Impressed Current Cathodic Protection
Impressed current cathodic
protection systems have the benefit of
using an external power supply to
drive current. This makes it possible to
protect virtually any structure,
regardless of size or current
requirements using long life anodes
and enough appropriately sized power
supplies.
The Corrosion
Problem
Corrosion of metals is a naturally
occurring electrochemical process that
causes the metal to oxidize and deteriorate when exposed to the environment
(commonly referred to as rusting.) Cathodic protection (CP) is a means to
prevent corrosion by applying a flow of electrical current from an external
source (anode) through the environment and on to the metallic structure that
is being protected. This protective current changes the environment around
the metal thus halting the corrosion reaction. When properly designed and
applied, cathodic protection systems stop the corrosion process. Cathodic
protection is used to prevent corrosion in a wide range of applications where
the structure being protected is surrounded by an environment that allows
current flow. Unfortunately, atmospherically exposed metal cannot be
cathodically protected because air is not a conductor of electrical current, but
most submerged and buried applications are suitable for cathodic protection
including pipelines, ships, docks, jetties, storage tanks, and a range of other
structures.
Basic Types of Cathodic Protection
There are two basic types of CP systems: galvanic (or sacrificial) and
impressed current. Galvanic anode systems (also termed sacrificial anodes
systems) use a metal that is naturally more negative than the metal being
protected and thus when the two metals are connected electrically to each
other, current flows from the metal that is more electrically negative to the
metal that is more electrically positive. This current flow results in a rapid
consumption of the anode, hence the common term “sacrificial anode” is often
used to describe these anode systems. Typical galvanic anodes include
magnesium, zinc and aluminum as each of these are more electrically
negative than carbon steel or other steels.
Impressed current anode systems are different than galvanic (sacrificial)
systems because they utilize an external DC power supply to create the
electrical current flow. The use of an external power supply enables an
impressed current system to generate significantly higher current output with
fewer, longer lasting anodes than any sacrificial anode system.
Why Impressed Current Cathodic Protection?
Longer Life Anodes. Because the choice of anodes is not dependent on the
electrical potential of the anode itself, impressed current anodes can be selected based
on other factors such as anode material cost, current density and consumption rates.
Today’s most efficient anodes are the dimensionally stable mixed metal oxide anodes
(MMO.) These anodes have exceptionally long anode life relative to other anode
choices.
Higher Current Systems. The basic formula for a DC circuit is that V = I x R
(Ohm’s law) where V is the voltage difference or driving force, I is the system current
and R is the system resistance. The system resistance is in large part dictated by the
environment and not easily changed. For galvanic anodes the value of V is fixed and
less than 1 Volt thus the amount of current that can be generated from a galvanic
anode is also limited. With an impressed current system, the driving voltage is a
function of the size of the rectifier and typical voltages can range from 20V to 100V.
Much greater than that of any galvanic system.
Greater System Control. With a galvanic anode system, there is only a very
limited amount of ways to control the system output. For most galvanic systems they
are installed and left to operate with no controls in place. In some cases they work as
designed, and in other cases they either operate too fast causing premature failure or
they do not operate sufficiently to protect the structure. But once installed you have
little control over their operation. With an impressed current system, the power supply
can be adjusted to change the current being supplied to the anode system. If too much
current is being discharged the system power supply output can be turned down, of
conversely if the current being supplied is not sufficient, then the system output can
be increased (at least up to the limit of the power supply being used.)
Ease of Monitoring and Control. With an impressed current system, the
power supply provides an easy means of monitoring and controlling the system
performance. Once installed and properly commissioned, the impressed current
cathodic protection system rectifier provides an easily verifiable monitoring point.
Monthly readings of the power supply output voltage and current can be checked to
assure consistency with previous readings. With a galvanic anode system, specialized
provisions for testing are required in the design to confirm the system performance.
