Trashracks and Gates
• Tanks
Requirements:
• High current requirements
Mixed Metal
• Can handle large or poorly coated structures Oxide Disk
• More effective in high resistivity soils Anode
Corrosion Management Programs
Effectiveness of Well Designed Program
Economic Benefits
Standard Items
Include:
• Steel-toed boots
with insulated
soles
• Hardhat
• Work gloves
• Safety glasses
• Reflective vest
CP System Components
Above-Ground Components
Test Station
Busbar
Bond Bar
Hardware
HMWPE Cu Cable
AC Primary
Breaker AC Secondary
Breaker
Shunt
Ammeter
Voltmeter
Negative DC
Positive DC Output - to
Output - to structure
anode
Lightning
Arrestor
Buried/Submerged Components
Mg Anodes in GA horizontal bed
Graphite anodes in deep well
IC system
Pt/Nb wire
anode in
slotted PVC
High-Silicon Cast Iron tube for
Metallurgical Bond anodes submersion
CP Testing Tools and
Equipment
Portable Reference Electrode
Saturated
CuSO4
solution Plastic
Container
Pure Cu Rod
Cap
Porous Plug
• Capable of measuring DC
voltages between +/- 0.1
millivolt to +/- 100 volts
Structure-to-
Corrosion Close-Interval Rectifier CP System
Standard/ Electrolyte
Inspection Survey Inspection Data Analysis
Guideline Survey
Frequency Frequency Frequency by TSC
Frequency
NACE Standard 2-month
Annually
SP0169 intervals
Every 5 yrs;
Annually. When when leaks
structure is occur, survey
USBR available due to adjacent line; if 2-month
Annually Every 3-5 years
Corrosion Staff dewatering, system has intervals
maintenance, been off for an
etc. extended period
of time
Record Keeping
• Testing Records should include:
– General: – Measurement Data:
• Tester’s Name • Type of Measurement (VON, VOFF)
• Date and Time of Test • Value
• Weather Conditions • Polarity (+/-)
• Location of Test Site (GPS) • Units (V, mV, mA, etc)
• Type of reference electrode (CSE)
Structure-to-Electrolyte Potential
Close Interval Survey
Inspection at Rectifier
Structure-to-Electrolyte Testing
* aka Pipe-to-Soil Potential
• Galvanic-
– Interruption is done manually
• Impressed Current-
– Interrupter must be hooked up at rectifier
– All rectifiers on a line must be hooked up to get a true VOFF
IR VOFF
Polarization
VNATIVE
(+)
Structure-to-Electrolyte Testing
• Bury cone end of Cu/CuSO4 reference electrode in ground above pipe
• Make sure contact to soil it good- wet with water if necessary
Remove for
VOFF
Structure
Cables
(black)
Anode Cable
(red)
Junction Box Variable
from Rectifier Resistors
For GACP:
• Measure VON and VOFF at Ground
structure cable, removing Ianode
structure cable manually
• Measure Ianode for each Shunts
anode across shunt
• Do not need to measure
Vanode unless system is new
or has been off for an
extended period of time
Structure
For ICCP: Cable
• Do not remove structure
cable- attach interrupter to
rectifier to measure VOFF
• Measure Ianode across
shunts
• Do not measure Vanode
Anode VON/ VOFF
Cables
Pipe-to-Soil Testing- GACP System
VIDEO
Close Interval Potential Surveys
• Conducted to assess effectiveness of
CP and to identify possible corrosion
problems over the entire length of the
pipe.
• Secure Cu reel wire to positive terminal
on voltmeter and to structure cable on
first TS/JB; negative terminal goes to the
reference electrode.
• Take structure-to-electrolyte potentials at
~3 foot intervals along pipe. Pipe locator
is useful to follow line.
• Use current interrupters at rectifier to
measure VON/VOFF of ICCP systems.
May also take VON only survey for GACP
systems.
Rectifier Inspection
One Last Note on Safety…
– What do you want to hear about? Please suggest topics for future
webinars!
Questions? Comments?