Fundamentals Of Cathodic Protection, Basic

Designing And Its Application

Arindam Samanta
1

Mechanism Of Corrosion
Corrosion is loss of metal by electrochemical reaction of metal with its
environment.
Almost always electrochemical reactions occur in aqueous solutions.
In all aqueous electrolytes such as soil, water, metal atoms go into solution as
metal ions.
For corrosion (electrochemical) reaction to proceed the following conditions
must be satisfied
i.

Setting up a galvanic cell in the same metal or between two different metals
resulting in a potential difference in the cell and current flow.

ii.

Existence of anode & cathode in the cell.

iii. Anode & cathode should be in contact with electrolyte.

iv.

Electrolyte shall be conductive to ions.

Mechanism Of Corrosion (Cont.)

At anode metal goes into solution as metal ions(oxidation reaction).
At cathode metal deposition or reduction of gases or cations occur (reduction
reaction).
Anodic sites have a more negative potential than cathodic sites in the same
electrolyte.
When metal atoms go into solution as metal ions, electrons are released at
anode which migrate to cathode by metal path where it is consumed by
reduction reaction. This flow of electrons gives rise to DC current. Thus the
magnitude of current which is called corrosion current is directly related to
mass of metal going into solution by Faradays Law.
Passage of electrons through external metal path from anode to cathode
means flow of conventional current from anode to cathode through
electrolyte. Thus any corrosion phenomenon is associated with passage of DC
current from anode to electrolyte.

Mechanism Of Corrosion (Cont.)

Corrosion Reactions
AT ANODE

M M +z + Ze

AT CATHODE
(Acid)

2 H + +2e H2

(Acidic solutions)

O2+ 4H+ + 4e 2 H2O

(Neutral

or Basic solutions)

O 2+ 2H2O+ 4e 4OH

For Iron
Fe Fe+++2e
Fe ++ + 2OH Fe (OH)2
4Fe (OH)2 + O2 + 2H2 O 4Fe (OH)3
Fe(OH)3 FeOOH+H2O (Hydrated Ferric oxide, Red Rust)
5

Corrosion Rate
Corrosion rate expressed as mm/yr or mils/year (mpy) or Mg/dm2/day(mdd).

The above units represent average rate of metal penetration or weight loss of
metal excluding any adherent or non adherent corrosion products.

For steel in sea water rate is = 0.13 mm/yr.

For steel in soil rate is = 0.021 mm/yr.

Above is derived from Faradays Law m = I t a / n F

where F= Faraday constant =96500 coulumbs /equivalent
I =current passed (Amps) (1Amp = 1coulumb for 1 sec )
m= mass reacted
a= atomic weight
n= number of equivalents exchanged( valency)
t = time
6

Corrosion Rate (cont.)

Corrosion rate = m/t A

where A= surface area

= It a / nF tA
=ia/nF

where i( current density)=I/A

The above relationship gives proportionality between mass loss per unit area per
unit time ( mg/dm2/day) and current density( A/cm2).The constant includes
factor a/nF and conversion factor for units
Corrosion rate expressed in penetration per unit time
a) corrosion rate in mils per year (mpy) = 0.129 x a i /n d
where d= density of the metal ( gm/cm3)
i = a/cm2
b) corrosion rate in mm/yr = 0.00327 x a i/n d
For FeFe++ + 2e ,

1a/cm2= 0.0116mm/yr
7

Classification On Basis Of Corrosion Rate

a)

< 0.15 mm/yr (<5mpy) Excellent corrosion Resistance.

b)

0.150.5 mm/yr (520 mpy) Good

c)

0.5 1.0 mm/yr (2050 mpy) Fair

d)

> 1.0 mm/yr (>50 mpy)Unacceptable.

Corrosion Prevention Method

Coating

Coating by coal tar enamel or polyethylene is primary method of external

corrosion protection.

Protection by coating alone is not recommended due to rapid attack of metal at

coating holidays (areas of coating defects) due to large anodic current density at
defects.

Therefore coating is always supplemented with cathodic protection which

essentially protects exposed metal at coating defects.

Application of coating drastically reduces cathodic protection current

requirement since C.P. Current is required at defect areas (holidays) of coating.

Current reduction is in order of 2000100 folds depending on type of coating

and electrolyte.

Corrosion Prevention Method (cont.)

Cathodic Protection

Cathodic protection being electrochemical technique, arrests all forms of

corrosion (uniform attack, galvanic, pitting, crevice, stress corrosion cracking)
excepting H2 damage.

Most effective method of corrosion control brings corrosion rate to zero.

The method consists of supplying electrons from external source to the

corroding metal so as to convert all anodic sites of corroding metal to cathode
where by only reduction reaction occurs by consuming the supplied electrons.

By comparison with value of asset protected cost of cathodic protection

(installed + operating) is low.

10

Types of Cathodic Protection

There are basically two methods of Cathodic Protection
SACP (Sacrificial Anode Cathodic Protection)
ICCP (Impressed Current Cathodic Protection)
In SACP system a galvanic anode, a piece of a more electrochemically "active"
metal (Anodic) than the metal to be protected is connected with the structure to
be protected. Due to potential difference in galvanic series the required cathodic
current is generated. This technique is used when current requirement is low
and the electrolyte has low resistivity.
For larger structures, or where electrolyte resistivity is high, galvanic anodes
cannot economically deliver enough current to provide protection. In these
cases, impressed current cathodic protection (ICCP) systems are used. These
consist of anodes connected to a DC power source, often a transformerrectifier
connected to AC power.

11

Types of Cathodic Protection (cont.)

Sacrificial Anode
Cathodic Protection

Impressed
Current Cathodic Protection

12

Cathodic Protection Reactions

a) At Cathode:
O2+H2+4e 4OH (neutral / alkaline solution)
2H2O+2e H2+20H (At Potential morevethan1.15v(Cu/CuSO4) in
neutral / alkaline solution)
2H++2eH2(acidsolution),
O2+4H+4e2H2O(oxygenated acid solution)
b) i) At Anode (Impressed Current System)
2H2O O2 + 4H+ +4e (in oxygenated solution)
2Cl Cl2 +2e (in chlorine rich solution)

ii) Sacrificial anode

Mg Mg ++ + 2e

Mg ++ + 2OH Mg( OH )2 ( soluble)

Al Al +++ + 3e

Al +++ + 3OH Al (OH)3( soluble )

13

Protection Criteria
Plain carbon steel and low alloy ferrous materials exposed to soil, fresh water
and sea water are fully cathodically protected when their interface potential to
electrolyte when measured with a coppercopper sulfate reference electrode is
minimum 0.850 volts for soil / freshwater and 0.800 volts w.r.t. Ag / Agcl in
seawater.
Measurement taken by placing the electrode in the electrolyte and measuring
the potential between structure and electrode with a high resistance voltmeter
(see figure).
Above potentials are at electrolyte metal interface temperature upto 40C. For
temp > 40C, protection potential shall be0.950 Volt (Cu / Cuso4) in soil / fresh
water and 0.900Volt (Ag / Agcl) in sea water.
For large bare structure drawing high current, minimum 100 mv potential shift
is recommended as protection criteria
Shift = Instant offpotential (Cu/CuSO4) Natural Potential (Cu/CuSO4)

14

Protection Criteria (cont.)

Basis of protection criteria

For effective cathodic protection ,all anodic process must be stopped i.e. all
anodic current shall be zero and there would not be solvation of metal atom.
To satisfy above condition potential of metal should be equal to reversible
potential of that metal electrode
Fe Fe++ + 2e in its own ions

Reversible potential for above system according to Nernst equation with

activity of Fe ions 106moles /litre would be at 250c
E = 0.440 + 0.0295 log ( conc Fe ++)
= 0.617 volt ( w.r.t standard Hydrogen electrode )

where 0.440 volt is the standard electrode potential of Fe /Fe++ at 25 degree

C having activity of Fe ++ = 1N

Therefore potential w.r.t. Cu/CuSO4 = 0.617 ( +0.337) = 0.954 Volt at 25

degree C.

At 35 degree C the w.r.t. Cu/CuSO4 is 0.85 Volt

15

Cathodic Protection Over Protection

Excessive current leads to very high cathode potential which has following
detrimental effects----

Damage to coating by sapponification (softening of coating) at potential more

negative than 2.0 VOLTS ( cu/cuso4).

High pH

Hydrogen generation at potential more negative than -1.2V (OFF) Cu/Cuso4

leading to blistering and dis-bondment of coating.

Wastage of energy.

16

Cathodic Protection Design

The following steps are involved in designing a cathodic protection system
using ceramic anodes:- a. Collect data.
1) History--Information from occupants in the area can indicate the severity of
corrosion problems. Data on failures and failure rates of nearby structures can be
invaluable and must be considered.
2) Drawings--- Drawings of the structure to be protected and the area where it is
or will be installed are needed to provide the physical dimensions of the structure
for determining surface area to be protected, and locations of other structures in
the area that may cause interference, of insulating devices, and of power sources.
3) Tests---Current requirement test and potential survey test results are needed
for existing structures that will be protected. Electrolyte (soil or water) resistivity
tests and evaluation of conditions that could support sulfate-reducing bacteria are
needed for all cathodic protection designs. This information will indicate the size
of the cathodic protection system that will be required as well as the probability
of stray current problems. Soil resistivity's contribute to both design calculations
and location of the anode ground bed.
17

Cathodic Protection Design (cont.)

4) Life-- The user must determine the required number of years that the structure
needs to be protected, or the designer must assume a nominal life span. The
structure will begin to deteriorate from corrosion at the end of the cathodic
protection system's design life unless the system is rejuvenated.
5) Coatings-- Cathodic protection complements the protective coating system. A
good coating system substantially reduces the amount of cathodic protection
current required. The coating efficiency has to be assumed.
6) Short circuits--- All short circuits must be eliminated from both new and
existing structures for which a cathodic protection system is being designed.
b. Calculate surface area to be protected----The overall current requirement of a cathodic protection system is directly
proportional to the surface area to be protected. This includes underground or
submerged pipes buried tanks, and wetted surfaces (up to high water(level) of
watertanks (including risers).

18

Cathodic Protection Design (cont.)

c. Determine current requirement---

For existing structures, a current requirement test will provide the actual current
requirement at the time of the test. Allowance should be made in the design for
future degradation of coatings or structure additions that will increase the current
requirement.

Total current required is given by the following equation:-I = (A)(I')(l.0 - CE)

where I is the total current requirement, A is the total surface area to be

protected, I' is the estimated current density, and CE is the efficiency of the coating
system.
d. Select anode type--

Ceramic anodes are made in a variety of shapes, such as, wires, rods, tubes,
strips, disks, and mesh.

19

Cathodic Protection Design (cont.)

e. Calculate number of anodes (N) or length of bare anode wire (LB)---

The number of anodes or length of anode wire required is determined from the
total current required and the manufacturer's published current rating for a given
life.

1) For rod, strip, tube and disk anodes:---

Number of anodes required = Total current required / Manufacturers rated

current for specific size, environment and life.

2) For wire anodes:-----

Total footage of anode = Total current requirement / Manufacturers rated current

capacity per foot of wire for a given environment and life.

The number calculated will determine the minimum number of anodes or anode
wire length required.

20

Cathodic Protection Design (cont.)

f. Calculate the total circuit resistance (RT)--

The total circuit resistance (RT) consists of the anode-to electrolyte resistance (RN)
plus the interconnecting wire resistance (RW) plus the structure-to-electrolyte
resistance (RC).
RT = RN + RW + RC

A criterion of 2-ohm maximum ground bed resistance is often used to limit the
rectifier output voltage and the associated hazards of overprotection. When the
total required current is low, a higher total resistance is often acceptable. As the
required current increases, the total resistance should be reduced.

The total anode-to-electrolyte resistance (RN) is calculated in different ways

according to the type of anode installation.

The anode-to-electrolyte resistance for a single anode is given by RA. For a single
vertical anode:

where RA is the anode-to-electrolyte resistance for a single anode, p is the

electrolyte resistivity in ohm-cm, L is the length of the backfill column in feet, and d
is the diameter of the backfill column in feet.
21

Cathodic Protection Design (cont.)

For a single horizontal anode:

where RA is the anode-to-electrolyte resistance for a single anode, p is the

electrolyte resistivity in ohm-cm, L is the length of the backfill column in feet, d
is the diameter of the backfill column in feet and h is the depth of the backfill
cylinder in feet.

For a multiple vertical anode:

where RN is the anode-to-electrolyte resistance, N is the number of Anodes, and

Cc is the center-to-center spacing of the anodes in feet. This equation assumes a
linear configuration of the groundbed anodes.
22

Cathodic Protection Design (cont.)

If the anode dimensions are different, another empirical expression may be used:

where RN is the anode-to-electrolyte resistance, RA is the anode-to-electrolyte

resistance for a single anode, p is the soil resistivity in ohm-cm, N is the number
of anodes used, PF is a paralleling factor and Cc is the center-to-center spacing of
anodes in feet. This equation assumes a linear configuration of the groundbed
anodes.

For a circle of rod anodes (as in a water storage tank):

where RN is the anode-to-electrolyte resistance, p is the electrolyte resistivity in

ohm-cm, LB is the length of each rod anode in feet, D is the tank diameter in feet, AR
is the radius of the anode circle in feet, and DE is an equivalent diameter factor.
23

Cathodic Protection Design (cont.)

For wire anode circle or hoop (in a water storage tanks):

where RA is the anode-to-electrolyte resistance, p is the electrolyte resistivity, DR

is the diameter of the anode circle in feet, DA is the diameter of the anode wire in
feet, and H is the depth below the high water level in feet.

Wire resistance (RW) is the sum of both the rectifier-to anode lead and the rectifierto-protected-structure lead.

where LW is the length of wire in thousands of feet and RMFT is the resistance of
the wire in ohms per 1000 ft.
24

Cathodic Protection Design (cont.)

The structure-to-electrolyte resistance (RC) is dependent primarily on the condition

of the coating.

where RS is the coating resistance in ohm-square feet and A is the total surface
area. If the structure surface is bare, negligible resistance is assumed (RC = 0).
g. Calculate required rectifier voltage and current.

The required rectifier voltage (VREC and maximum current rating should include at
least an extra 20 percent to allow for variations in calculations from actual
conditions and for changes in the system over the system's life.

VREC = (I) (RT) (1.2) = (IREC ) (RT)

where I is the total current required and RT is the total circuit resistance as
calculated above and IREC is the minimum current rating for a rectifier for this
particular application.

25

Cathodic Protection Components

Following are the major components of Cathodic Protection system :

Power source (for impressed current system)

Anodes

Cables

Backfill

Reference electrodes (permanent & portable)

Junction boxes

Potential measurement test points

Corrosion probes / coupons

Potential recorder

Zinc grounding cells

Insulating joints / flanges

26

DC Power Source

Automatic potential control or constant voltage / constant current transformer

Rectifier unit (TRU) of following :
25A / 25V D.C.
50A / 50V D.C.

PSP Feedback
facility TR Unit Drawing

75A / 75V D.C.

50A / 75V D.C.
100A / 12V D.C.
For cross country pipelines or underwater structures auto potential control units are
recommended.
For plant structures constant voltage / constant current units are recommended.

27

Anodes
Sacrificial Anodes:--1.

Zinc

2.

Aluminum Alloy

3.

Magnesium

Impressed current anodes: ----

1. Graphite
2. Silicon-chromium-iron alloy
3. Metal oxide coated titanium
4. Platinised titanium
5. Platinised niobium

28

Sacrificial Anodes
Sacrificial anodes generate their own DC Charges and require no external DC
Power source.
Sacrificial anodes are made of metals which are more electronegative in E.M.F
series than protected metal
They have fixed driving voltage to protected metal which is in range of 0.60.25 volts.
They are not pure metals but alloys . Alloying elements have several functions
which are :i. Giving a fine grained structure to give uniform corrosion.
ii. Reduce self corrosion by local cell action.
iii. Prevent passivation due to formation of insoluble corrosion products on anode
surface
29

Composition of Sacrificial Anodes

a) High purity Magnesium (AZ 63 C as per ASTM B 843)---

Element

% wt

Aluminium

5.3-6.7

Zinc

2.5-3.5

Manganese

0.15-0.7

Silicon

0.3 Max

Copper

0.05 Max

Nickel

0.003 Max

Iron

0.003 Max

Others ( total )

0.3 Max

Magnesium

Remainder

Note -Heavy metals( Cu, Ni, Fe, Pb ) should never exceed specified values since they
lower efficiency due to local cell formation.

Al,Zn, Si, Cd are activators to prevent surface films.

30

Packed Magnesium Anode

31

Composition of Sacrificial Anodes

b)Zinc ( ASTM B418)

Type I

Type II

Element

% wt

% wt

Iron

0.005 max

0.0014 max

Lead

0.006 max

0.003 max

Copper

0.005 max

0.002 max

Aluminium

0.1-0.5

0.005max

Cadmium

0.025-0.07

0.003 max

Others ( total )

0.1 max

----

Zinc

remainder

remainder

Note: 1) Cu ,Fe ,Pb should not exceed specified limit as they passivate the anode
2) Al and Cd are for grain refinement and prevent passivation
32

Composition of Sacrificial Anodes

c) Aluminium alloy( Al-Zn-Si-In alloy)

Galvanum III

Alanode

Element

wt %

wt %

Iron

0.12 max

0.13 max

Silicon

0.08-0.2

0.10 max

Copper

0.006

max 0.01 max

Zinc

2.0-4.0

0.5-5.0

Indium

0.01-0.02

0.005-0.05

Others (each) 0.02 max

0.02 max

Aluminum remainder

remainder

Note: Heavy metal (iron, copper and others i.e. Nickel, lead should not exceed
specified limit)
33

Properties of Sacrificial Anodes

Magnesium

Zinc

Aluminium

a) Open circuit potential(Cu/CuSo4) -1.55 v

-1.1 v

b) Closed circuit potential(Cu/CuSo4) -1.50 v

-1.05 v

-1.05 v

c) Electrochemical Capacity( Ah/Kg) 1100-1200

780

2500-2700

d) Current efficiency

95%

50%

-1.1 v

95%

34

Use of Sacrificial Anodes

a)Magnesium: External surface of Underground pipelines ,vessels equipments having soil
resistivity upto 10,000 ohm-cm.
Internal of tank ,vessel, condensers containing fresh water .
Seldom used for sea water application
Not recommended for internal of vessels/equipments handling explosive / combustible
liquids and alloys susceptible to HIC.
b) Zinc: Undergound application ( External surface pipelines / vessels / sheet piling, piles
for soil resistivity <1000 Ohmcm (only Type II to be used)
For internal surface of vessels/condensers/tankage/equipments carrying sea water ( Type I
).
For underwater sea water application (jetty piles, wharfs, offshore platform jackets,
submarine pipelines, ship hulls, ballast tanks)
Not recommended in fresh water and soils with resistivity > 1000 ohm cm
Not recommended where electrolyte temperature is >500C

35

Use of Sacrificial Anodes (cont.)

c) Aluminium Alloy
Best choice for marine application because of its large Ah/Kg and light weight. All
offshore structures, submarine pipelines, jetty piles, wharfs, other marine under
water structures.
Internal protection of tanks /vessels /condensers exchangers carrying sea water or
brine up to temperature of 75C. Only anode for concentrated brine at elevated
temperature (heater treaters, dehydrators)
Not suitable for soil application and fresh water . Can be used in brackish water
containing minimum 500 ppm chloride ions.
Chemical Backfill--- Sacrificial anodes when used in soil are always pre packed with chemical bacfill of
composition 70% gypsum + 20 % bentonite +5% sodium sulfate.
Backfill are essentially chemicals having high ionic conductivity( low resistivity)

36

Anode Weight Calculation

Anode Wight
W( Kgs)= Ip X L x 8760 / C x 0.85
where C = Current capacity of anode material ( Ah/kg)

Ip = Protection current ( Amps ) = A x i, A = Surface Area, i = current

density.
L = Design life of anode /CP system ( yrs)
1 yr= 8760 hrs
0.85= Utilisation factor
Anode current output Individual anode current output( Ia Amps)= (Ea-Ec)/Ra
where Ea( v)= Closed Circuit potential of anode( Cu/CuSo4)
Ec( v) = Protective potential of cathode ( Cu/CuSo4)
Ra( ohms) = Resistance of individual anode to earth
37

Impressed Current Anode

These are made of metals/alloys having very low wear rate (gms/a-yr.)

Can have life of 30 years at large current discharge and therefore often termed as
permanent anodes.

They need not be of more negative electro-chemical potential than protected metal.

These anodes are used for impressed current C.P. System using external DC Power source.

Anodes range from consumable to non- consumable anodes

38

Impressed Current Anode (cont.)

a)

Fe-Si-Cr Cylindrical( solid ) ---

14 % Si, 1%C, 1% Mn, 5% Cr,

Density 7-7.2gms/cm3

On passage of current Si converted to Si02 which is electronic conductor and

excellent resistance to acid.
Material is bulky ,heavy and extremely brittle and therefore handled with care
and difficulty. Requires good foundry practice during casting. For these reasons
replaced by metal oxide coated Ti anodes
Maximum allowable current for intermittent period soil / fresh water @ 30A / m2 =
7 amps, in salt water @ 50A / m2 =12Amps
Wear rate:-150-200 gms / Ayr in coke back fill or fresh water at 15A/m2,
500gms/Ayr in salt water at25A/m2

39

Image of Ceramic Anode

40

Impressed Current Anode (cont.)

b) i) Metal Oxide Coated Titanium Tubular

25mm dia x1000 mm long x 0.8 mm thick 350gms

16mm dia x1000 mm long x 0.8mm thick 230gms

Ti tubes coated with noble metal oxides (RuO, IrO)of thickness20-30microns.

Wearrate:- 2mg/Ayr in soil (coke backfill) / salt water at maximum density of

8mg/Ayr in fresh water or salinemud.

Individual Anode end or center connected to cable 16/50mm2 copper of desired

length or multiple anodes mounted on a single cable (anode string)

ii) Metal Oxide Coated Titanium Wire Anode

1.5mmor3mmdiaTitaniumsolidwirecoatedwithoxides

41

Image of Tubular Anode

42

Different Parts of Anode

43

Anode Cable Connection

44

Vertical Canistered Anode

45

Horizontal Canistered Anode

46

Image of Multiple Anode String

47

Image of Vertical Shallow Anode Ground Bed

48

Horizontal Continous Anode Ground Bed

49

Deep Bed Anode

50

Cable for CP System

Cathodic protection cables are usually copper conductor to have less voltage drop and
durability.
Header Cables / Bonding Cables are 25-50mm2 single core.
Measurement Cables are 4 or 6mm2 single core.
Anode Cables (cables factory joined to anode ) are 6-10mm2 single core.
All cables excepting anode cables are armouredwith PE or PVC insulation & PVC sheath.
Anode cables are unarmoured with PVDF (Polyvinylidene fluoride) insulation with
HMWPE sheathing for acid resistance.

51

Backfill of Anode
Anodes in soil application are always used in combination with backfill.
Anodes are usually supplied prepacked with backfill.
The function of the backfill are--

Provide low resistance around anode (lower anode to earth resistance)

Prevent anode to come into contact with harmful ions in soil and contaminants
which can passivate the anode (Phosphates ,carbonates, nitrates).

Retain moisture around the anode

a) Chemical Backfill for sacrificial anodes

Never use coke or graphite as backfill for sacrificial anodes.

52

Backfill of Anode (cont.)

b) Calcined petroleum Coke Backfill for permanent anodes ( Impressed Current

anodes):

Extremely low resistivity

Increases anode area( electronic conductor)
Lower anode to earth resistance
Extends life of anode ,majority of current discharged electrolytically at backfill to soil
interface
Helps venting of gas because of high porosity
Provides Low resistance around anode when wet
Properties of calcined petroleum coke backfill---

a) Chemical composition: Carbon 97.6%, Sulfur 0.7%,Ash 0.5%,Nitrogen 0.5%,

Volatiles 0.4%, Moisture 0.3%

b) Density 2.1gms/cm3,
53

Backfill of Anode (cont.)

c) Resistivity < 50 ohm-cm( loose)
d) Particle size Analysis
>1 mm 2%
0.5-1mm 41%
0.12-0.5 42.6%
0.05-0.12 10.6%
<0.05 3.7 %
e) Consumption 1 kg/A-yr at max 10A/m2.
Each single anode is prepacked in a galvanised sheet steel canister
Anode is centrally located in canister around which the loose coke backfill is
poured and compacted

54

Reference Electrode
Stable non-polarizable electrodes with stable electrode potential
Consists of high purity metal element in the solution of its own salt.
Most commonly used electrodes are
Saturated Copper-copper Sulfate (Cu/CuSO4)
Silver-silver Chloride/Sea Water ( Ag / Agcl)
Silver-silver Chloride / Saturated KCl (Ag/AgCl/KCl)
High purity zinc

55

Reference Electrode

56

Test Station

Test points are installed at regular intervals or at desired locations to serve

following functions :

Termination of measurement cables from structure and reference electrodes

Connection of sacrificial anodes

Bonding of different structures

Connection of grounding cells across

Connection of probes / coupons

57

Test Station (cont.)

58

Corrosion Probes Coupons

Coupons are installed to measure instant off potential measurement and are
placed at critical locations as follows :

Areas of marginal protection

Location of large IR drop

Interference location

Highly corrosive / aggressive spots

With coupons, TR unit interruption is not required.

59

Corrosion Probes Coupons (cont.)

60

Cathodic Protection at TCL Babrala

PCC/MCC/ASP/MLP EXISTING POWER SUPPLY SOURCE

4Cx50 Sq.mm Al,PVC

( 400 MTRS )

OR

PDB

WALL MTG TYPE 125A ( 6 O/G ) / 63A ( 3 O/G )

QTY - 10 Nos

3Cx25 Sq.mm Al
TO T/R UNITS

T/R UNIT
-- -+

--

INTPUT - 230V, 1PH A.C.

OUTPUT - 75 V D.C / 75 A D.C.
QTY - 35 Nos

1Cx95 Sq.mm Al, PVC

( 10 KMS)

1Cx95 Sq.mm Al

CJB
CJB

QTY - 14 Nos
CLASSIFIED / NON CLASSIFIED

1Cx50 Sq.mm Cu
(DRAINAGE CABLE)

FIRE HYDRANT PIPE ( U/G )

CW SUPPLY & RETURN PIPE ( U/G )
CY & SY DRAIN PIPING ( U/G )

1Cx50 Sq.m m Cu,PVC (DRAINAGE CABLE)

TANKS
NAPHTHA BULK STORAGE
NAPHTHA DAY TANK
NPDU
1Cx95 Sq.mm Al

AJB

AJB
AJB

1Cx50 Sq.mm Cu,PVC ( NEGATIVE HEADER CABLE )

( 4 KMS )
FIRE HYDRANT PIPE ( U/G )
CW SUPPLY & RETURN PIPE ( U/G )
QTY - 38 Nos
CY & SY DRAIN PIPING ( U/G )
CLASSIFIED / NON CLASSIFIED

1Cx10 Sq.mm Cu, XLPE

( 18 KMS)
VERTICAL BED
AT 4 MTR DEPTH

1000 x 20 x 3 MM - 69 Nos
2000 x 20 x 3 MM - 133 Nos
MATERIAL - MMO (MIXED METAL OXIDE)
COATED TITANIUM

HORIZONTAL
BED AT 1.5 MTR
DEPTH

2000x20x3 MM CANNISTERED - 89 Nos

MATERIAL - MMO (MIXED METAL OXIDE)
COATED TITANIUM

ANODE BED

DEEP W ELL
BED AT 16 MTR
DEPTH

16 MTR TUBULAR STRING ANODES - 6 Nos

MATERIAL - MMO (MIXED METAL OXIDE)
COATED TITANIUM

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