TRAINING MANUAL- ELECTRICAL DOC No.

: 29040-EL-UFR-
0021
CATHODIC PROTECTION SYSTEM Rev. : R0
Uhde India
Limited Page : 1

CONTENTS

Page

0.0 Cover Sheet 1

1.0 Introduction 2

2.0 Corrosion Mechanisms 2

3.0 Soil Conditions 2-3

4.0 Cathodic Protection 3

5.0 Sacrificial Anode System 3

6.0 Impressed Current System 4

7.0 Protection Criteria 4

8.0 Enquiry Preparation 4

ANNEXURE

1. Pipe to Soil Potential as Cathodic Protection Criterion 2 Sheets

Slides 2 Sheets

Applicable Revision:
Prepared: Checked: Approved:

Date: Date: Date:

First Edition: R0
Prepared: Checked: Approved:

R.N. BHUSHAN A.Y. CHITRE A.Y. CHITRE

Date: Date: Date:
File Name: Cathodic.doc Server: KUMUS 205

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 TRAINING MANUAL- ELECTRICAL DOC No. : 29040-EL-UFR-
0021
CATHODIC PROTECTION SYSTEM Rev. : R0
Uhde India
Limited Page : 2
1.0 INTRODUCTION

1.1 Corrosion may be defined as the deterioration of a metal due to its reaction with its
environment. For the corrosion process to occur, areas with different electrical potentials
must exist on the metal surface. These areas must be electrically connected and shall be
in contact with an electrolyte.

1.2 There are four components in each corrosion cell – an Anode, a Cathode, a metallic path
connecting the anode and the cathode and an electrolyte.

1.3 Roles of the four components (Refer figure-1)

a. Anode - Base metal goes into solution (Fe…>Fe +2 + 2e-)

and releases electrons.

b. Cathode - Cathode receives electrons released by the Anode.

(O2 + 2H2O + 4e-  4OH-)

c. Metallic path - Provides the path for electrons released at the

anode to flow to the cathode.

d. Electrolyte - Moist soil is the most common electrolyte.

1.4 There are two most common forms of corrosion, one general type and other pitting
corrosion. In general corrosion, thousands of microscopic corrosion cells occur on an area
of metal surface resulting in relatively uniform loss. In pitting corrosion, the individual
corrosion cells are larger and distinct anode and cathode areas can be identified. Metal loss
in this case is concentrated.

1.5 Soil characteristics substantially affect the type and rate of corrosion, on a structure in
contact with soil.

2.0 CORROSION MECHANISMS

2.1 Stray Current Corrosion (Refer figure-2)

2.2 Bimetallic Corrosion (Refer figure-3)

2.3 Internal Corrosion (Water, sludge, dissolved gases inside vessel cause corrosion)

3.0 SOIL CONDITIONS

3.1 Soil resistivity provides valuable information on corrosion of the material used.

Resistivity Range Ohm - cm Potential Corrosion Activity

< 500 Very corrosive

500 – 1000 Corrosive
1000 – 2000 Moderately Corrosive
2000 – 10, 000 Mildly Corrosive
> 10, 000 Progressively less corrosive

3.2 Soil analysis is often useful test for helping to determine whether the potential corrosion
activity will be high enough to make cathodic protection necessary.
 TRAINING MANUAL- ELECTRICAL DOC No. : 29040-EL-UFR-
0021
CATHODIC PROTECTION SYSTEM Rev. : R0
Uhde India
Limited Page : 3
Guide line Reviewing Soil Analysis Data

Constituent Corrosive Very Corrosive

pH 5 – 6.5 < 5.0

Chlorides 300 -1000 ppm > 1000 ppm

Sulphates 1000 - 5000 ppm > 5000 ppm

4.0 CATHODIC PROTECTION

4.1 Cathodic protection is an electrical method for preventing corrosion by making the entire
surface of the metal needing protection, act as the cathode.

4.2 In Chemical Industries, following equipments are generally cathodically protected.

a. Underground pipelines, tanks, steel structure.

b. Tank Bottoms.
c. Steel structures, pipelines in contact with seawater.

4.3 There are two methods of cathodic protection.

a. Through sacrificial anodes

b. By the Impressed current methods

5.0 SACRIFICIAL ANODE SYSTEM

5.1 Sacrificial anode system uses a metal more active than the structure to be protected, to
supply the current required to stop corrosion. The more active metal is called a sacrificial
anode and is connected electrically to structure to be protected. Sacrificial anode supplies
the protective current and prevents the flow of corrosion current from metal surface. See
Figure - 4.

5.2 Advantages and disadvantages in the usage of sacrificial anode :

Advantages Disadvantages

a. No external power supply required. a. Limited driving potential

b. Installation is relatively easy. b. Current output is low.
c. Low capital investment. c. Limited to use in low soil resistivity
d. Low maintenance (& cost) d. Not practical for large structures
e. Minimum monitoring

5.3 Material / Metals used for sacrificial anode.

Following materials are commonly used.

a. High potential magnesium alloys.

b. Standard magnesium alloy.
c. Zinc.
 TRAINING MANUAL- ELECTRICAL DOC No. : 29040-EL-UFR-
0021
CATHODIC PROTECTION SYSTEM Rev. : R0
Uhde India
Limited Page : 4
6.0 IMPRESSED CURRENT SYSTEM

6.1 This system uses Impressed D. C. current from an external source. For this purpose
rectoformer is used. D. C. current flows to the buried impressed current anode through soil
electrolyte and onto buried pipes / vessel / tank bottom. See figure – 5.

6.2 Advantages and Disadvantages

Advantages Disadvantages

a. Availability of large driving potential. a. Interference problems (stray currents)

on foreign structures.

b. High & variable current output b. Loss of power causes loss of

protection

c. Suitable for protecting large c. High O & M cost structures

d. Suitable for high soil resistivity d. High capital cost

e. Safety aspects of rectoformer

location, anode J. B. & negative
lead to be looked into.

f. Frequent monitoring.

6.3 Material used for impressed current anode.

Following materials are commonly used.

a. Graphite
b. Hi-silicon cast iron
c. Lead silver alloy.

7.0 PROTECTION CRITERIA

7.1 Following criteria has been developed to determine adequacy of cathodic protection.

A minimum voltage of – 0.85 Volts measured across the structure – electrolyte interface
relative to a saturated copper – copper sulphate reference electrode.

7.2 This criteria is also shown in Annexure – 1.

8.0 ENQUIRY PREPARATION

8.1 Following information is essential:

a. Site plan and system layout (i.e. piping layout), pipe length(s), diameter, wall
thickness.
b. Hazardous area classification.
c. Soil data / soil resistivity.

8.2 Enquiry shall be prepared based on the previous project specification.

(UIL standard specification is under preparation.)