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Galvanic Anode System Design PDF
Galvanic Anode System Design PDF
Galvanic Anode System Design PDF
by
James B. Bushman, P.E.
Principal Corrosion Engineer
Bushman & Associates, Inc
Medina, Ohio USA
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Galvanic anodes are an important and useful to the protected structure. Once
means for cathodic protection of installed, very little maintenance is
underground storage tank systems, pipelines required for the life of the anode. The
and other buried or submerged metallic anode of a galvanic anode system is
structures. The application of cathodic not subject to the same degree of
protection utilizing galvanic anodes is electrical or mechanical malfunction as
nothing more than the intentional creation of that of an impressed current system.
a galvanic electrochemical cell in which two
Efficient and non-interfering The
dissimilar metals are electrically connected
relatively low, and normally well
while immersed in a common, electrically
distributed, current output of the
conductive electrolyte. In the "dissimilar
galvanic system can result in a more
metal" cell, the metal higher in the
constant current density at the
electromotive series (or more "active")
protected structure. This minimizes
becomes anodic to the less active metal and
over protection and wasted current.
is consumed during the electrochemical
The low current output reduces the
reaction. The less active metal receives
possibility of interference to a
some degree of cathodic protection at its
minimum. The advantages mentioned
surface due to the current arriving from the
enable the galvanic cathodic protection
anodic metal. The design of a galvanic
system to be utilized efficiently in a
cathodic protection system involves
variety of applications, such as:
consideration of all factors affecting the
proper selection of a suitable anode material a. For well-coated underground
and its physical dimensions, placement, and storage tanks and piping
method of installation.
b. In rural areas and offshore where
ADVANTAGES AND LIMITATIONS power is not available
There are several important advantages to c. For supplemental protection,
using galvanic anodes: such as at pipeline crossings
No power source is required Due to d. In isolated corrosive areas ("hot
the fact that the protective current is spots")
generated by the electrochemical e. In highly congested, urban areas
reaction between the metals, no where current distribution and
externally supplied power is required. interference present problems
Installation and maintenance cost is f. On electrically discontinuous
reduced Normally, galvanic anodes structures
have the advantage of not requiring g. Well coated pipelines
additional right-of-way purchase since
the anodes are usually installed close
However, the galvanic anode system is not The efficiency is dependent upon the alloy;
without limitations. The difference in the therefore, it is important that once the proper
potential of the anode and cathode alloy has been selected, the material
(protected structure) that causes the purchased meets the alloy specifications.
protective current to flow is normally quite The next two tables list some typical alloy
small. The small potential difference, or specifications in common usage.
"driving potential," results in very limited
current outputs, especially in high soil The following elements, most commonly
resistivity areas. This fact severely limits the present in magnesium, affect the efficiency
economic use of galvanic systems on: of magnesium anodes used for cathodic
Large structures protection in soils:
Poorly-coated structures Aluminum Significant effects
AVAILABLE ANODE MATERIALS outside ranges shown
The most commonly used materials for
galvanic anodes on buried structures are Manganese Controls to some degree
alloys of magnesium and zinc. the negative impact of iron by
surrounding the iron particles during
When the anode alloy is placed in the
casting solidification
electrolyte for the protection of a structure, a
certain amount of the current is generated
Nickel Detrimental to efficiency
due to the self-corrosion of the anode. The
current efficiency is a measure of the actual Copper Detrimental to efficiency
current available for cathodic protection of
the primary structure expressed as a Iron Detrimental to efficiency, but
percentage of the total current generated. can be controlled to some degree by
Because the anode corrosion rate is directly larger amounts of manganese
proportional to the current output delivered,
the efficiency is an important consideration Silicon Detrimental above 0.1
in the selection of anode material. The percent
higher the efficiency is, the more useable
energy per pound of material purchased. Zinc Only slightly detrimental in
H-1 Alloy Hi- Hi- higher amounts
Characteristic (AZ-63) Potential Purity
Mag. Alloy Mag. Alloy Zinc Other (lead, tin, beryllium) Minor
Solution -1.55 -1.80 -1.10 impurities that do not significantly
potential to
Cu-CuS04 ref.
affect anode efficiency in amounts
cell commonly found, but can be
Faradaic 8.8 8.8 23.5 detrimental above these limits
Consumption
Rate The following two tables provide industry
Current 25-50 50 90+ standard alloy elements for both magnesium
efficiency (%)
and zinc anodes commonly used in cathodic
Actual 250-500 500 360
amps-hrs/lb protection applications. Deviation from
Actual 35-17.5 17.5 26.0 these alloy specifications can result in
lb/amp/year anodes that suffer from pacification, inter-
on a per anode basis regardless of the actual amount of current required. Current
alloy or size of anode selected. testing can be performed utilizing temporary
Therefore, consideration of installation ground bed of one or more driven metallic
costs normally involves an rods energized by a test rectifier or storage
investigation of the number of anodes battery.
required. The temporary ground bed is energized and
Maintenance costs--The cost of its effect upon the structure is measured.
maintenance normally involves only Utilizing proper measurement techniques,
the periodic testing of the cathodic the current output is adjusted until the
protection system, which would not be selected criterion for protection is achieved
substantially affected by the type of with the least amount of current. One or
anode selected. This cost is usually more such temporary ground beds may be
neglected in the selection process. required to analyze sections of the structure,
especially if the physical characteristics of
PRE-DESIGN CONSIDERATIONS
the structure vary significantly. One must
The primary consideration in the design of remember that the resistance to ground of
the galvanic system is the efficient the driven rods is likely to be much higher
distribution of sufficient current to achieve than permanent buried anodes; therefore, the
cathodic protection. Due to the limited range driving voltage required in the test is not
of voltages available the problem of indicative of the actual driving voltage
achieving the desired current becomes one requirement.
of regulating the resistance of the electrical
DESIGN CALCULATIONS
circuit.
The electrical circuit that governs the current
The most important (and least controllable)
output of a galvanic anode is depicted in the
factor affecting the circuit resistance of
next figure.
underground galvanic cathodic protection
systems is soil resistivity. For a small Galvanic Anode Electrical Circuit Components
structure, such as an isolated, very well
coated buried tank, it is often more Grade
R
A
TAV
where:
E E
I = = amperes
A P
Imb = current output for magnesium anode
R +R +R +R +R
A
Since RAF + RAP + RPG is equal to RTAV Izb = current output for zinc anode on bare
calculated above and since RCG + REF + RW structure in milli-amperes
Imc = current output for magnesium anode Note: Anodes are installed vertically.
on coated structure in milli-amperes
Driving voltage correction - Table (y)
Izc = current output for zinc anode on Structure
coated structure in milli-amperes Potential Std. Hi-Pot
Zinc
(vs. Cu- Mag. Mag
P = soil resistivity in ohm-centimeters CuSO4)
F = factor from anode shape table -0.70 1.21 2.14 1.60
Y = factor from driving voltage table -0.80 1.07 1.36 1.20
Anode shape correction - Table (f) -0.85 1.00 1.29 1.00
Anode
-0.90 0.93 1.21 0.80
Weight Packaged -1.00 0.79 1.07 0.40
Alloy Factor
(lbs.) Dimensions (F) -1.10 0.64 0.93 n/a
Mg 3 3" x 3" x 4.5" .53 -1.20 0.50 0.79 n/a
Mg 5 3" x 3" x 7.5" 0.60
Mg 9 3" x 3" x 13.5" 0.71 The equation assumes a minimum resistivity
Mg 9 2.75" x 2.75" x 26" 1.01 of 500 ohm-centimeters and a distance
1.5" x 1.5" x 72" between anode and structure of 10 feet. It
Mg 10 ingot, 4" x 78" 1.71
Package can be seen immediately from the tables that
1.6" dia. x 10' increasing the surface area of the anode
Mg 15 extrusion, 6 x 10 2.61 (especially length) or use of a high potential
Backfill alloy has the effect of increasing resultant
Mg 17 4" x 4"x 17" 1.00 current output, assuming other factors are
2" x 2" x 72" ingot,
Mg 18 1.81 equal.
5" x 78" Package
2.5" x 2.5" x 60" For example, compare the current output of
Mg 20 ingot, 5" x 66" 1.60 17-pound standard alloy, high-potential
Package
1.3" dia. x 20'
alloy, and 20-pound (2" dia. x 60")
Mg 20 extrusion, 6 x 20 4.28 magnesium anodes. Assume a well coated
Backfill structure, a soil resistivity of 3000 ohm-
2" dia. x 10' centimeters, and an anticipated structure-to-
Mg 25 extrusion, 8 x 10 2.81 soil potential of 0.85 volt.
Backfill
Mg 32 5" x 5" x 21" 1.06 Standard 17# H-1 Alloy Magnesium Anode
3.75" x 3.75" x 60"
Mg 40 ingot, 6.5" x 66" 1.72 120,000(1.0)(1.0)
I = = 40mA
Package MC
3000
3" x 3" x 72 ingot,
Mg 42 1.90
6" x 78" Package Standard 17# High Pot. Magnesium Anode
Mg 50 8" dia. x 16" 1.09
Mg 50 5" x 5" x 31" 1.29
120,000(1.0)(1.29)
1.4 x 1.4 x 36 I = = 51.6mA
3000
MC
Zn 18 ingot, 5 x 42 1.68
Package
2 x 2 x 30 ingot, Long 20# H-1 Alloy Magnesium Anode
Zn 30 1.44
5 x 36 Package
1.4 x 1.4 x 72 120,000(1.60)(1.0)
Zn 36 ingot, 5 x 78 1.81 I = = 64mA
3000
MC
Package
2 x 2 x 60 ingot,
Zn 60 1.72 Anodes may be connected in parallel, in
6.5 x 66 Package
order to achieve a higher total current output
For a more exact calculation, an adjusting 13 7.83 9.83 10.72 11.23 12.68
factor may be determined from the 14 8.37 10.54 11.51 12.07 13.64
following equation (based upon the E.D. 15 8.91 11.25 12.30 12.91 14.61
Sunde formula for resistance to earth of 16 9.44 11.96 13.09 13.75 15.57
multiple anodes). This equation is provided 17 9.98 12.68 13.89 14.58 16.54
immediately following the table developed
18 10.51 13.39 14.68 15.45 17.50
by Mr. Tefanjian.
19 11.05 14.10 15.47 16.26 18.47
N 20 11.59 14.81 16.26 17.10 19.43
MA =
ADJ
2 L(ln 0.656 N )
1+
8L
S ln 1 To determine the approximate current output
d
of six 17-pound standard alloy anodes
spaced on 10-foot centers in 3000 ohm-
Where:
centimeter soil with a structure potential of
MAADJ = Multiple Anode Adjusting (-)0.85 volts, it was determined earlier that
Factor the current output of a single 17 pound
N = number of anodes in parallel anode under these same conditions = 40
milli-amperes.
L = length of the anode in feet
From the Multiple Anode Adjusting Factor
d = diameter of the anode in feet Table, select 4.90 from the 6 anode row and
S = spacing, center-to-center in feet the 10 column.
Therefore the output of the six anodes = The utilization factor accounts for a
(40)(4.90) = 196 ma. reduction in output as the surface area of the
anode decreases with time, limiting the
Having arrived at an anode configuration
anode output. This factor is usually assumed
that will produce the required current output
to be 0.85. The equation may then be
is not sufficient in itself. An examination of
reduced to simpler form by substituting the
the estimated life of the anodes must be
constant factors:
undertaken in order to determine whether
the design will provide protection for a
For magnesium:
reasonable period of time. The following
expression may be used to calculate the
estimated life of the anode: 48.5W
L =
I
M