Cathodic Protection

Training Course
Level 1

Presented by

Mahdi Aki

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 Chapter 1

-Basic Electricity

-Basic chemistry & basic corrosion

-Type of corrosion

-Potential and EMF series

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 Basic Chemistry
- Corrosion definition

❑ Is the deterioration of a substance (usually a metal) or its properties

because of a reaction with its environment

❑ 2 major types of environment:

- Atmospheric

- Electrolyte

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- Oxidation and Reduction

- Oxidation
- loos one or more electron from an atom or molecules which
form a positive Ion

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 Reduction

-Gain one or more electron from an atom or molecules

which forms a negatively changes Ion or natural

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- Electrochemical circuit

- Electrolyte

- Ionization

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- Corrosion Cell
- Anode

- Cathode

- Electrolyte

- Metallic connection

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 Galvanic Corrosion and EMF series
• EMF series • Metal with smaller
o
Vmetal o
metal Vmetal corrodes.
Au +1.420 V • Ex: Cd-Ni cell
Cu +0.340
Pb - 0.126
Sn - 0.136
Ni - 0.250 o
Co - 0.277 DV =
Cd - 0.403 0.153V
Fe - 0.440
Cr - 0.744
Zn - 0.763
Al - 1.662
Mg - 2.262
Na - 2.714
K - 2.924 www.PSB-CO.com 8
 Due to the potential difference existing between the anodic and
cathodic areas, positively charged metal ions leave the metal
surface at the anode while electrons leave the surface at the
cathodes.
 At the cathode area dissolution of metal does not take place but
reactions occur in the electrolyte.

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- Anode & Cathode reaction

𝑀 ՜ 𝑀𝑛+ + 𝑒 − 𝐴𝑙 ՜ 𝐴𝑙 3+ + 3𝑒 −

𝐹𝑒 ՜ 𝐹𝑒 2+ + 2𝑒 − 𝐻𝑔 ՜ 𝐻𝑔+ + 𝑒 −

𝐻+ + 𝑒 − ՜ 𝐻0 2𝐻2𝑂 + 𝑂2 + 4𝑒 − ՜ 4𝑂𝐻 −

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Forms of Corrosion
 Uniform

 Pitting

 Crevice Corrosion or Concentration Cell

 Galvanic or Two-Metal

 Stress Corrosion Cracking

 Intergranular

 De-alloying

 Erosion Corrosion

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 General Corrosion

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 Pitting

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 Crevice Corrosion

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 Galvanic Corrosion

Big Cathode, Small Anode = Big Trouble www.PSB-CO.com 15

 Galvanic Corrosion
1.Different Metals

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2.Old & New Steel

PETUNIA TRAINING INSTITUTE

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3- Other shapes of galvanic corrosion

3.Dissimilar Alloys

4.Impurities in Metal
No manufacturing is perfect ,Small impurities may be mixed into the
metal as it is produced or cooled. this impurities may be anodic or
cathodic
5.marred or scratched surface
A marred or scratched surface becomes anodic to the surrounding surface

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3- Other shapes of galvanic corrosion

6.Stressed Metallic Section

Metal which is under stress becomes anodic to metal
which is not under stress

7.Temperature
Metal which is at an elevated temperature becomes
anodic to the same metal at a lower temperature

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 SCC

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 Inter-granular corrosion

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 Selective corrosion

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 Layer Corrosion

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 Erosion Corrosion

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Acidity & Alkalinity
❑ Acid : higher concentration of H+
❑ Alkaline : higher concentration of OH- ions than H+ ions .
❑ PH= -Log (H +)
❑ PH is important in corrosion ,cathodic protection and
anodic protection work.

❑ For some metals such as steel ,the rate of corrosion

increases appreciably below a PH of about 4 .

❑ Between 4 and 8 corrosion rate is fairly independent of PH.

❑ Above 8 ,the corrosion rates tend to decrease . (passivity )

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 Pourbaix Diagram

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❑ The corrosion rate of some metals such as : aluminum lead
and zinc tend to increase in alkaline environment above a
pH of about 8.

❑ This is because the protective oxide film on the surfaces of

these metals is dissolved in by alkalis as well as strong
acids .

❑ Metals that corrode under

low and high PH conditions
are termed amphoteric
metals .

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Causes of Corrosion
1.Dissimilar Environment

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2.Different Concentration of Oxygen

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3.Concrete & Soil Electrolyte

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4.Non Homogeneous

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5- Other Causes of Corrosion

Backfill Impurities

Biological Effects
most bacteria grow best in temperature of 15°c to 45°c

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Stray Current Corrosion

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Stray Current Corrosion
B: Discharge
point ,Tank
Corroded

A:Pick Up
point,
Tank not
corroded

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 Chapter 2 Cathodic Protection principals

-Standards
-Definition And Principals
-Primary Site Survey And Tests
-Reference Electrodes
-Type of Cathodic Protection Systems
-Criteria
- System Choosing

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 Standards
RP0169 - C ontrol of External Corrosion on Underground or Submerged
Metallic Piping Systems
RP0575 - Internal C athodic Protection Systems in Oil-Treating Vessels

- NACE RP0180 - C athodic Protection of Pulp and Paper Mill Effluent Clarifiers

RP0285 - C orrosion Control of Underground Storage Tank Systems by

C athodic Protection

BS 7361 (1991)
RP0186 - Application of Cathodic Protection for External Surfaces of Steel Well
- C asings
RP0286 - Electrical Isolation of Cathodically Protected Pipelines

RP0388 - Impressed Current C athodic Protection of Internal Submerged

ISO 15589-1,2
Surfaces of Steel Water Storage Tanks
- RP0290 - C athodic Protection of Reinforcing Steel in Atmospherically Exposed
C oncrete Structures
RP0193 - External Cathodic Protection of On-Grade Metallic Storage Tank
Bottoms

- DNV-401 RP0194 - C riteria and Test Methods for Cathodic Protection of Lead Sheath
C able
RP01 96 - Galvanic Anode Cathodic Protection of Internal Submerged
Surfaces of Steel Water Storage Tanks
TM0294 - Testing of Embeddable Anodes for Use in C athodic Protection of

- API 651 Atmospherically Exposed Steel-Reinforced Concrete

TM0497 - Measurement Techniques Related to C riteria for C athodic Protection

on Underground or Submerged Metallic Piping Systems

- Military Standards(UFC 503)

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 E-Books

- Cathodic protection J. H. Morgan

- Control Of Pipeline Corrosion Peabody

- Pipeline corrosion and CP Marshal E. Parker

- Hand book of cathodic corrosion protection W. von Baekmann

- Corrosion and Protection Eainar Bardal

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 Definition and principals
 The concept of cathodic protection (CP) involves reducing
the potential difference between the local anodic and
cathodic sites to zero.

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 Cathodic protection is a polarization phenomenon

 When current goes from the electrolyte to the metal, a

reduction reaction occurs.

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 Cathodic protection steps

Current Requirement?

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 Type of CP system

 Galvanic (sacrificial System)

 Impressed current

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 Summery

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 Definition
 Anode
 Cathode
 Backfill
 Stray current
 Continuity bond
 Current density
 Electrical isolation
 Electrode potential
 Electrolyte
 Ground bed
 Impressed current
 IR drop
 Polarization
 Rectifier
 Reference electrode
 Test station

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 Site survey

 Soil resistivity (ASTM G57)

 pH
 Moisture
 Cl and Sulphate Determination
 SRB

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 Reference Electrodes
 Reference electrodes, or half-cells, are important devices that
permit measuring the potential of a metal surface exposed to an
electrolyte.

 TYPES
 SHE (standard Hydrogen Electrode)
 CSE ( copper/ copper sulphate Electrode)
 Silver-Silver Chloride Reference Electrode
 Calomel Reference Electrode
 Zinc Reference Electrode
 Manganese Dioxide
 Graphite Electrode

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 SHE

• basic standard

• Laboratory only!

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 CSE (copper/Copper Sulphate Electrode)

 most commonly used

 underground structures
 fresh water
 Not suitable for use in a chloride electrolyte

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 Tips

1. Keep clean
2. Periodically replace copper sulfate
3. super-saturated solution only
4. Chloride contamination (–20 mV at 5ppm Cl ~ -95mV in
10 ppm Cl)
5. Calibrate with new and fresh one
6. Temperature ( above 25°C , 0.9 mV/°C must be added)
7. Sunlight ( 0~50 mV)

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 Silver-Silver Chloride Reference Electrode

 Ag-AgCl
 Used in seawater
 concrete structures

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 Calomel Reference Electrode

 mercury-mercurous
 laboratory electrode

 Manganese Dioxide

 reinforced concrete structures

 Graphite Electrode
 reinforced concrete structures

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 Criteria
 There are three NACE criteria that apply to steel: two involve a
structure-to electrolyte potential of equal to or more negative
than −850 mV in reference to a copper-copper sulfate reference
electrode (CSE), and one is a polarization change of 100 mV.

1. A negative (cathodic) potential of at least 850 mV

E−850= Eon −IR.

2. A negative polarized potential of at least 850 mV

Instant Off Potential

3. A minimum of 100 mV of cathodic polarization

∆E100= EOFF −EDEPOLARIZED

∆E100= EOFF −ECORR

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 Field Measurement

Structure-to-reference potential
Test coupons
Current measurements
Surface potential measurements
Soil resistivity
Direct observation
Leak frequency
In-line inspection.

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 Potential survey

Locate anodic areas on non-cathodically protected

pipelines

Determine the effectiveness of cathodic protection on

cathodically protected structures
Locate stray currents
Locate electrical shorts and contacts
Locate coating holidays.

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 Error source

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 Minimizing the distance between the reference electrode
and the surface

 Measuring the potential when the current flow is

interrupted (instant-off potential)

 Measuring the formation of polarization or decay of

polarization of the structure when the current is energized
or disconnected

 Installing external CP coupons in the vicinity of the

structure to replicate a coating holiday

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On a coated pipeline, most of the voltage drop is concentrated in the
immediate vicinity of the holiday. Typically 95% of the total voltage drop
between the reference and the steel exposed at the holiday is found within
about 10 diameters of the holiday (i.e., 10 d). For a 1 cm (0.393 in) diameter
holiday, 95% of the voltage occurs within a radius of 10 cm from the holiday.

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 Voltage drops also occur incurrent-carrying metal paths and if the
connection to the pipe is remote from the location of the reference
electrode,

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 Interrupt the current and measure the potential before significant depolarization
occurs (often called the “instant off” potential).

 Place the reference electrode close to the exposed metal surface of the structure
being measured. On a coated structure the reference must be placed next to a
coating fault (holiday).

 Place the reference electrode at remote earth to include maximum IR-drop error
and then subtract this error from potentials measured with the reference located
nearer the structure.

 Decrease the current in steps while measuring the change in structure-to

electrolyte potential and the resultant surface voltage gradient. The curve created
from this data is extrapolated to zero current to identify total IR drop error in the
structure-to-electrolyte potential at full current.

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 Key factors in selecting an interruption cycle include:

 Minimizing depolarization during the day

 Minimizing depolarization during the OFF period
 Maintaining polarization over the duration of the survey project
 Ability to measure accurate OFF potential data after the “spike” has
dissipated.
 Maintaining an 80%/20% or 75%/25% “duty cycle” is important to
minimize depolarization during the day and over the duration of the
survey project. The duty cycle is the percentage of ON time to OFF time.
An example would be 3 seconds ON and 1 second OFF.
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 Stepwise Current Reduction Method

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 CIPS

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 Current Measurement

 Using an Ammeter to Measure Current

 Using a Shunt to Determine Current Magnitude

 Zero Resistance Ammeter

 Clamp-On Ammeter

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 Pipe current :

 Clamp meter

 2-Wire Line Current Test

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 Earth Current Measurements

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 Surface Coating Evaluation

 Pearson Survey
 DCVG Survey
 Pipeline Current Mapper
 Coating Resistance

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 Direct Curent Voltage Gradient (DCVG)
Survey

 The interrupter is set to cycle at a

very fast rate with the ON period
less than the OFF period, such as
a 1/3 second ON and 2/3 second OFF.

 The analog voltmeter is a very sensitive meter with the ability to

adjust the input impedance and the scale with which the meter is
displaying the data. Deflections of less than 1 mV are easily
noticeable on this voltmeter. In addition, the needle has the
ability to deflect in both the positive and negative directions from
the zero point which assists in determining the direction the
current is flowing in the soil.
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 System Choosing
 Sacrificial System
GALVANIC ANODE
1) They are independent of any source of electrical power.
2) Their usefulness is generally restricted to the protection of well-coated structures Or the provision of local
protection, because of the limited current that is economically available.
3) Their use may be impracticable except with soils or waters with low resistivity.
4) They are relatively simple to install; additions may be made until the desired Effect is obtained.
5) Inspection involves testing, with portable instruments, at each anode or between adjacent pairs of anodes.
6) They may be required at a large number of positions. Their life varies with conditions so that replacements
may be required at different intervals of time at different parts of a system.
7) They are less likely to affect any nearby neighboring structures because the output at anyone point is low.
8) Their output cannot be controlled but there is a tendency for their current to be self-adjusting because if
conditions change such that the metal to be protected becomes less negative, driving e.m.f., and hence current,
increases. It is possible, by selection of material, to ensure that the metal cannot reach a potential that is
sufficiently negative to damage paint.
9) Their bulkiness may restrict flow and/or cause turbulence and restrict access in circulating water systems.
They introduce drag in the case of ships' hulls.
10) They may be bolted or welded directly to the surface to be protected thus avoiding the need to perforate
the metal of ships' hulls, plant to be protected internally, etc.
11) Their connections are protected cathodically.
12) They cannot be misconnected so that polarity is reversed.

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 ICCP
IMPRESSED CURRENT
1) Requires a mains supply or other source of electric power.
2) Can be applied to a wide range of structures including, if necessary, large, uncoated structures.
3) Use is less restricted by the resistivity of the soil or water.
4) Needs careful design although the ease with which output may be adjusted allows unforeseen changing
conditions to be catered for.
5) Needs inspection at relatively few positions; instrumentation at points of supply can generally be placed
where it is easily reached.
6) Requires generally a small total number of anodes.
7) Requires the effects on other structures that are near the ground bed of protected structures to be
assessed but interaction is often easily corrected, if necessary.
8) Requires relatively simple controls and can be made automatic to maintain potentials within close limits
despite wide variations of conditions. Since the e.m.f. used is generally higher than with galvanic anodes the
possible effects of ineffective control or incorrect adjustment, for example damage to paintwork or coatings,
are greater.
9) Allows of more compact anodes by the use of suitable materials; drag is negligible.
10) Requires perforation in all cases on ships' hulls, plant to enable an insulated connection to be provided.
11) Requires high integrity of insulation on connection to the positive side of the rectifier which are in contact
with soil or water: otherwise they will be severely corroded.
12) Requires the polarity to be checked during commissioning because misconnection, so that polarity is
reversed, can accelerate corrosion.

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 Chapter 3 Equipment

 Sacrificial Anodes

 ICCP anodes

 CP boxes

 Transformer Rectifiers

 Cables

 Insulating kits (isolation equipment)

 Other

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 Sacrificial anodes

 Magnesium

 Aluminum

 Zinc

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 Magnesium

 Types

 1- high potential Anode (–1.75 V)

 2- Low potential anode (-1.2 V~–1.55 V)

 Use:
1- low-resistivity Soil
2- Water

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 Standard Size

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Aluminum
Types:

-Galvalum I (contains zinc and mercury for use in seawater)

-Galvalum II (contains zinc and mercury for use in saline mud )
-Galvalum III (contains zinc and indium for use in seawater,
brackish water, and saline mud)

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 Zinc
 Types:
-Soil
ASTM B418 Type II

-Sea water
MIL-A-18001 or ASTM B418 Type I

Limitation:
- Zinc may undergo rapid inter-granular corrosion at temperatures
above 49C.

- At temperatures above 54C and particularly in the presence of

carbonates, zinc can passivate and the potential of the passive
film can become more noble than steel

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 ICCP Anodes

✓ High Silicon Cast Iron Anodes

✓ Magnetite Anode

✓ Graphite Anodes

✓ Lead Silver Anodes

✓ Platinum Anodes

✓ Ceramic & Mixed Metal Oxide Anode

✓ Polymer Conductive Anodes

✓ Scrap Metal

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 High Silicon Cast Iron

 Fresh water, seawater, or underground applications

 The consumption rate of HSCI ranges from 0.25 to 1 kg/A-
y (0.55 to 2.20 lb/A-y).

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 MMO Anode (Mixed Metal Oxide)
Ti based

The consumption rate 1 mg/A-y

-Ribbon

-Wire

-Mesh

-Tubular

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 installation

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 Polymer Conductive

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 CP boxes

Bond Box (negative and positive)

Anode junction box

Current control box

Negative connection box

Test box

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 Transformer Rectifiers

 Type of cooling:
 Oil cooled (out door application)

 Air cooled ( natural, forced) (ONAN, ONAF)

(Indoor application)
 Type of controlling

 Constant Current
 Constant Voltage
 Constant Potential
 63 Steps

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 Schematic diagram

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 Cables

 Common uses in CP:

 XLPE/PVC

 XLPE/AWA/PVC

 HMWPE/PVDF ( kynar)

 Halar/Polyethylene
G: Good
VG: very good
EX: excellent
F: Fair

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 Installation (common)

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 Insulating Devices
- Insulating kits
- Types:
- E
- F
- D

Mono-block

Type D

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 Interferences

 spark gap

 Polarization cell

 Zinc Earthing cell

PCR

Spark gap

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 Others

1-Back fill
-ICCP Anodes
- Galvanic anode

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 Pin brazing

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 PET weld Connection

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 Chapter 4 Primary Test

1- Corrosion Cell

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 Steps

1 2

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 2- Sacrificial Anode

M
g

M
g

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3-ICCP system

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