TECHNICAL BULLETIN AST-01

TAH 12.31.08 v1.0 Page 1 of 10

NEW CONSTRUCTION ABOVE GROUND STORAGE TANKS

Overview:

This technical bulletin addresses the design and installation of cathodic protection systems for
new construction above ground storage tanks (ASTs). Cathodic protection (CP) is typically
applied to all above ground storage tanks built on a ring wall foundation to protect the external
tank bottom in contact with the soil/sand foundation. Smaller tanks built on concrete slab
foundations typically do not have cathodic protection applied to them.

In many locations, cathodic protection is mandated by local regulations for tanks storing
hydrocarbons or hazardous materials; however, even in the absence of such mandates, good
engineering practice would generally dictate cathodic protection.

Summary/Conclusion:

MATCOR typically recommends the use of linear anodes in a concentric ring configuration as
the most reliable system design for new construction above ground storage tanks, combining
economy of material requirements with ease of installation.

Galvanic vs. Impressed Current

Historically, various configurations of galvanic anodes, including discreet anodes and ribbon
type anodes, have been used to protect AST bottoms. Experience has shown that these systems
do not provide the uniform current distribution necessary over the entire CP system design life
and result in premature failure as the galvanic anodes consume. ASTs require significant
current, which generally precludes the use of galvanic anodes. Almost all AST CP systems
today are designed with impressed current systems to provide the current required over a long
period of time.

Design Information:

The following information is required to develop a CP design for ASTs:

Tank Diameter
This is necessary to calculate the surface area to be protected.

Tank Bottom Coating
Typically tank bottoms are bare plate steel, but in some cases the plate steel may be
coated on the bottom, which reduces the current required for cathodic protection. CP is
still recommended for tanks with coated bottoms.





TECHNICAL BULLETIN AST-01

TAH 12.31.08 v1.0 Page 2 of 10

Current Density Required
Typical design current density requirements of 1 mA/ft
2
(10 mA/m
2
) are sufficient to
achieve NACE criteria for cathodic protection (see discussion on operating temperature).

Depth of Anode
The separation distance between the anode and the tank bottom affects current spread and
anode spacing.

Sand/Soil Resistivity
This information is necessary to estimate overall system resistance necessary to properly
size the rectifier voltage. In many cases, it may make sense to install the anode system
and test the actual circuit resistance using a portable rectifier or car battery before
committing to a specific rectifier size.

Tank Operating Temperature
Corrosion rates increase significantly with elevated temperature, necessitating more
current. MATCOR uses the following temperature correction formula for its CP designs
for heated tank bottoms: for every 10 C above 30 C the current requirement increases
25%.

Area Classification
Rectifiers and junction boxes must be designed with suitable enclosures for the area
classification where they will be installed. Often, these can be located in non-classified
areas with minimal additional cost of cable while saving significantly on the cost of the
enclosures and classified components.

Secondary Containment Liners
If polyethylene or other such plastic liners are to be placed underneath the tank, these
liners act as a barrier to the flow of current and the anodes must be placed between the
liner and the tank bottom. If Claymax or other conductive type liners are to be used, the
anodes do not have to be placed between the liner and the tank bottom.

Design Life
Typical design life for new construction ASTs is 25 to 30 years. It is important to note
that the actual operating life of ASTs often exceeds this value and depending on the
design of the tank, its location, and the selection of a containment liner. Replacement of
the CP system may be difficult to impossible so some consideration should be given to
the economic value of extending the design life. For MATCORs SPL-FBR concentric
ring configuration, the incremental anode cost to go from 30-year design life to 50- year
design life is approximately 25% additional anode cost, with no increase in installation
costs, making this a very attractive alternative.





TECHNICAL BULLETIN AST-01

TAH 12.31.08 v1.0 Page 3 of 10

CP Configurations for New Construction ASTs

Shallow Distributed Anodes around Tank Periphery:

One common design approach to AST bottom CP is to install a shallow distributed point
anode system around the periphery of the tank (Figure 1). These are typically augured in
to depths of 5-10 feet. This design approach only works when there is no electrically
isolating secondary containment liner under the tank.

For these designs, the critical issue is assuring that sufficient current reaches the center of
the tank. Above ground storage tank bottoms are large bare surfaces requiring a lot of
current. To assure that current distributes properly, the anode depth and distance from
the tank are critical. Shallow peripheral anodes are not able to throw current to the center
of all but the smallest of ASTs.

MATCOR generally does not recommend shallow peripherally distributed anodes for
ASTs with tank diameters exceeding 20 ft (6 m) due to the quantity of anodes required
and the risk of poor current dis tribution to the center of the tank.



Depth of Anode
d
Figure 1
Shallow Peripheral Distributed Anodes
NTS
Offset from Tank
t




TECHNICAL BULLETIN AST-01

TAH 12.31.08 v1.0 Page 4 of 10

Deep Well Anode Systems

This approach is based on using one or more deep well anode systems located well below
the tank bottom to provide current uniformly to the tank bottom. This approach has some
limitations in heavily congested plant environments where current can flow to other
buried structures. When multiple deep wells are employed to protect more than one tank
in a cluster, care must be taken to assure proper current distribution.

As with any deep well, there are concerns with drilling (typically 150+ feet to bottom of
hole) including access issues for a drill rig, environmental concerns, permitting and
handling of drilling spoils. Even with a deep well approach, when dealing with new
construction, reference electrodes should be installed under each tank.

Many operators prefer a close coupled dedicated CP system for each tank rather than the
blanket coverage afforded by a deep well system

Should the design for the new construction tank utilize a containment liner that shields
current (i.e. polyethylene liner), the deep well anode system cannot be used.

Distributed Anodes Below Tank Bottom

While not as common today, many older designs utilized individual anodes laid
horizontally along the tank bottom and connected parallel to header cables exiting the
ring wall. The economics of this design, both in terms of installation costs and material
costs, are not favorable and this design has been dropped in favor of either a grid system
or linear anodes in a parallel concentric ring arrangement.

The Grid System

Developed, patented and heavily promoted by Corrpro, this proprietary system involves
laying out parallel titanium conductor bars and then running mixed metal oxide (MMO)
ribbon anode perpendicular to the conductor bars. The MMO ribbon anode is field spot
welded to the titanium conductor bar to provide both mechanical and electrical
connections. Wherever the titanium conductor bars cross, they too must be field welded
together. Power feeds (preassembled cables with a flat plate to connect to the conductor
bar) are secured to the titanium bar in multiple locations and routed to the ring wall
penetration.

Patented in 1991, this system continues to be used by Corrpro; however, it is a labor and
QA/QC intensive installation process requiring significant field welding and on-site
testing to assure electrical continuity. The attachment of the power feeds to the titanium
grid is critical to the system reliability. From a design perspective, the spacing of the
anodes and conductor bars must be sufficient to assure even current distribution. In




TECHNICAL BULLETIN AST-01

TAH 12.31.08 v1.0 Page 5 of 10

Photo 1 Installation of concentric
MATCOR SPL-FBR anode rings
Photo 2 Completed installation of
anode rings prior to backfilling
competitive situations, the temptation is to increase the spacing to reduce the materials
costs.

SPL-FBR Linear Anode Systems

Unlike the Grid system promoted by
Corrpro, MATCORs SPL-FBR linear
anode system for AST tanks can be factory
assembled to eliminate the need for any
field fabrication, which greatly simplifies
installation and reduces QA/QC issues,
eliminating field welds and power feed
connections that are relied upon with the
Grid system to assure electrical
continuity and system integrity.

The principal advantage of the linear
system is that everything under the tank is
factory assembled and tested prior to
installation and the only installation effort
is to lay the anode assemblies in accordance
with the design drawings and installation
instructions. This provides for an
exceptionally simple installation while
assuring the highest system reliability;
installation costs are minimal. Please refer
to MATCORs Installation, Operation and
Maintenance (IOM) Manual for a detailed
installation description with pictures.

There are two primary configurations for
linear anodes under tank bottoms as shown
in Figure 2. The parallel linear anode
arrangement has multiple parallel anode
segments, which are fed from each end of
the anode. The anode connections are field
spliced to loop cables, which terminate at
two anode junction boxes.

The use of concentric rings offers two key
advantages over parallel anode segments. The first advantage is that this configuration
does require junction boxes on both sides of the tank, thus eliminating one of the anode
junction boxes and reducing the cabling required to run from two anode junction boxes




TECHNICAL BULLETIN AST-01

TAH 12.31.08 v1.0 Page 6 of 10

back to the transformer/rectifier unit. The second key advantage to this configuration is
that it eliminates the need for two field splices for each anode segment. Each ring can be
manufactured with the appropriate length of header cable to run each end directly to the
single anode junction box. These field splices are weak links subject to premature failure
over the life of the anode system.

As with any system, spacing between anode segments is another key design element.
MATCORs experience with ring configurations is extensive and we have determined
through numerous installations and our own in- house testing that for tank bottom
applications with bare bottom plates and an anode depth of 1 foot, concentric rings with a
spacing of 10 feet provide thorough current distribution. When the anodes can be placed
deeper than 1 foot, the anode spacing can be extended. Based on the 1 foot depth, typical
ambient temperature tanks can be protected for 30+ years with 16 mA/ft linear anode,
while a 50+ year design life is typically achieved with a 25 mA/ft rated anode with a
modest 25% increase in the anode cost.


Provisions for Testing

With any CP system for tank bottoms, it is critical that provisions for testing be installed with the
anode system. Once the tank is erected, making accurate potential measurements at various
locations along the tank can only be accomplished if reference electrodes have been installed
below the tank. Typically, copper-copper sulfate (Cu-CuSO
4
) reference electrodes are installed
in strategic locations underneath the tank. These reference electrodes are often mistakenly called
permanent reference electrodes; however, they are not permanent as over time the copper-
copper sulfate solution becomes contaminated and ceases to provide accurate information. Once
Figure 2 Linear Anode Configurations
Linear Anode

Anode
Junction Box

Field Splice

Anode Cable

Parallel Linear Segments
Concentric Rings
to T/R

to T/R
to T/R




TECHNICAL BULLETIN AST-01

TAH 12.31.08 v1.0 Page 7 of 10

Photo 3 - Dual reference electrode installation
with copper-copper sulfate shown to the left and
zinc to the right.

a baseline for performance is established over a
sufficient operating period, maintaining the
appropriate current output to achieve NACE
criteria is all that is required.

In some cases, clients may also specify dual
reference electrodes such as both zinc and copper-
copper sulfate. While the zinc reference electrodes
are not as consistent, they provide a much longer
operating life and can be calibrated against the
copper- copper sulfate electrodes.

In addition to the fixed reference electrodes, it is
also common to provide a reference electrode
tube/conduit underneath the tank bottom to allow
sliding of a calibrated reference electrode through
the monitoring tube to take potential readings.
These can also function as leak detection tubes.

Maintenance/Inspection

MATCOR typically recommends annual testing/inspection of the tank CP system by a qualified
NACE CP level 1 or higher technician familiar with testing CP systems for ASTs. As with any
impressed current system, monthly rectifier checks should be performed by plant maintenance to
assure that the rectifier is on and that the voltage and current outputs remain stable.




TECHNICAL BULLETIN AST-01

TAH 12.31.08 v1.0 Page 8 of 10

2d tan 60
(3.46)
60
d
Figure 4 Current Distribution per
NACE CP3 Course
NTS
Appendix A MATCORS DESIGN PROGRAM

System Design:

Once all of the design parameters have been established, MATCORs design program uses the
following process to create a completed design.

1. Basic Calculations
a. Tank Bottom Surface Area simple geometric calculation of the area of a
circle. If the tank bottom is coated MATCOR assumes a 75% coating
efficiency (25% bare) as some coating degradation can be expected at all
of the weld seams.
b. Current Requirement the bare surface area times the temperature
corrected current density requirement provides the total design current
required.

2. Anode Spacing MATCOR typically assumes that the anode will be located a
minimum of 1 foot below the tank bottom. Based on 1 foot depth, MATCOR
uses 10 foot spacing between anodes. This is not based on any theoretical
modeling but has been derived empirically by testing performed by MATCOR
and validated on numerous actual applications. MATCOR has researched the
available literature and has not found any published data or theoretical modeling
that can be used to determine current distribution for concentric rings beneath a
storage tank bottom. For depths greater than 1 foot, MATCOR increases the
anode ring spacing at a rate of 0.5 feet/additional foot of depth.

Occasionally, clients have asked
MATCOR to provide a theoretical
basis or some sort of calculation to
confirm the spacing of the anodes.
NACE, in its CP3 design course,
provides a geometric guideline of
2*tan60 for spacing of galvanic ribbon
anodes under a tank bottom to assure
distribution; however, we have found
no reasonable scientific or theoretical
explanation as to how this value was
selected (Figure 4).




TECHNICAL BULLETIN AST-01

TAH 12.31.08 v1.0 Page 9 of 10

We have discussed this with NACE instructors and Senior Corrosion Engineers
and they cannot provide any justification for this calculation. It just makes for a
nice geometric value.

MATCOR has tested numerous tanks with impressed current CP systems using 10
foot spacing between anodes with a depth (d) of 1 foot. This equates to a
geometric equation of 2d tan(78.7), which is not as elegant a number as 60. But
we know from our testing using reference electrodes that have been placed in
close proximity to the tank bottom that current distributes sufficiently to meet
NACE criteria between ring segments.

3. Current Capacity once the preliminary anode spacing is determined, the total
number of rings can be calculated with the rings spaced equally apart in
concentric circles. The total anode length is then calculated. The current rating of
the anode is a function of the total current required divided by the anode length.
For ambient temperature tanks, using 10 foot spacing, the typical design requires
MATCORs SPL-FBR-16 mA/ft anode and yields a 30+ year design life. The
same design using MATCORs 25 mA/ft anode will generally provide for a 50+
year design life for only a modest increase in material cost.

For elevated temperatures MATCOR calculates a temperature correction factor
based on increasing the current required 25% for every 10 C above 30 C. To
accommodate the higher current requirements at elevated temperatures, either a
higher output anode is necessary or tighter spacing with more anode length is
required. MATCORs design program allows for the anode spacing to be
adjusted to optimize the anode length and anode rating as needed to meet the
desired design life requirements.

4. Anode Resistance Calculations each anode ring is connected parallel to one
another through the anode junction box to the rectifier. The resistance of each
anode ring is calculated using Dwights equation for a ring of wire:







TECHNICAL BULLETIN AST-01

TAH 12.31.08 v1.0 Page 10 of 10

where:

R= resistance of each ring
? = soil resistivity
D = diameter of ring
d = diameter of anode
s = twice the depth of anode

Each rings resistance is calculated and then the total resistance is calculated as:



It is important to note that the resistivity directly impacts the resistance
calculations and that often the actual sand resistivity can vary from the design
basis affecting the resistance calculations and rectifier sizing.

5. Design Life MATCORs linear anodes are rated for 20 years at the rated output
of 16 mA/ft. The actual design life is calculated based on the design output
divided by the rated output times 20 years to provide a calculated design life at
design output. For ambient temperature tanks, the design life is typically around
30 years for 16 mA/ft rated anode and 50+ years for the 25 mA/ft rated anode.




SPL-Anode
TANK BOTTOMS CALCULATIONS SHEET
Design Information:
Tank Diameter ft 120
Current Density mA/sq ft 1
Sand Resistivity ohm-cm 50000
Depth of Anode ft 1.00
Tank Operating Temp F Ambient
Rectifier Margin % 20%
Cable Tail
Length ft 20

Design Results
Surface Area sq. ft. 11304
Temperature Correction Factor 1
Corrected Current Density mA/sq ft 1
Current
Required amps 11.30
Total Number of Rings 6
Anode Spacing ft 10.0
Anode
Selection 16 mA/ft
Anode Life (est) yrs 32.0
Total
Resistance ohms 2.80
Rectifier Sizing Voltage 40
Amperage 15
Total Anode Length ft 1130.9
Total Cable Length ft 600
Ring Configuration
Ring # Diameter ft Linear ft Total ft
Cable Tail Length
ft
1 10 31 31 150
2 30 94 126 130
3 50 157 283 110
4 70 220 503 90
5 90 283 785 70
6 110 346 1131 50