Corrosion

Control
 Definition

Corrosion Control is the application of

engineering principles and procedures to
minimise corrosion to an acceptable level
by the most economical method. It is
rarely practical or economical to eliminate
corrosion completely and in practice.
 Methods
 DESIGN

 MATERIAL SELECTION

 ENVIRONMENT CONTROL

 BARRIER COATINGS

 CP (CATHODIC PROTECTION)
 Design

 Avoidance of water traps in above ground pipe-work and

structural steelwork or if they cannot be avoided, provide
necessary drainage facilities.

 Use of welding instead of bolting to avoid crevices.

 Planning a pipe route to avoid known corrosion hazards.

 Avoidance of dissimilar metal contacts using isolating joints

or selecting materials as close together as possible in the
Galvanic Series.
 Material Selection
 To select a material with a very high corrosion
resistance to the environment. In making such
selection, consideration must be given to cost,
mechanical strength, ease of production, welding,
bimetallic corrosion etc.

HOWEVER

Whilst it is relatively simple to select a material

that will not corrode, this is of no use if the other
properties required are not met. It is, therefore,
of vital importance that decisions to change a
material are made by all interested parties.
 Environmental Control
 To modify the environment to reduce its corrosiveness by
eliminating or neutralising the corrosive elements.

 The use of imported backfill around pipelines.

 The use of inhibitors (generally used for controlling internal

corrosion) including oxygen scavengers and biocides.
 Barrier Coatings
 To insert an insulating barrier
to minimise contact between
the metal and the electrolyte
and reduce the flow of
corrosion currents. If it was
possible to provide a perfect
coating, then corrosion could
be eliminated. However, it is
not practical to achieve
perfection due to the
limitations of materials
commercially available,
construction practices and of
course, cost considerations.

 For above ground atmospheric

corrosion, a barrier coating is
the normal choice i.e., a
suitable paint system for the
application. Should the coating
break down then this will be
visible and repair/repainting
can be readily carried out.
 Cathodic Protection (CP)
This approach to control of corrosion using
electrical current is limited to metals exposed to
an electrolyte such as soil, water and concrete.
It does not work in the atmosphere.

Cathodic Protection is often used in conjunction

with other corrosion control methods including
protective coatings and electrical isolation.
Cathodic

Protection
 Cathodic Protection
Cathodic Protection Definition
…….in cases where corrosion is entirely
electro-chemical in nature it is necessary
to polarise the cathodes in the corrosion
cell to the open circuit potential of the
local anodes in order to obtain complete
cathodic protection.

R.B.Mears and R.H.Brown – “A Theory of Cathodic Protection,” 1938

 Theory
On a corroding surface there are hundreds of
local or microscopic corrosion cells.

There is a potential or voltage difference between

the anode and cathode of these cells, this
potential difference drives the corrosion current.
CP Applied to a Structure
 Concept
 The concept of Cathodic Protection involves
reducing the potential difference between the
local anodic and cathodic site on a metal surface
to zero, resulting to zero corrosion current flow.

 Cathodic Protection does not actually eliminate

corrosion, instead it transfers it from the
structure to be protected to the anode.
 Uses of Cathodic Protection
Most metallic structures that are immersed or
embedded in an electrolyte can be cathodically
protected.
Some examples include:
 Underground tanks and piping works
 Exterior bottoms of above grade storage
tanks
 Ship hulls
 Docks
 Sheet pilling
 Reinforcing steel in concrete
Types of Cathodic Protection Systems
There are two methods of providing
Cathodic Protection to a Structure

 Galvanic/Sacrificial Anode System

 Impressed Current System
Galvanic/Sacrificial Anode System

Galvanic (or sacrificial) cathodic protection makes

practical use of dissimilar metal corrosion. The
galvanic anode is connected to the structure it is
protection either directly or thru a test station so
it can be monitored
 Sacrificial Anode CP
_
+

_
+

-0.6 V,PIPE -1.5 V

Primary structure
Cathode Magnesium Anode
 Sacrificial Anode CP
_
+

_
+

-0.6 V,PIPE -1.5 V

Primary structure
Magnesium Anode
Cathode
 Sacrificial Anode CP
_
+

_
+

-0.85 V,PIPE -1.5 V

Primary structure
Cathode Magnesium Anode
 Advantages of Galvanic Anodes
 No External power source required
 Low maintenance requirements
 Small current output resulting in little or no stray
current inter-ference
 Easy to install
 Easy to add anodes in most cases
 Provide uniform distribution of current
 Limitations of Galvanic Anodes

 Low driving voltage/current output

 Many anodes may be needed for poorly coated
structures
 May be ineffective in high-resistivity
environments
Impressed Current Cathodic Protection (ICCP)

An impressed current cathodic protection

system (ICCP) consists of an external
power source and anodes. The power
source forces current to flow from the
anode to the structure through the
electrolyte.
 Impressed Current CP
_
+
_ +
protective current

PIPE

anode

primary structure
FeSi anode in
cathode Coke backfill
 Impressed Current CP
- 0 + DC CURRENT SOURCE

- 0.4 CATHODIC AREA

STEEL
- 0.6 ANODIC AREA

ANODE

- 0.4
CATHODIC AREA
 Impressed Curent CP
I - 0 + DC CURRENT SOURCE

- 0.55 CATHODIC AREA I

STEEL
- 0.6 ANODIC AREA

ANODE

- 0.55
CATHODIC AREA
 Impressed Current CP
I - 0 + DC CURRENT SOURCE

- 0.6 CATHODIC AREA

I

STEEL
- 0.6 NEUTRAL AREA

ANODE

- 0.6
CATHODIC AREA
 Impressed Current CP
I - 0 + DC CURRENT SOURCE

- 0.85 CATHODIC AREA

I

STEEL
- 0.85 NEUTRAL AREA

ANODE

- 0.85
CATHODIC AREA
 ICCP Power Sources
 The power source for an impressed
current system produces direct current
(DC)

Types of power sources include:

 Rectifiers
 Solar Cells
 Engine Generators
 Wind-powered Generators
 Advantages of an ICCP
 Flexible with capability to handle a wide
range of voltage and current outputs
 Satisfy high current requirements with a
single installation
 Effective in protection uncoated and poorly
coated structures
 Effective in high-resistivity envirnoments
 Less anode consumption that with galvanic
anodes
 Limitations of an ICCP
 Higher inspection and maintenance cost
that with galvanic anodes
 Requires external power
 Constant power supply cost
 High risk of causing stray current
interference
Cathodic Protection – Hardware

Cathodic Protection
Hardware

Offshore
Onshore
 Cathodic Protection – Hardware
Offshore
 Generally a sacrificial anode
system
 Galvanic systems
- More reliable
- Better current distribution
- Protection at installation
 Impressed current systems
- Less costly
- More flexible
- Cables, connections, shorts
- Less weight
Cathodic Protection – Hardware
Offshore
Cathodic Protection – Hardware
Offshore
 Cathodic Protection – Hardware
Offshore Pipelines
 Short pipelines may be protected from ends

 Longer pipelines protected by use of galvanic

anode bracelets spaced along pipeline
- Al-Zn-In alloys with at least 2 percent Zn
- Zn anode alloys

 Place sufficient anode material on pipe to last the

design life

 Place anodes closely to protect the pipe

 Use off-the-shelf anode shapes whenever possible

 Cathodic Protection – Hardware
Offshore Pipelines
Pipeline anodes are usually installed as bracelets that are
welded onto the pipeline as it is being laid
Cathodic Protection – Hardware
Ships
Cathodic Protection – Hardware
Retrofitting
Cathodic Protection – Hardware
Retrofitting

Retrofits are very EXPENSIVE

 Cathodic Protection – Hardware
Offshore Jackets

 Usually by galvanic anodes

- Al-Zn-In alloys

 Anodes installed during construction for

the life of the jacket or pipeline

 Retrofits are EXPENSIVE

 Use of Mercury activated anodes is

now not acceptable
 Cathodic Protection – Hardware
Onshore Pipelines
 Anodes
 Backfill
 Groundbeds
 Power sources
 Cables
 Test points
 Insulating (isolating) joints and gaskets
 Reference electrodes
 DC blocking devices
 Galvanic Anodes
 Zinc
 Magnesium
 Aluminium
Impressed Current Anodes
Vertical Anode Bed
Deep-well Groundbed
 DC Power Sources
Manual and Auto-controlled

TEG’s

Solar

Transformer Rectifiers and more

 Test Points
 Regularly Spaced

 Located at current pick-up/discharge points

 At rail/road crossings
 At IJ’s

 Foreign Structures and pipeline crossings

 Anode Connections
 Test Points
 Regular Intervals
Monitoring Points
 Test Points
 At Foreign
Crossings
 Test Points
 Anode
Connection
Point
 Test Points
 At IJ’s
 Insulating Devices

Isolating Joints or Monoblocs

Insulating Flanges
 Reference Electrodes
 The most frequently used reference half
cells are (in order of frequency of usage):

 Copper/copper sulphate (saturated)

 Silver/silver chloride

 Zinc (as a permanent installation)

Copper-Copper Sulphate Ref Cell
 DC Blocking Devices
 DC blocking cells (alkaline nickel – nickel)

 Diodes

 Capacitors (usually large value electrolytic

capacitors)

 Polarisation Cells – Kirk Cells and PCR’s

 AC Mitigation
 Shield Wires

PCR Unit
Gradient control mats
Cathodic Protection
System Design
 Design Objectives
Provide sufficient current density continuously to all parts
of a structure and to polarise the structure to an acceptable
level or criterion

Minimise interference with other structures such as nearby

buried pipelines.

Provide flexibility to allow for changes in the environment,

coating condition and operational requirements of the
structure during its lifetime.
 Design Objectives
Ensure the safety of the general public, operating personnel
and the environment.

Provide a system that meets the required life expectations

for the structure or CP system as required by the owner or
regulator.

Provide adequate testing facilities to enable system

performance and operation assessment as required by
industry and regulatory standards.
 Design Process
START
Sacrificial Choose System Type Impressed Current

Evaluate Structure and Choose Anode Size Weight NO Choose Anode Size Weight
Environmental Factors and Configuration and Configuration

Determine Protective Current Calculate Anode Required Calculate Anode Resistance

Requirements Weight

IS DESIGN ACCEPTABLE Choose Power Supply

Calculate Number and
? Type, Size and Rating
Spacing of Anodes

Calculate System Life Calculate System Life

YES

Estimate System Cost Estimate System Cost

DESIGN
COMPLETE
Structure & Environmental Information
Structure
Construction Specification
Materials, sizes, surface areas, thickness etc.
Coating types and application
Electrical continuity
Availability of AC supplies
Location – right of way etc

Environment
Soil or water (electrolyte) resistivity
Flow rates
Geotechnical data
Seasonal variations
Other
Nearby metallic structures
Nearby operating CP system
Electrical transit systems
AC power transmission lines
 Current Requirements
Cathodic Protection Current Requirements may be determined by any
of the following:-

* Theoretically Determined

* Empirically Estimated – utilising surface areas and historical data

* Site Tested
 Empirical Current Requirements
Environmental Current Density
Conditions   mA/m²

Immersed in Seawater(a)  
Stationary  
Well coated 1 to 2
Poor or old coating 2 to 20
Uncoated 20 to 30
Low Velocity(b)  
Well coated 2 to 5
Poor coating 5 to 20
Uncoated 50 to 150
Medium Velocity(c)  
Well coated 5 to 7
Poor coating 10 to 30
Uncoated 150 to 300
High Velocity(d)  
Poor coating or uncoated 250 to 1000
Buried Underground(e)  
Soil Resistivity  
0.5 to 5 Ω-m 1 to 2 TABLE 1
5 to 15 Ω-m 0.5 to 1
15 to 40 Ω-m   0.1 to 0.5
(a)Structures or vessels (d)Turbulent flow
(b)0.3 to 1 m/s (1 to 3 ft/s) (e)Pipelines or structures, coated or wrapped
(c)1 to 2 m/s (3 to 7 ft/s)

Source: NACE Corrosion Engineers Reference Book, NACE International 3 rd Edition, Robert Baboian Ed., 2002, p.162

Useful Estimate -3LPE coated pipeline in soils use 0.01mA/m² current density where no AC mitigation is present, where AC mitigation
is present in the form of direct connected zinc wires use 0.03mA/m²

Current Density required to polarise bare copper buried in soil = 100mA/m²

 Empirical Current Requirements
Depolarising Agents leading to increased current requirements

• An increase in Agitation or velocity – more reactants are brought to

the reaction surface and reactant products are swept away.

• An increase in aeration (oxygen concentration) – Oxygen is a major

cathodic reactant and increases the CP current requirement as the cathodes become
more noble.

• Increase in temperature– greater ion mobility and ionisation

• Decrease in pH– increases cathodic reactants (Hydrogen ions) and increases the
CP current requirement as the cathodes become more noble.

• Increase in surface area – greater coating damage or other structures

connected unintentionally
 Troubleshooting

Cathodic Protection Systems

 CP Troubleshooting
 A good maintenance program can
often detect potential CP systems
failures before hand allowing
scheduled repair before an actual
outage.
 CP Troubleshooting
Cathodic Protection systems problems include but are not
limited to:

Transformer Rectifiers failures

Failed Anode Ground beds
Faulty connections
Faulty isolation joints
Broken cables
 TR Troubleshooting
 Basic cases of TR problems:

 Zero current and voltage outputs

 Zero current output with unchanged output voltage
 Significant current change with unchanged voltage
 Significant changes in both voltage and current outputs
 TR Troubleshooting
Zero Current and Voltage Outputs:

 AC voltage may not be present

 Tripped circuit breaker
 Open circuit
 TR Troubleshooting
Zero Current with Unchanged Voltage Output

 Open fuse in the circuit

 Faulty connections
 An open positive or negative lead cables
 Failed anode ground bed
 TR Troubleshooting
Significant current change with unchanged voltage

 Anode deterioration
 Discontinuity due to disconnection of system
component
 Gas blockage
 Seasonal variations in soil conditions
 TR Troubleshooting
Significant changes in both voltage and current outputs

 Failure of TR stacks causing half waving

 Shorts (winding to winding)
Flow chart for locating a short circuit in a TR