Cathodic Protection

CATHODIC PROTECTION
22 November 2009 CATHODIC PROTECTION 1

CATHODIC PROTECTION
• Introduction
• Training development
Part 1 Basic theoretical training
Module 01 - Principles of Corrosion

Module 02 - Corrosion Control
Module 03 - Materials Selection
Module 04 - Corrosivity of Soils
Module 05 - Principles of Cathodic Protection
Module 06 - Cathodic Protection Interaction
Module 07 - Cathodic Protection Systems
Module 08 - Instrumentation
Module 09 - Monitoring and Maintenance
Part 2 Specific training
Module 01 - Transformer and rectifier
Module 02 - Balhaf Cathodic Protection

CATHODIC PROTECTION
• Part 1 Basic theoretical training
• Module 01 – Basic Principles of Corrosion
Electromotive Series
Corrosion Reaction
Electrochemical Corrosion Cell
Forms of Corrosion
Electro-chemical Series
Type of Corrosion Cells on Pipelines

CATHODIC PROTECTION
• Introduction
Only a few metals can be found in nature in

metallic state
Most metals are found in form of oxides, sulfides
etc (as ore)
Corrosion is the natural process for the metals to
return to their natural state

CATHODIC PROTECTION
• Electromotive Series
Common elements listed in the order how much energy will be

needed to extract metals from their ores
Or how much energy will be released during the corrosion process
Ore Metal Product Rust
Energy Energy
input released

CATHODIC PROTECTION
• Electromotive Series
METAL ION FORMED POTENTIAL

Potassium K+ -2.92
Magnesium Mg++ -2.40
Aluminium Al+++ -1.70
Zinc Zn++ -0.76
Chromium Cr++ -0.56
Iron Fe++ -0.44
Nickel Ni++ -0.23
Hydrogen H+ 0.00
Copper Cu+ +0.47
Silver Ag+ +0.80
Gold Au+ +1.50

CATHODIC PROTECTION
• The Corrosion Reaction
For corrosion to occur, all of the following conditions must be present:

Anode
Cathode
Potential difference between anode and the cathode
Metallic path connecting the anode and the cathode
Conducting electrolyte surrounding both the anode and the
cathode

CATHODIC PROTECTION
• The Corrosion Reaction
When the previous conditions are met an electrical current will flow
and the metal at the anode will be consumed:
SOIL
ANODE Current Flow CATHODE

M +
METAL

CATHODIC PROTECTION
• Anode and Cathode Reactions
Anodic Reaction
Fe  Fe2+ + 2e-
Cathodic Reaction
2H2O + O2 + 4e-  4OH- Basic solutions
2H+ + 2e-  H2 Acidic solutions
Overall Reaction
2Fe + 2H2O + O2 = 2Fe(OH)2 Rust

CATHODIC PROTECTION
• Electrochemical Corrosion Cell
Fe2+ + 2OH Fe (OH)2
OH Fe2+
Cathode Anode
e
H2 + O2 = 2e 4OH Fe Fe2+ + 2e
Typical electrochemical reactions for corrosion of Iron in water.

CATHODIC PROTECTION
• Forms of Corrosion
Uniform Corrosion
Typical for climatic conditions
Localised Corrosion
Steel in sea water e.g.

CATHODIC PROTECTION
Pitting
Crevice Corrosion
Typical problems for stainless steel and aluminium

CATHODIC PROTECTION
Erosion Corrosion Direction of flow
Cavitations Gas bubbles collapsing
Steel in sea water e.g.

CATHODIC PROTECTION
Stress Corrosion Cracking
Galvanic Corrosion
Less Noble Metal More Noble Metal
Anode Cathode

CATHODIC PROTECTION
• Electro-chemical Series
Galvanic series in Sea Water

Alloy Potential (V) vs. Cu/SO4
Magnesium -1.75 Active End

ZINC -1.6
Aluminium Anodes -1.05
Pure Aluminium -0.8
Mild Steel -0.6
Cast Iron -0.5
Lead -0.5
Stainless Steel active -0.3
Stainless Steel passive +0.1
Graphite +0.3 Noble End

CATHODIC PROTECTION
• Type of Pipeline Corrosion Cells
• Overview
Dissimilar Metal Corrosion Cell

Dissimilar Soil Corrosion Cell
Differential Aeration Corrosion Cell
New Pipe Old Pipe Corrosion Cell
Mill Scale Corrosion
Microbial Induced Corrosion
Atmospheric Corrosion (Above Ground)

CATHODIC PROTECTION
• Type of Corrosion Cells on Pipelines
• Dissimilar Metal Corrosion Cell
-0.5 -1.1
V V
IRON ZINC
H+ H2 Zn ++ Zn ++

CATHODIC PROTECTION
• Dissimilar Soil Corrosion Cell
-0.2V -0.5V
V V
A C A C A C A

CATHODIC PROTECTION
• Differential Aeration Corrosion Cell
-0.2V -0.5V
V V
IRON
DE-AERATED SOLUTION AERATED SOLUTION

CATHODIC PROTECTION
• Differential Aeration Corrosion Cell
O2 O2
ROAD
ANODIC AREA
HIGH OXYGEN LOW OXYGEN HIGH OXYGEN
PIPELINE UNDER ROAD

O2 O2 H2O
O2
HIGH OXYGEN
LOW OXYGEN
ANODIC AREA
PIPE LINE IN TRENCH WATER DROPLET

CATHODIC PROTECTION
• New Pipe Old Pipe Corrosion Cell
-0.4V -0.65V -0.5V
V V V
OLD PIPE NEW PIPE OLD PIPE
ANODIC AREA

CATHODIC PROTECTION
• Module 02 – Corrosion Control
• Types of Corrosion Control
Design
Materials Selection
Environmental Control
Protective Coatings
Cathodic Protection
Coating and Cathodic Protection Combined

CATHODIC PROTECTION
• Design for Corrosion Control
Dissimilar metals
Welding not bolting
Type of material
Construction ( water traps)
Environmental issues (high corrosion risk area)

CATHODIC PROTECTION
• Materials Selection
Some factors effecting the aggressiveness of corrosion
Internal
Type of product
Acidity / alkalinity e.g. sour gas, water part of crude oil
Flow rate and pressure
Temperature

CATHODIC PROTECTION
Some factors effecting the aggressiveness of corrosion
External
Temperature
Environment (underground, under eater, atmospheric)
Atmosphere i.e. rural, industrial, costal, etc

CATHODIC PROTECTION
Polymers
Alloys
Ceramics
Composites

CATHODIC PROTECTION
• The main Alloys for structural applications are based on
Magnesium
Aluminium
Copper
Titanium
Iron
Nickel

CATHODIC PROTECTION
• Material Selection
Fabrication
Cost
Availability

CATHODIC PROTECTION
• Environment Control
Chemical Inhibitors
O2 Scavengers
Biocides
Modification of the process
Selected imported backfill
Anti - fouling

CATHODIC PROTECTION
• Protective Coatings
Barrier coatings – exclude environment from material

Increase the resistance of the metal to the environment
Reduces the amount of corrosion current flow
Reduces the amount of reactants at the material surface
Sacrificial Cathodic protection coatings – Galvanised steel

Protect the underlying steel by sacrificial dissolution of the zinc
coating

CATHODIC PROTECTION
• Pipeline Coating Types
Coal tar based

Application – on site hot flooding with glass tissue tape
Bitumen based
Application – same as coal based
Polyethylene
Application – loose sleeve on site, factory applied extrusion of
sinter coating
Fusion bonded epoxy
Application – factory applied
Wrapping tapes
Application – site repairs
CATHODIC PROTECTION
• Extruded Coatings
Preheat Blast Clean
Polyolefin Asphaltic mastic Final Surface

Treatment
Quench Electrical Inspection Stock pile

CATHODIC PROTECTION
• Wrapping Tapes
Preheat Blast Clean
Polyolefin Butyl Adhesive Final Surface

Treatment
Quench Electrical Inspection Stock pile

CATHODIC PROTECTION
• Fusion Bonded Epoxy Coating
Preheat Blast Clean Grind Surface Surface

Defects Inspection
FBE Application Gas / Induction Heat Final Surface

Treatment
Stockpile
Cure Time Quench Electrical Inspection Separators
CATHODIC PROTECTION
• Three layer Copolymer Coating
Preheat Blast Clean Grind Surface Surface

Defects Inspection
Polyolefin FBE Application Final Surface

Copolymer Induction Treatment
Heat
Quench Electrical Inspection Stockpile

CATHODIC PROTECTION
• Cathodic Protection
A means of converting all Anodic Sites on the metal surface to

Cathodic Sites
A typical corroding surface will contain anodes and cathodes
on the same surface
SOIL

M +
METAL

CATHODIC PROTECTION
• Cathodic Protection
By shifting all Anodes from the metal surface to a separate location we can
prevent any further corrosion from occurring on the metal surface
DC Current
source
SOIL SOIL
ANODE SACRIFICIAL
ANODE
NEGATIVE NEGATIVE
CABLE CABLE
IMPRESSED CURRENT SACRIFICIAL ANODE

SYSTEM SYSTEM
CATHODIC PROTECTION
• Cathodic Protection and Coatings
Coating provide a localised increase in the resistance between the

metal surface and the environment
All coatings contain defects of “Holidays”
A holiday will act as a small localised anode and lead to pitting
corrosion
Above ground these holidays can be located and repaired but below
ground???
Large Cathode Small Large Cathode

Anode
e- e-
Pitting Corrosion

CATHODIC PROTECTION
Cathodic Protection requires a source of external current to

shift the anodes
Bare structures require huge amounts of current to shift the

anodes
Coated structures only require enough current to protect the

coating defects. 90% less current (cost saving)

CATHODIC PROTECTION
Cathodic protection with a well coated structure offers the best combination, reducing cost and
extending service life
GROUND BED
POWER SOURCE
PIPE in CROSS
SECTION
COATING MATERIAL
CATHODIC PROTECTION
• Module 03 – Materials Selection
• Materials are selected for their particular properties
Strength
Ductility
Stiffness
Impact resistance
Weight
Electrical properties
Magnetic properties
Optical properties
Corrosion resistance
Wear resistance
CATHODIC PROTECTION
• Other factors are also important in final selection
Fabrication
Cost
Availability

CATHODIC PROTECTION
• The main classes of engineering materials
Polymers
Alloys
Ceramics
Composites

CATHODIC PROTECTION
• Alloys
A mixture of two or more metals or elements

Two kinds of alloys
Homogeneous
Solid solution complete mixing (18Cr-8Ni stainless steel)
Heterogeneous
Mixture of two or more separate phases ( steel - mixture of Fe3C
cementite and iron)
In addition alloy are divided in to
Ferrous Alloys – Iron based
Non Ferrous Alloys– less than 50% iron

CATHODIC PROTECTION
• Ferrous Alloys greater than 50% Fe
Cast irons – greater that 2% carbon

Grey cast iron
White cast iron
Spheroidal (ductile) cast iron
Carbon and low alloy steels – up to 2% carbon
Stainless steels
Martensitic stainless steel (12-18% Cr + other alloys)
Ferritic Stainless steels (13-27%Cr + other alloys) – 400 series
Austenitic Stainless Steels (18-20%Cr + 8 -18%Ni) – 300 series

CATHODIC PROTECTION
• Non – Ferrous Alloys
Nickel -Iron –Chromium or Nickel base alloys

Less than 50 % iron as an alloy addition
Copper base alloys
Aluminium alloys
Magnesium alloys

CATHODIC PROTECTION
• The compositions, and heat treatments of alloys are designed to produce
optimized properties
Elastic modulus
Ratio of pressure (stress) applied to a body to the resistance (strain) produced by the body.
Ultimate tensile strength (UTS)
Is indicated by the maxima of a stress-strain curve and, in general, indicates when necking will
occur.
Yield strength
The yield strength or yield point of a material is defined as the stress at which a material begins to
deform plastically.
Elongation
Is the ductility of steel. When a material is tested for tensile strength it elongates a certain amount
before fracture takes place.
Toughness
Toughness, in materials science and metallurgy, is the resistance to fracture of a material when
stressed
Fatigue resistance
The ability of a material to withstand repeated and varying loads.
Creep strength
The ability of a metal to withstand a constant weight or force at elevated temperatures.
CATHODIC PROTECTION
• Heat Treatments
Annealing – heating an alloy in a furnace at a particular temperature for a given time,

switching the furnace off, then allowing the metal to cool in the furnace.
Normalizing – heating an alloy in a furnace at a particular temperature for a given time,
removing the alloy from the furnace and allowing the alloy to cool in air.
Tempering – a secondary heat treatment usually applied to soften a hardened alloy.
Solution treatment – heating of an alloy at a high temperature for a given time to cause
the alloy constituents to dissolve in the host matrix thereby forming a solid solution.
Ageing – a secondary heat treatment applied usually after solution treatment to cause
precipitation of second phase.
Quenching – rapid cooling of an alloy, following heat treatment, by immersion into cold
water or oil.

CATHODIC PROTECTION
• Module 04 – Corrosivity of Soils
• Ohm Law
V = R/I
Corrosion is an electro-chemical reaction
Corrosion will only occur if electrons (current) can flow
If the environment surrounding the metal surface has a High resistance then
at a small amount of current (corrosion) can flow at a given voltage
If the environment surrounding the metal surface has a Low resistance then
at a larger amount of current (corrosion) can flow at a given voltage

CATHODIC PROTECTION
• Soil formation
Factors in soil formation:

• parent material
• time
• climate
• atmospheric composition
• topography
• organisms

CATHODIC PROTECTION
• Factors Influencing Soil Corrosion
Soil type
Water content
Oxygen content
Soluble salts
pH
Bacteria
Note: all these require laboratory analysis

CATHODIC PROTECTION
• Soil Type
Sandy / good drainage - Low Corrosivity

Loams / Fair to good drainage – Moderate Corrosivity
Clays / Poor drainage – High Corrosivity
Marsh /Organic /Wet – Sever Corrosivity

CATHODIC PROTECTION
• Water
Water is present as capillary and gravitational water
Water content is also determined by the type of soil eg. clay of

sand
Water is required to provide the electrolytic path to complete the

corrosion reaction

CATHODIC PROTECTION
• Oxygen content
Oxygen reduction is the main cathodic process in the corrosion cell
Soil type will determine the degree of oxygenation which is related

to the particle and pour size
Differential aeration can occur along a pipe route due to differing

types of soils

CATHODIC PROTECTION
• Soluble salts
Soluble salts which form ions like Na K Ca Mg & Cl SO4 H2CO will
lower the resistance of the soil
If the resistance is decreased an increase in corrosion (current)

occurs
Agricultural chemicals like fertiliser, weed and pest killers all

introduce additional ions into the soil and have an effect on the
corrosion rate

CATHODIC PROTECTION
• Soil Type
• pH
pH - the amount of free H+ in solution
With most metals the rate of corrosion will increase with a decrease in the pH
pH can be increased due to rotting vegetation eg.Bogs

CATHODIC PROTECTION
• Soil Type
• Bacteria
Sulphate reducing bacteria
SO42- + 8H(SRB) = S- + 4H2O

CATHODIC PROTECTION
• Soil Type
• Soil Resistivity
Soil resistivity is the function of:
Moisture content
Salt content
Salt type
Temperature of Soil

CATHODIC PROTECTION
• Soil Type
The measurement can be performed on site by two methods:
4 pin Wenner probe method
Soil box
These tests provide a direct method of determining the corrosiveness of a soil
OHM M DESCRIPTION
Below 10 Severely Corrosive
10 – 50 Corrosive
50 -100 Moderately corrosive
Above 100 Slightly corrosive

CATHODIC PROTECTION
• Soil Type
Wenner four pin method

RESISTIVITY METER
The resistance is determined by the
C1 C2
ratio R = E/I
P1 P2
The resistivity is given by  = 2a R
PINS DEPTH = a /20
a a a

CATHODIC PROTECTION
• Soil Type
• Selective Backfill
Selective backfills are needed as additional protection for the pipe and pipe coating in
certain well defined situations.
(a) In any ground containing industrial waste materials.
(b) In rocky or very stony ground.
(c) In peaty areas, if the pipe can be laid on a firm bed.
(d) In very heavy clay soils likely to cause coating problems. (Some very heavy clay soils
expand and contract on wetting and drying. This action can crack or tear coatings).
(e) In conditions where backfilling with natural soil is likely to cause coating problems (e.g.
compacting a very dry clay around a pipe can damage wrapping tapes; where the natural
soil cannot be compacted to give a stable reinstatement that will not subside around the
pipe).

CATHODIC PROTECTION
• Soil Type
• Selective Backfill
The best backfills to use are:
(1) Washed concreting sand
(2) Fine gravel’s (3mm, 6mm)
(3) Coarser gravel’s (10mm - 50mm) may be needed in special conditions.
Sands and gravel’s should normally be of quartz but crushed limestone or

whinstone can be used if the particle sizes are suitable.
All backfills must be well compacted especially when used underneath or beside a
pipe. They should all be compacted in 150mm - 225mm (6 - 9 in) layers.

CATHODIC PROTECTION
• Module 05 – Principles of Cathodic Protection
• Cathodic protection
A means of converting all anodic sites on the metal surface to cathodic

sites
A typical corroding surface will contain anodes and cathodes on the

same surface
SOIL

M+
METAL

CATHODIC PROTECTION
• Electro Chemical Corrosion Cell
Typical electrochemical reactions for corrosion of Iron in water
Fe2+ + 2OH Fe (OH)2
OH Fe2+
Cathode Anode
e
H2 + O2 = 2e 4OH Fe Fe2+ + 2e

CATHODIC PROTECTION
• Anode and Cathode Reactions
Anodic Reaction
Fe  Fe2+ + 2e-
Cathodic Reaction
2H2O + O2 + 4e-  4OH- Basic solutions
2H+ + 2e-  H2 Acidic solutions
Overall Reaction
2Fe + 2H2O + O2 = 2Fe(OH)2 Rust

CATHODIC PROTECTION
By shifting all Anodes from the metal surface to a separate location we can
prevent any further corrosion from occurring on the metal surface
DC Current
source
SOIL SOIL
ANODE SACRIFICIAL
ANODE
NEGATIVE NEGATIVE
CABLE CABLE
IMPRESSED CURRENT SACRIFICIAL ANODE

SYSTEM SYSTEM
CATHODIC PROTECTION
Metallic coupling for

Electrical charge flow
Aqueous solution for Ionic

charge flow
Steel Zinc
Cathode Anode

CATHODIC PROTECTION
• Galvanic Series in Sea Water
Alloy Potential (V) vs. Cu/SO4
Magnesium -1.75 Active End

ZINC -1.6
Aluminium Anodes -1.05
Pure Aluminium -0.8
Mild Steel -0.6
Cast Iron -0.5
Lead -0.5
Stainless Steel active -0.3
Stainless Steel passive +0.1
Graphite +0.3 Noble End

CATHODIC PROTECTION
• Galvanic Coupling
Metallic coupling for

Electrical charge flow
2e-
Aqueous solution for

Ionic charge flow
Steel 2OH- Zn2+ Zinc

Cathode Anode
Ionic reaction
2OH + Zn2+  Zn(OH)2
-
Cathode Anode
2H20 + O2 + 2e-  4OH- Zn + 2e-  Zn
2+

CATHODIC PROTECTION
• Impressed Current
AC to DC Transformer
Rectifier
- +
Electron flow
Aqueous solution for

Ionic charge flow
Steel OH- Titanium

Cathode Anode
Na+, Ca2+, Cl+
Cathode Anode

CATHODIC PROTECTION
• Potential Shift vs Corrosion Current
Natural Corrosion Rate
50 mV depression Corrosion
Rate more than halved

Rate greatly reduced

limited
0mV 50mV 100mV 200mV

CATHODIC PROTECTION
• Protection and Coatings
Cathodic Protection requires a source of external current
Bare structures require huge amounts of current
Coated structures only require enough current to protect the

coating defects i.e. less current (cost saving)

CATHODIC PROTECTION
Coatings provide a localised increase in the resistance between the

metal surface and the environment
All coatings contain defects of ‘Holidays’
A holiday will act as a small localised anode and lead to pitting

corrosion
Above ground these holidays can be located and repaired but

below ground?
Larg Cathode
Large Small Large Cathode
Anode
e- e-
Pitting Corrosion

CATHODIC PROTECTION
Cathodic protection with a well coated structure offers the best combination, reducing cost and
extending service life
GROUND BED
POWER SOURCE
PIPE in CROSS
SECTION
COATING MATERIAL
CATHODIC PROTECTION
• Cathodic Protection Criteria
Pipe to Soil Potential Measurement

TEST POST
1.234
Cu/CuSO4 Half-cell

CATHODIC PROTECTION
• Cathodic Protection Criteria
Metal or alloy Reference Electrode (and conditions of use) All readings in Volts
Cu/CuSO4 Ag/AgCI/KCI Ag/AgCI/Sea Zn

Iron and steel
– 0.85 – 075 – 0.80 + 0.25
(aerobic)
Iron and steel
– 0.95 – 0.85 – 0.90 + 0.15
(anaerobic
Lead – 0.60 – 0.50 – 0.55 + 0.5
Copper based
– 0.50 to – 0.65 – 0.40 to – 0.55 – 0.45 to – 0.60 + 0.60 to + 0.45
alloys
Aluminium
– 0.95 – 0.85 – 0.60 + 0.15
(positive limit)
Aluminium
– 1.20 – 1.10 – 1.15 – 0.10
(negative limit)

CATHODIC PROTECTION
• Module 06 – Cathodic Protection Interaction
• Introduction
The operation of a cathodic protection system protecting one structure

can cause the accelerated corrosion of an adjacent structure
Interaction arises where a foreign structure offers a lower resistance

path to current flow, than the surrounding ground through which
current from the ‘anode’ would normally flow to the protected pipeline

CATHODIC PROTECTION
• Types of Interaction
Impressed current cathodic protection
Sacrificial anodes (Not a problem)
AC interference (overhead, and trains)
DC interference (trams)

CATHODIC PROTECTION
• Impressed Current Cathodic Protection
• Interference
Due to high currents needed to protect long lengths of pipe the

risk of interference to other structures is present
These systems are not used in urban or built up areas
Ground bed location is critical minimum of 100m from pipeline to

be protected

CATHODIC PROTECTION
• Foreign Pipeline Interaction
ENDWISE CURRENT
Area of influence surrounding ground bed.

Within this area soil potentials are positive
(+) with respect to remote earth
Foreign pipeline or
other metallic structure
Remote
ground bed
Current flow from foreign

structure to protected line
in crossing area
Rectifier
Protected
Pipeline

CATHODIC PROTECTION
• Foreign Pipeline Interaction
Foreign pipeline not Area of Influence surrounding Endwise Current Flow
crossing protected line the ground bed
Current discharge from foreign pipeline

in remote areas
Rectifier
PROTECTED PIPELINE

CATHODIC PROTECTION
• Sacrificial Anodes
• Protection Interference
Due to the large number of closely distributed anodes, sacrificial

anode systems do not cause sever interaction in soil applications
Sacrificial anodes can be used to address other types of

interference:
Act as an earth for AC currents
The large exposed area prevents pipe penetration due to current

discharge over larger surface area

CATHODIC PROTECTION
• AC Interference
Occurs where you have:
Well coated pipelines eg PE
Pipe crossed by overhead high voltage power lines
Pipe runs parallel with overhead high voltage power lines
Potential health risk to workers

CATHODIC PROTECTION
• Other DC Source Interference (e.g trams)
DC Traction systems can cause sever corrosion on buried pipe work
DC
Load Current required Overhead Positive Feeder
SUB STATION
to operate train
Tracks Negative return
Moving Current Current flowing around high Discharge Area

Pickup Area resistance or insulating gasket subject to Corrosion

CATHODIC PROTECTION
• Interference Testing
Testing of Impressed systems can be performed by switching the system

on and off at a set interval ( 4 sec On 1 sec OFF)
Potential measurements are then taken at the foreign structures and

recorded
Potential shifts of greater than 20 mV indicates interaction
It is the responsibility of the CP system owner to inform foreign parties of

the CP system and prevent detrimental effect from their CP systems to
foreign structures

CATHODIC PROTECTION
• Remedial Action
The following actions can be performed to correct interaction on

foreign structures:
Drainage bonds
Additional high resistivity coatings
Galvanic anodes

CATHODIC PROTECTION
• Remedial Action
• Drainage Bond
Typical foreign line crossing test point installation.
Terminal box may be buried if necessary, rather
than post-mounted
Typically bond an adjustable slide
resistor connected between the heavy High resistance test voltmeter
lead terminals for wires from foreign and
protected lines V Foreign line being affected
by stray current interference
Copper Sulphate electrode

directly over foreign line at
Typical black point of maximum exposure
insulated wires from
foreign line
Protected pipeline with
rectifier causing interference
Typical white insulated on foreign pipeline
wires from protected line

CATHODIC PROTECTION
• Remedial Action
• Additional Coating
Distance A and B are areas of
depressed potentials on pipeline under
test prior to corrective measures
Foreign line causing

A interference
Limit of potential
Coating with good electrical depression area
and mechanical strength B’
applied to the foreign line
B
Protected pipeline
under test
A’
A’ and B’, equal to distances A and B

respectively, represent the length of
foreign line to be coated
CATHODIC PROTECTION
• Module 07 – Cathodic Protection Systems
• Introduction
When planning a cathodic protection system a
number of questions need to be resolved
How much current will be required to protect the structure initially?
How much current will be required to protect the structure at the end
of the structure life, following coating break down?
How should the system be designed?
Which system should be used?
What distance between installations?
What testing, commissioning and monitoring facilities will be required?

CATHODIC PROTECTION
• Introduction
In order to answer some of these questions it is necessary to
obtain information about the structure and the environment.
Is structure bare or coated?

If coated, what type of coating system, quality, electrical resistance, inspection
standards etc.?
Diameter and wall thickness of pipeline?
What grade of steel is used?
Presence of other metallic structures crossing or in close proximity to the
pipeline.
Soil types and resistivity?
Any known corrosion history in the area?
Availability of A.C supply?
Presence of any other cathodic protection systems or sources of stray currents
that could interfere with the system being designed?

CATHODIC PROTECTION
• Sacrificial Anode and Impressed Current Systems
• Comparison table
SARIFICIAL ANODES IMPRESSED CURRENT
They are independent of any source of electrical Requires a mains supply or other source of
1 1
power electric power
Their usefulness is generally restricted to the Can be applied to a wide range of structures
protection of well-coated structures or the including, if necessary, large, uncoated
2 2
provision of local protection, because of the structures. Large currents can be provided.
limited current that is economically available.
Their use may be impracticable except with soil or Use is less restricted by the resistivity of the soil
3 3
waters with low resistivity. or water.
They are relatively simple to install; additions may Needs careful design although the ease with
4 be made until the desired effect is obtained. 4 which output may be adjusted allows unforeseen
or changing conditions to be catered for.
Can be installed within the pipeline easement. The ground bed must be a minimum of 100m from
5 5 the pipeline - a separate easement must be
negotiated.
Inspection involves testing, with portable Needs inspection at relatively few positions;
6 instruments, at each anode or between adjacent 6 instrumentation at points of supply can generally
pairs of anodes. be placed where it is easily reached.

CATHODIC PROTECTION
• Sacrificial Anode and Impressed Current Systems
• Comparison table
SARIFICIAL ANODES IMPRESSED CURRENT
They may be required at a large number of positions. Requires generally a small total number of anodes.
Their life varies with conditions so that replacements
7 7
may be required at different intervals of time at
different parts of the system.
They are less likely to affect any nearby neighbouring Requires the effects on other structures that are near
structures because the output at any one point is low. the ground bed of protected structures to be
8 8
assessed, but interaction is often easily corrected, if
necessary.
Their output cannot be controlled but there is a Requires relatively simply controls and can be made
tendency for their current to be self-adjusting because automatic to maintain potentials within close limits
if conditions change such that the metal to be despite wide variations of conditions. Since the
9 protected becomes less negative, driving voltage and 9 voltage used is generally higher than with galvanic
hence current, increases. It is possible, by selection anodes the possible effects of ineffective control or
of material, to ensure that the metal cannot reach a incorrect adjustment, for example, damage to
potential that is sufficiently negative to damage paint. paintwork or coatings, are greater.
Their connections are protected cathodically Requires high integrity of insulation on connections to
the positive side of the rectifier which are in contact
10 10
with soil or water: otherwise they will be severely
corroded.
They cannot be misconnected so that polarity is Requires the polarity to be checked during
11 reversed. 11 commissioning because misconnection, so that
polarity is reversed, will accelerate corrosion.

CATHODIC PROTECTION
• Sacrificial Anodes
In practice the choice of system is generally as follows
Small structures
Short pipelines
Urban areas with large numbers of other services
Water tanks
Offshore structures
Submarine pipelines
Small ships and boats

CATHODIC PROTECTION
In practice the choice of system is generally as follows
Large structures
Long pipelines
Bare structures
Tank storage depots
Well casings
Jetties and harbours
Offshore structures
Large ships and tankers

CATHODIC PROTECTION
• Sacrificial Anode System
Typically a sacrificial anode cathodic protection system for a pipeline

will contain the following components
Sacrificial anode surrounded with suitable backfill
Negative connection to the pipe
Negative cable to pipe and positive cable to anode
Test post or box
Isolation flanges

CATHODIC PROTECTION
Link box
Typical Cathodic protection of buried pipeline with prepackaged
Terminal board sacrificial anodes
Test connection
Removable link
Test post Ground level
Top soil
Subsoil
Cables connecting Backfill

to pipeline Gypsium – 75%
Anode cable
Bentonite – 20%
Sodium Sulfate – 5%
In most cases anodes need

to be distributed along the
pipeline route
= Current flow

CATHODIC PROTECTION

CATHODIC PROTECTION

CATHODIC PROTECTION
ANODES ARE TYPICALLY
Magnesium
Zinc
Aluminium - for sea water

CATHODIC PROTECTION
ADVANTAGES
No power source required
Simple to install
Cannot be misconnected
Self regulating
Unlikely to affect other structures
Can be used effectively in built up areas
Can be installed within pipe easement

CATHODIC PROTECTION
DISADVANTAGES
Cannot be used in high resistivity soils
Limited current output
Large numbers of anodes and pipe connections are

required

CATHODIC PROTECTION
• Magnesium anode

CATHODIC PROTECTION
• Test post

CATHODIC PROTECTION
Typically an Impressed Current Cathodic Protection system for a

pipeline will contain the following components
DC Power Source
Suitable Anode with Back Fill Material
Anode control box
Negative connection and control box with resistors
Cabling
Test posts
Isolation flanges

CATHODIC PROTECTION
• Typical system
TRANSFORMER
RECTIFIER
ANODE JUNCTION BOX
GROUND BED
POSITIVE
CABLE
ANODE BACKFILL
TEST POST NEGATIVE BOX
NEGATIVE CABLE
Insulating
Flange

CATHODIC PROTECTION
• DC Power Source
The DC power is provided to the system via a

Transformer Rectifier (T/R) with an incoming AC feed.
Typical outputs for T/R’s are between 12 - 48 Volt,

1- 300 Amp.
The T/R can be manually (local) or remotely

controlled depending on the system.

CATHODIC PROTECTION
• Anode Materials
Mixed Metal Oxide on Titanium Substrate
Silicon Iron
Graphite

CATHODIC PROTECTION
• Pipe connections
Pin brazing
Arc welding a metallic plate

CATHODIC PROTECTION
• Cabling
Typical Cables
Positive Cable XLPE/PVC Red.
Negative Cable XLPE/PVC Black.
Reference Electrode cable 10 - 2.5mm2 XLPE/PVC Blue or

Yellow.
Test Cable 10mm2 XLPE/PVC Black

CATHODIC PROTECTION
• Monitoring Devices
True Reference electrode, measure actual voltage of the steel.

Silver/Silver Chloride Potassium Hydroxide (Ag/AgCl KOH)
Copper/Copper Sulphate (CU/CuSO4)
Coupons provide IR free potential readings

CATHODIC PROTECTION
• Advantages
Can protect long sections of pipe from one

installation
Can be used in high resistivity soils
Can be easily adjusted
Can provide large currents

CATHODIC PROTECTION
• Disadvantages
Requires power supply
Needs to be located outside of pipeline easement
Can affect other metallic structures
Cannot usually be used in built up areas
Polarity must be correct

CATHODIC PROTECTION
• Typical road side enclosure

CATHODIC PROTECTION
• Module 08 – Instrumentation
• Introduction
The instrumentation used most frequently by CP personnel is as follows
Basic Multi meter, usually digital for ac volts and amps, dc volts and
amps and ohms.
Resistivity Meter, null balance earth tester hand cranked or battery
driven.
Less frequently used instrumentation includes
Recording ammeter and voltmeter

Clip on ammeters
Pipe locators
Pearson survey equipment
Holiday detectors
Data loggers

CATHODIC PROTECTION
• Application of Meters
VOLTMETERS
To measure ac and dc voltage i.e. ac power supplies, transformer rectifier voltages, battery voltages, voltage drops.
AMMETERS
To measure ac and dc currents i.e. ac power supplies T-R outputs, sacrificial anode outputs, impressed current anode
outputs.
VOLTMETER/POTENTIOMETER
To measure structure to environment potentials.
OHMMETERS
To measure resistance i.e. insulating flanges, resistance bonds, control resistors.
RESISTIVITY METERS
To measure resistivity of soil or water to determine if an environment is corrosive, to design anode ground beds and
sacrificial anode outputs.
PIPE LOCATORS
For locating and tracing buried pipelines and cables and locating discontinuities or breaks in pipelines and cables .
PEARSON SURVEY EQUIPMENT
For locating coating faults in buried pipelines.
HOLIDAY DETECTORS
For locating faults in painted or coated surfaces prior to burial or immersion.
RECORDING AMMETER/VOLTMETER
For measuring currents, voltages or potentials in fluctuating conditions caused by interference, faulty equipment or power
supplies, telluric effects etc.

CATHODIC PROTECTION
• Current, voltage and resistance measurements.
Voltage, current and resistance can be measured directly through

the Multi-meter
Current shunts can also be used to convert a current to a voltage

without interrupting the circuit

CATHODIC PROTECTION
• Potential measurements
Digital
Voltmeter
Reference
Electrode
Pipe Test Lead
Electrode potential
does not vary
Pipe potential
Is the variable

CATHODIC PROTECTION
• IR free potential
IR free means applied voltage free reading.
The cathodic protection potential criteria require an IR free potential
The best way to overcome the applied voltage gradient of a cathodic

protection system is to interrupt the current (1 sec Off 4 sec On)
This method will produce the true pipe to soil potential

CATHODIC PROTECTION
• Soil resistivity
The two methods are:
Wenner four pin method
Soil resistivity box

CATHODIC PROTECTION
• Module 09 – Monitoring and Maintenance
• Introduction
If cathodic protection is considered in its rightful place in the total

scheme for prevention of corrosion in modern pipeline systems, the
word ‘premium’ could alternatively be used, since cathodic protection
will be an insurance policy, used only to back up the primary
protective coating.
If the insurance is to remain valid, the policy must not lapse because
of non-payment of the annual premium - i.e. the cost of monitoring
and maintenance. Without acceptance of this principle, a great deal
of the effort put into establishing this course will have been wasted.

CATHODIC PROTECTION
• Overview
Monitoring
Field facilities and procedures
Records
Maintenance
Preventative
Fault finding and remedial work

CATHODIC PROTECTION
• Field facilities and procedures
• Potential measurement Test post
240
face plate
Potential measurements along the pipe

route are critical to ensuring that full
protection has been achieved
Concrete M28
1220
test post
A good pipe connection will ensure the
potentials are not erroneous Concrete
foundation

CATHODIC PROTECTION
• Potential measurement
Potential measurements through concrete of gravel will not produce a good

contact for the reference electrode and can cause errors
Soil filled
Name plate
152
Porous concrete
pipe
76
610
Stone chippings

CATHODIC PROTECTION
• Records
Accurate records of the following should be produced and archived
As-Built details of pipe work, foreign structures and the

cathodic protection systems
Current, voltage, pipe to soil potentials
Test post and equipment condition

CATHODIC PROTECTION
• Maintenance and Prevention
By performing regular site inspections of the cathodic protection

systems most maintenance can be prevented or identified and
corrected
The regular attention to systems will discourage vandalism and foreign

systems or structures been installed which could cause problems
Coating evaluation of the pipe work immediately after installation and

detailed CIPS during the life of the structure will provide the user with
an operating and protection standard
Should any deviations from the developed standard become apparent,

then the cause of the deviation can be investigated further.

CATHODIC PROTECTION
• Maintenance fault finding and remedial works
Two essential aspects of cathodic protection of a coated pipeline are

that:
The flow of the protection currents shall be limited to the coated pipeline
(by the use of isolating joints etc.)
The coating standard shall be as high as possible.
A deterioration in the level of protection will, more usually, be symptomatic of an

extension of the surface area of metal exposed to the ground.

CATHODIC PROTECTION
• Maintenance fault finding and remedial works
It is interesting to note that an extension of surface area of metal to be

protected may arise from any one of the following:
Electrical failure of an isolating joint
Deliberate connection of additional buried pipe work without the use of

isolating joints
Inadvertent metallic contact with other buried services or protective

metal sleeves
Damage to protective coating by other agencies

CATHODIC PROTECTION
• Electrical failure of an isolating joint
This would normally be evident from routine monitoring since all isolating
joints should be provided with facilities for measurement of potentials on
both protected and unprotected sides.

CATHODIC PROTECTION
• Deliberate connection to additional buried pipe work without isolating joints
This is a case of dealing with ‘the enemy from within’ and maintaining a
continuous educational effort to ensure that the purposes of coatings, isolating
joints, and cathodic protection are understood within the organisation.

CATHODIC PROTECTION
• Inadvertent metallic contact with other buried services or protective metal sleeves
This is associated with either malpractice’s during the construction stage or

with the subsequent activities of other agencies. Surprisingly enough, an
initial proximity between two buried services can take a number of years
before developing into a metallic contact. ( coating break down)

CATHODIC PROTECTION
• Damage to protective coating by other agencies
This is probably the most difficult to trace or diagnose, other than by the
carrying out of a Pearson Survey and/or a close internal potential survey
as a preventive maintenance measure and as suggested previously
In a purely cathodic protection sense, however, an initially high standard

of protective coating can assist considerably in relating pipe/soil potentials
to coating damages.

CATHODIC PROTECTION
• Maintenance of equipment
The following equipment should be regularly maintained and tested:
Transformer rectifiers (T/R)
Test posts
Isolation joints
Cables and ground beds

CATHODIC PROTECTION
• Maintenance schedule for impressed current systems
MONTHLY
Check and record ammeter and voltmeter readings on transformer

rectifiers.
Do not adjust the transformer rectifier output but note and report any
deviation from the previous current and voltage.
Check and record pipe/soil potential at drain point, at mid-points between

Transformer rectifiers, and at isolating flanges/joints using a
copper/copper sulphate half cell and approved high resistance voltmeter.
Report any marked deviation from minimum requirements.

CATHODIC PROTECTION
SIX MONTHLY
Carry out the following in addition to those listed in the monthly checks
Check and record pipe/soil potentials at all measuring points including

those on the unprotected or ‘dead’ side of insulating flanges.
Check condition of all measuring and bonding points and ensure that
posts and/or surface boxes are freely accessible, visible and undamaged.

CATHODIC PROTECTION
YEARLY
Carry out the following in addition to those in the 6 and 1 months visits
Check level and condition of oil and silicon gel breathers in transformer rectifiers and replenish or
change as per manufacturers’ instructions.
Examine transformer rectifier enclosure and refurbish by painting, etc., as required.
Check transformer rectifier mounting or auxiliary enclosure. If pole mounted, examine pole
mounting bolts and stay wires. Adjust stay wires as required if poleis your property. Where poles
remain the property of the Electrical Board, report any defects to the respective Electrical Board
Area office.
Visually inspect by opening junction boxes, etc., all interference bonds connected to other buried
structures - with particular reference to those bonds carrying relatively larger currents (say in
excess of 250mA).
Check and record the potential of all ‘foreign’ structures to which the pipeline is bonded, with the
bonds still connected. Compare with potentials obtained when initially bonded.
Where sacrificial anodes have been employed either to afford protection (instead of impressed
current) or to overcome interaction, check the anode installation visually. Measure the potential of
the ‘foreign’ structure and compare with values obtained when the anodes were first installed.

CATHODIC PROTECTION
• Maintenance schedule for sacrificial anode systems
MONTHLY
Visually check all surface components including anode test and bond points
Check and record pipe/soil potentials at insulating flanges only

CATHODIC PROTECTION
THREE MONTHLY
Carry out the following in addition to that detailed in monthly
Check and record pipe/soil potentials at all measuring points including

those on the unprotected or ‘dead’ side of insulating flanges.
Clear silt from surface boxes.

CATHODIC PROTECTION
YEARLY
Carry out the following in addition to those detailed in 3 and 1 monthly
Visually inspect by opening junction boxes etc. all interference bonds connected to other buried
structures.
By switching off anodes in turn, record ‘off’ potentials and compare with those on schedule.
Where the level of protection is either marginal or unsatisfactory, with on all anodes and record
potentials at mid-points between anodes.
Check and record the solution potential of all ‘foreign’ structures to which the gas main is
bonded, with the bonds still connected compare with potentials obtained when initially bonded.
Where sacrificial anodes have been employed to overcome interaction check and record the
solution potential of the ‘foreign’ structure and compare with values obtained when the anodes
were first installed.

CATHODIC PROTECTION
• Part 2 Specific training
• Module 01 – Transformer and Rectifier
• Function of a Transformer Rectifier
The transformer rectifier converts an AC power supply into a direct current,

which will be used for providing an impressed current for Cathodic protection.

CATHODIC PROTECTION

CATHODIC PROTECTION
AC DC

CATHODIC PROTECTION
• Types of Transformer Rectifier
Single Phase Supply
Three Phase Supply
Air Cooled
Force Air Cooled
Oil Cooled

CATHODIC PROTECTION
• Types of Transformer Rectifier
64 Step control
Variable Transformer Control
Thyristor Control
Manual Control
Constant Current / Constant Current
Control
Auto Potential Control

CATHODIC PROTECTION
• 64 Step Control Unit

CATHODIC PROTECTION
• 64 Step Control Unit

CATHODIC PROTECTION
• Variable transformer controlled unit

CATHODIC PROTECTION
• Variable transformer controlled unit

CATHODIC PROTECTION

CATHODIC PROTECTION
• Thyristor controlled unit

CATHODIC PROTECTION
• Maintenance of a Transformer Rectifier
A SERVICE ENGINEER MUST CARRY OUT THE MAINTENANCE
Persons having appropriate technical training, safety training and

experience necessary to be aware of hazards to which they are
exposed in performing a task and of measures to minimise the danger
to themselves or other persons.

CATHODIC PROTECTION
Periodic inspection of the equipment may prevent loss of valuable

rectifier ‘ON’ time. It is suggested that the units be checked every three
months.

CATHODIC PROTECTION
Proceed as follows:
Check unit is functioning at expected levels
Isolate the incoming mains supply to the rectifier and allow a few minutes
for the rectifier to cool down.
Verify that the mains supply is indeed isolated by measuring with a suitable
AC voltmeter Live relative to earth and neutral to earth. If either of the
measurements shows voltage then the equipment is not isolated and the
cause must be identified and corrected before proceeding further.
Visually inspect the cleanliness of the component parts and remove any
excess dust or foreign bodies.
Test all fuses for continuity.
Check all LED’s are functioning.

CATHODIC PROTECTION
Look for any signs of overheating.

Check for tightness of all electrical connections.
Check the condition of the paintwork and touch up if necessary.
Check tightness of all external fittings e.g. sunshades, hinges, catches,
mounting bolts etc.
Check the condition of the silica gel breather and replace or reactivate as
required. The desiccant should be changed once the colour has changed
from orange to green.
DO NOT ATTEMPT TO UNSCREW THE BREATHER BY HOLDING THE

BODY WITH YOUR HANDS. USE A SPANNER ON THE FLATS
PROVIDED.

CATHODIC PROTECTION
Check oil level and top up if required. To add oil remove filler cap from the
top of the oil tank, then using a funnel to avoid spillage add the required
amount of oil. Minimum oil level is the mid point of the oil level indicator.
Check the condition of door and panel sealing gaskets. These are
required to be in a good condition to maintain the IP rating.
Close and lock the internal door before switching on the mains supply.

CATHODIC PROTECTION
Check Silica
Gel Breather
Crystal colour
Check Oil Level

CATHODIC PROTECTION
Balhaf
TRU unit

CATHODIC PROTECTION
• Fault finding on a transformer rectifier
A TEST ENGINEER MUST CARRY OUT THE MAINTENANCE.
Persons having appropriate technical training, safety training and experience

necessary to be aware of hazards to which they are exposed in performing a
task and of measures to minimise the danger to themselves or other persons.
First verify the fault.
Work in a systematic way to isolate the fault.

CATHODIC PROTECTION
• Fault description: NO DC OUTPUT

CATHODIC PROTECTION
Remove and check

Remove and check Control fuses
Secondary fuses
Check Thyristor
Control Card is
powered
Check the MCB

reset if tripped
Check the incoming

Remove and check AC power supply
PCB fuse
Remove and check

DC fuse

CATHODIC PROTECTION
Check Voltmeter is reading correctly
Check Ammeter is reading correctly
Check with a multi-meter the auxiliaries

connections
Check Voltmeter fuses
WARNING – THE AMMETERS EXTERNAL

MONITORING POINTS WILL READ 75mV AT FULL
CURRENT. DO NOT CONNECT A DC AMMETER
ACROSS THESE POINTS AS IT WILL SHORT OUT
THE SHUNT AND DAMAGE THE RECTIFIER.
MULTIMETERS MUST BE SWITCHED TO mV

BEFORE CONNECTING TO THE AMMETER
MONITORING TERMINALS.

• Thank you

Cathodic Protection - Rev 1

Uploaded by

Copyright:

Available Formats

You might also like

Cathodic Protection - Rev 1

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Cathodic Protection - Rev 1

Uploaded by

Copyright:

Available Formats

22 November 2009 CATHODIC PROTECTION 1

Module 01 - Principles of Corrosion

22 November 2009 CATHODIC PROTECTION 2

22 November 2009 CATHODIC PROTECTION 3

Only a few metals can be found in nature in

22 November 2009 CATHODIC PROTECTION 4

Common elements listed in the order how much energy will be

Ore Metal Product Rust

22 November 2009 CATHODIC PROTECTION 5

METAL ION FORMED POTENTIAL

22 November 2009 CATHODIC PROTECTION 6

For corrosion to occur, all of the following conditions must be present:

22 November 2009 CATHODIC PROTECTION 7

ANODE Current Flow CATHODE

22 November 2009 CATHODIC PROTECTION 8

22 November 2009 CATHODIC PROTECTION 9

Fe2+ + 2OH Fe (OH)2

Typical electrochemical reactions for corrosion of Iron in water.

22 November 2009 CATHODIC PROTECTION 10

Typical for climatic conditions

Steel in sea water e.g.

22 November 2009 CATHODIC PROTECTION 11

Typical problems for stainless steel and aluminium

22 November 2009 CATHODIC PROTECTION 12

Erosion Corrosion Direction of flow

Cavitations Gas bubbles collapsing

Steel in sea water e.g.

22 November 2009 CATHODIC PROTECTION 13

Stress Corrosion Cracking

Less Noble Metal More Noble Metal

22 November 2009 CATHODIC PROTECTION 14

Galvanic series in Sea Water

Magnesium -1.75 Active End

22 November 2009 CATHODIC PROTECTION 15

Dissimilar Metal Corrosion Cell

22 November 2009 CATHODIC PROTECTION 16

22 November 2009 CATHODIC PROTECTION 17

22 November 2009 CATHODIC PROTECTION 18

DE-AERATED SOLUTION AERATED SOLUTION

22 November 2009 CATHODIC PROTECTION 19

HIGH OXYGEN LOW OXYGEN HIGH OXYGEN

PIPELINE UNDER ROAD

PIPE LINE IN TRENCH WATER DROPLET

-0.4V -0.65V -0.5V

OLD PIPE NEW PIPE OLD PIPE

22 November 2009 CATHODIC PROTECTION 21

22 November 2009 CATHODIC PROTECTION 22

22 November 2009 CATHODIC PROTECTION 23

Some factors effecting the aggressiveness of corrosion

22 November 2009 CATHODIC PROTECTION 24

Some factors effecting the aggressiveness of corrosion

22 November 2009 CATHODIC PROTECTION 25

22 November 2009 CATHODIC PROTECTION 26

22 November 2009 CATHODIC PROTECTION 27

22 November 2009 CATHODIC PROTECTION 28

22 November 2009 CATHODIC PROTECTION 29