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30.01.2012
Rev.
No.

ISSUED FOR INFORMATION

Date

O.Y

O.Y

E.D

Prepared

Checked

Contr. By

Approved

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Description
ORIGINATOR

Published by

EDOPEC ENERJ PETROL MHENDSLK SANAY VE TCARET LMTED

RKET
Contractor
Document Title

Corrosion Management and Cathodic Protection

Office :

Palmiye Mah. Adnan menderes Bulv. Oktay Sitesi

No: 9/8 PK = 33100 Yeniehir /Mersin TURKEY
P:+90 324 3260595
F:+90 324 3260596
Ankara Office :
UUR MUMCU CAD(krolu cad) ERDL APT
87/13 Gop-ankaya -Ankara-TURKYE
P: +90 312 447 17 18 / 20
F:+90 312 447 17 21
stanbul Office:
Burhanye Mahalles amlca Caddesi
hlamur villalar no 28 / 6^RD3K Villa ^
Beylerbeyi skdar stanbul / TURKEY
P : +90 216 4220414 PBX
F: +90 216 4220415
www.edopec.com. info@edopec.com

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EDOPEC ENERJ PETROL MHENDSLK SANAY VE TCARET LMTED

RKET

www.edopec.com. info@edopec.com

Corrosion Management and

Cathodic Protection

Head Office : Palmiye Mah. Adnan menderes Bulv. Oktay Sitesi No: 9/8 PK = 33100 Yeniehir /Mersin TURKEY
P:+90 324 3260595 F:+90 324 3260596
Ankara Office : UUR MUMCU CAD(Krolu cad) ERDL APT 87/13 Gop-ankaya -Ankara-TURKYE
P: +90 312 447 17 18 / 20 F:+90 312 447 17 21
stanbul Office: BURHANIYE MAHALLESI AMLICA CADDES HLAMUR VLLALARI NO 28 / 6 ^^RD 3K VLLA ^^
Beylerbeyi skdar STANBUL / TURKEY P : +90 216 4220414 PBX F: +90 216 4220415

Edopec Corrosion divisions

is organized with a vision of providing engineering services and manufacturing
for Authorities and Clients located in Turkey , Iran , irak Syria and Middleeast.Libya ,
Our focus is on complete Cathodic Protection services including all of the
Consultation, Survey, Design, production and installation related work for Onshore & Off-shore facilities, Off-shore & Marine inspection and Industrial
Automation for:
Oil and Gas Industries (offshore & onshore)
Petrochemical industry
Energy
Cement industry

Edopec Co. carries out its business under five separate functional
divisions as follows;

Engineering Design and R&D

Manufacturing and Fabrication

Installation, Commissioning and Maintenance

Strategic Planning and Project Control

Financial and Commercial

Edopec. is a Company having a powerful blend of management
experience, young and dynamics and technical expertise. Each Purchase order
or Work order is considered as a separated project and required team is
organized to undertake assigned Project manager to conduct the relevant
steps of Procurements, Quality Control, fabrication/erection/commissioning
along logistics and documents.
We continuously strive to perform all of our projects with the best quality to
satisfy clients' needs, using the qualified engineers and specialists. We realized
that our success is largely dependent upon customer satisfactions witch is
directly involved within each member products and managed projects.

Project
Manger

Procurement
body

QC and Test
body

Logistic
coordinator

Technical
Support

Erection Group

Electrical
Group

Documentation
Group

PROJECT ACTVTES

ACTIVITY

DETAILS

ENGINEERING & DESIGN

Direct Assessments Services;

Soil Resistivity
Survey, CAT (Current Attenuation Test)
Survey, DCVG (Direct Current Voltage/Gradient) Survey, Current
Requirement/Drainage Survey, CIPS (Close Interval Potential) Survey, Stray Current Interference Survey, Polarization and On/Off Potential
Survey, Coating Resistance Survey, Anode bed Resistance Survey, Buried Structures Natural Potential Survey, Overhead line Effect on
Buried Structures Survey, (SRB) Sulphur Reduced Bacteria Survey, pH Survey, Carbonate And Sulphate Ions Survey, Grounding System
Resistance Survey, Internal Cathodic Protection and microbial corrosion monitoring and inspections.
Engineering Design;
Basic & Detailed Design of Cathodic Protection systems for Pipelines, Tank Forms, Petro-Chemical Plates, Power Plants, vessels, harbors,
Jetties, offshore and marine structures by both means of SACP and ICCP system (where applicable) Design of SCADA based ICCP
systems, Design of Stray Current and AC mitigation Systems.
Materials/Equipment Design;
Design and development of various types of CP Trans/rectifier Units, Design and development of Special Power Supply units, Design and
development of RRU systems ( Remote Rectifier Units), Design and development of RMU systems ( Remote Monitoring Units), Design and
development CP Remote Monitoring and Control systems. Design and development of GPS synchronized On/Off control of T/R units,
Design and Development of Current Control boxes, Sacrificial anode design.

PROJECT MANAGEMENT

Project management of SCADA based ICCP systems, Project management of ICCP and SACP systems, Project management of Local
Cathodic Protection of Oil and Gas and Energy Facilities.

COMMISSIONING
& START UP

Deepwell and shallow groundbed installations, ICCP systems for Pipelines and Storage Tanks, ICCP systems for Congested area and
Tank Farms, SACP installation for interior surfaces of storage tanks, SCADA based Cathodic Protection systems, CP Remote monitoring and
Control systems, Galvanic CP and ICCP systems for Pipelines, Storage Tanks and Tank Farms, CP systems for Marine Structures and
Offshore Pipelines, Galvanic CP and ICCP systems for Ships, Vessel, Jetties and Piers, Internal Galvanic CP and ICCP systems for Water
Tanks and Boilers, Galvanic CP and ICCP systems for Reinforcing steel in Concrete Structures, SCADA communication systems (Wireless,
Satellite, GSM, Fiber Optics) , Installation and replace of permanent reference electrodes under the tank bottom plate for further potential
monitoring proposes via. horizontal drilling technology.

EQUIPMENT MANUFACTURE

Fabrication and production of TR units ICCP anodes, Sacrificial anodes, current control and junction boxes, Coupons and reference
electrodes.

PRODUCTION and SUPPLY

Item

Product

Transformer Rectifier Units

Test, Junction, Bond Boxes

Current Control and Compensation Boxes

Reference electrodes and coupons

Cables and connections

Remote Monitoring System& Software

MMO coated Ti anodes

Silicon Iron Chromium Anodes

Magnesium anodes

10

Zn Anodes

11

Al Anodes

12

Backfill Materials

13

Miscellaneous

14

Cathodic Protection Software

CATHODIC
PROTECTION
SCADA SOFTWARE

SYSTEM

CATHODIC
PROTECTION
SCADA SOFTWARE

SYSTEM

CATHODIC
UNIT

PROTECTION

RECTIFIER

PRODUCTION and SUPPLY

MAJOR
EDOPEC

CP

SERVICES

OF

SITE SURVEYS & INSPECTIONS

SERVICES
ENGINEERING DESIGN, PLANNING
AND R&D SERVICES
INSTALLATION AND COMISSIONING
SERVICES
BACK-UP SERVICES
TRAINING

SITE SURVEYS & INSPECTIONS

SERVICES

Site surveys are undertaken to evaluate

the corrosion behaviour of different
environments, Cathodic Protection
monitoring, underwater inspection of
structures, anodes, and coatings ,
Earthing and lightning activities by
means of soil, water, location, stray
current and so on testing.
EDOPEC , undertakes the following
surveys and inspections

Soil Resistivity Survey

CAT (Current Attenuation Test) Survey
DCVG (Direct Current Voltage/Gradient) Survey
Current Requirement/Drainage Survey
CIPS (Close Interval Potential) Survey
Stray Current Interference Survey
Polarization and On/Off Potential Survey
Coating Resistance Survey
Anode bed Resistance Survey
Buried Structures Natural Potential Survey
Overhead line Effect on Buried Structures Survey
(SRB) Sulphur Reduced Bacteria Survey
pH Survey
Carbonate And Sulphate Ions Survey
Grounding System Resistance Survey
Contact Voltage (Touch and Step Voltages) Survey
Lightning Protection Installation Survey
Lightning Protection Level Survey
Internal Cathodic Protection and microbial corrosion monitoring
and inspections.
Potential Profile, Current Distribution Survey of Power Plants,
Take-off yards and substations

Sub-sea Platform inspection for maximum deep of 40

meters including repair, wet welding, cutting, anode
inspection ( Cleaning, montage, re-montage,
photography)and NDT tests (MPI, FMD, Thickness
testes)

BACK-UP SERVICES

EDOPEC . maintains close contact with the market so that it can

tailor its product offering to the needs of the clients. The
considerable experience has ensured that the Company can
provide complete back-up services from initial design to final
commissioning and maintenance. The aim is to give customers an
efficient, professional service of the highest quality. Comprehensive
range of maintenance and support services provides a further level
of back up, as appropriate.

ENGINEERING DESIGN, PLANNING AND R&D

SERVICES
The engineering and design phase is one of the key processes during the project execution stage. EDOPEC.
Currently has a core staff of several engineers. All of these have been selected because of their unique alternative
experience.
We are more than able to provide our clients with the project teams to meet the challenges presented by
mature fields.
Advantages have been successfully involved in almost every advanced engineering project carried out in EDOPEC..
Clients have recognised, through the provision of project services, EDOPECs ability to efficiently provide their
requirements.
Basic & Detailed Design of Cathodic Protection systems for Pipelines, Tank Forms, Petro-Chemical Plates, Power Plants,
vessels, harbours, Jetties, offshore and marine structures by both means of Galvanic and ICCP system (where applicable).
Design and development of various types of CP Trans/rectifier Units
Design and development of Special Power Supply units
Design and development of RRU systems ( Remote Rectifier Units)
Design and development of RMU systems ( Remote Monitoring Units)
Design and development CP Remote Monitoring and Control Systems
Design and development of GPS synchronized On/Off control of T/R units
Project Design of SCADA based ICCP systems
Project Management of ICCP Galvanic CP systems
Project Design of Local Cathodic Protection of Oil and Gas and Energy Facilities
Design and Planning of CP installation of special ICCP anodes
Design and Planning of Subsea and Offshore Structure CP systems
Design and Planning of Ships and Vessels ICCP systems
Design and Planning SCADA communication systems
Design and Planning of ICCP Systems for Internal Cathodic Protection
R & D of CP systems of Reinforcing steel in Concrete Structures
R & D on AC interference analysis and mitigation system design
R & D on Projects Safety and Economics

INSTALLATION AND COMISSIONING SERVICES

Edopec Co. have ability to provide installation and commissioning services for the following projects and systems relevant to
Oil & Gas and Energy Industries.

Deepwell and shallow groundbed installations

ICCP systems for Pipelines and Storage Tanks
ICCP systems for Congested area and Tank Farms
Galvanic CP installation for interior surfaces of storage tanks
SCADA based Cathodic Protection systems
CP Remote monitoring and Control systems
Galvanic CP and ICCP systems for Pipelines, Storage Tanks and Tank Farms
CP systems for Marine Structures and Offshore Pipelines
Galvanic CP and ICCP systems for Ships, Vessel, Jetties and Piers
Internal Galvanic CP and ICCP systems for Water Tanks and Boilers
Galvanic CP and ICCP systems for Reinforcing steel in Concrete Structures
Ribbon anode installation for new constructed storage tanks
ICCP system for existing tanks using horizontal drilling technology.
Installation and replace of permanent reference electrodes under the tank bottom plate
for further potential monitoring proposes via. horizontal drilling technology.

Fundamentals of Corrosion
Corrosion Cell:
Conditions required for corrosion
Corrosion Rate
Corrosion Types
Commonly Affected Structures
Corrosion Control
Materials Selection
Inhibitors/Altering the environment
Coatings
Cathodic Protection
Measuring potentials
Criteria

Fundamentals of Corrosion
Corrosion Cell:
Conditions required for corrosion
Corrosion Rate
Corrosion Types
Commonly Affected Structures
Corrosion Control
Materials Selection
Inhibitors/Altering the environment
Coatings
Cathodic Protection
Measuring potentials
Criteria

Introduction to Corrosion

Corrosion can be defined as the deterioration of metal

due to its interaction with the environment. Corrosion
is a natural phenomenon, which should not surprise
one, but rather should be expected to occur. Metals are
high energy materials, which exist because heat energy
was added to natural iron ores during the smelting
process. Nature, by environmental contact, constantly
attacks these high energy materials and breaks them
down to the natural elements from which they were
derived.

Conditions Required for

Corrosion

Corrosion is an electrochemical process occurring at

the interface between metal and environment. Three
conditions must be present for this to occur.
1. Two areas on a structure or two structures must
differ in electrical potential.
2. Those areas, called anodes and cathodes, must be
electrically interconnected.
3. Those areas must be exposed to a common
electrolyte (soil or water).

Two areas or two structures

that differ in electrical
potential (different amounts of
stored energy)

The two areas, called the

Anode and Cathode, must
be electrically connected
(conductive path)

Those areas must be exposed to

a common electrolyte
CURRENT
FLOW

WIRE

CATHODE
(COPPER)

ANODE
(IRON)

CURRENT FLOW
IONIZED ELECTROLYTE
CURRENT FLOW
(- TO + IN ELECTROLYTE)

Those areas must be exposed to a

common electrolyte
CURRENT
FLOW

WIRE

CATHODE
(COPPER)

ANODE
(IRON)

CURRENT FLOW
IONIZED ELECTROLYTE
CURRENT FLOW
(- TO + IN ELECTROLYTE)

Corrosion Cell Dissimilar Metals

i.e. steel pipe connected to copper ground rod
CURRENT
FLOW

WIRE

CATHODE
(COPPER)

ANODE
(IRON)

CURRENT FLOW
IONIZED ELECTROLYTE
CURRENT FLOW
(- TO + IN ELECTROLYTE)

Corrosion Rate

24

As a result of this process, electric current flows

through the interconnection between cathode
and anode. The cathodic area is protected from
corrosion damage at the expense of the metal,
which is consumed at the anode. The amount
of metal lost is directly proportional to the
current flow. Mild steel is lost at approximately
20 pounds for each ampere flowing for a year.

Factors Affecting Corrosion Rate

25

Potential Difference Between Anode and

Cathode (Galvanic Series)
Circuit resistance Resistivity of the Electrolyte
Chemical Activity
Stray Currents

Potential Difference
Interconnecting two dissimilar metals in an
electrolyte will create a corrosion cell. The
strength of this cell increases as the distance
within the galvanic series increases.

26

Galvanic Series
Example: connecting magnesium to copper will produce a corrosion cell with a
potential of about 1.5 volts.

27

METAL
VOLTS (CSE)
Commercially Pure Magnesium -1.75
Magnesium Alloy
-1.60
Zinc
-1.10
Aluminum Alloy
-1.05
Commercially Pure Aluminum -0.80
Mild Steel (clean & shiny)
-0.50 to -0.80
Mild Steel (rusted)
-0.20 to -0.50
Cast Iron (not graphitized)
-0.50
Lead
-0.50
Mild Steel in Concrete
-0.20
Copper, Brass, Bronze
-0.20
High Silicon Cast Iron
-0.20
Carbon, Graphite, Coke
+0.30

Circuit Resistance
Circuit resistance includes the following:
Resistance of the anode
Resistance of the cathode
Resistance of the electrolyte
Resistance of the metallic path
Increasing the resistance will reduce the corrosion rate.

28

Resistance of Common Electrolytes

Soils High resistivity water reduces the

corrosion rate, while low resistivity water
increases the corrosion rate.

CLASSIFICATION

29

ELECTROLYTE
RESISTIVITY
(ohm-cm)

ANTICIPATED
CORROSIVITY

Low Resistance

0 to 2,000

Severe

Medium

2,000 to 10,000

Moderate

High

10,000 to 30,000

Mild

Very High

Above 30,000

Increasingly Less

Resistance of Common Electrolytes

Water Approximate resistivity values

Water resistivity
open sea
seawater (coastal)
river water
tap water
rain water
distilled water
pure water

30

Ohms-cm
20-25
30-40
500-10,000
1,000-10,000
20,000
500,000
20,000,000

Chemical Activity
Passive (less corrosive) Environment
High pH (neutral or basic)
Low Moisture Content
Lack of Salts
High Resistivity
Low Temperature
Homogenous Environment
31

Chemical Activity
Active (more corrosive) Environment
Low pH (acidic)
High Moisture Content
Salts
Low Resistivity
Moderate to High Temperature
Heterogeneous Environment
32

Stray current corrosion

Boat 1

Boat 2

Boat 3

Ground
wire

Corrosion Type

34

Uniform or near uniform - Corrosion attacks all

areas of the metal at the same or similar rate.
Localized - Some areas of the metal corrode at
different rates due to heterogeneities in the
metal or environment. This type of attack can
approach pitting.
Pitting - Very highly localized attack resulting in
small pits that may penetrate to perforation.

35

Commonly Affected Structures

36

Buried Piping
Steel Piles
Storage Tanks - Above Ground / Underground
Reinforcing Steel in Concrete
Ships/Boats

37

38

Methods to Control Corrosion

39

Use of Corrosion resistant materials (plastic, stainless

alloys, fiberglass).
Use of the same or similar metals per the galvanic
series.
Altering the environment (utilizing homogeneous high
resistivity backfill or inhibitors).
Utilize coatings and linings that electrically insulate the
structure from the electrolyte (paints, plastic films, etc).
Use of Cathodic Protection.

Fundamentals of Cathodic
Protection

40

Cathodic Protection (CP) Defined - Minimize

corrosion by utilizing an external source of
electrical current which forces the entire
structure to become a cathode.

1824: Earliest practical use of cathodic protection

41

Sir Humphrey Davys work on protecting the

copper sheathing on wooden hulls in the
British Navy by sacrificial zinc or iron anodes is
generally considered to be the earliest
example of practical cathodic protection.

Galvanic CP

42

When metals such as magnesium or zinc are

placed in the environment in contact with a
more noble metal such as steel, a current flows
from the more active anode to the noble
cathode (corrosion cell).

Anodes Used for Galvanic CP

43

Magnesium Magnesium is often used in soil to

protect small electrically isolated structures, such
as underground storage tanks, and well coated
pipelines.
Zinc Zinc is often used in marine
environments. They are commonly found on
boats.
Aluminum Aluminum can be used for a variety
of marine applications.

Keys to obtaining enough cathodic protection

Determine amount of current required

Theoretical calculations based on coating quality
and environment
Or, perform current requirement testing
Calculate output expected from anode and
determine number of anodes required.

44

Galvanic CP
Pros of Galvanic CP
Inexpensive
Little Maintenance cost
No external Power source
A variety of install methods can be used. For
example, many USTs are shipped with anodes
attached.
45

Galvanic CP
Cons of Galvanic CP
Typically work best with electrically isolated structures.
No external power source, limited driving potential
(driving potential based on the galvanic series)
Limited output makes it ineffective when trying to
protect large uncoated surfaces.
Require a low resistivity electrolyte to function well.

46

Impressed Current CP

47

Utilize an external power source to develop a

high potential difference between the surface to
be protected and an anode.

Impressed Current CP
IMPRESSEDCURRENTSYSTEM
AnodeGroundbed
PositiveCable
Rectifier
ACPower Supply
Pipeline

NegativeCable

Impressed Current CP
Pros of Impressed Current CP
Unlimited driving potential.
Capable of protecting large steel structures
when designed properly.
Requires less anodes then a galvanic system.
Output can be controlled using a permanent
reference electrode, desirable when the
electrolyte resistivity is known to change.
49

Impressed Current CP
Cons of Impressed Current CP
Initial costs can be more expensive.
Requires an external DC power source along
with an AC supply.
System requires routine maintenance and
monitoring.
Anode wires can be susceptible to damage.
50

Impressed Current CP Rectifier

A rectifier converts available AC power to low
voltage DC power. Most cathodic protection
rectifiers are provided with a means to vary the
DC output voltage in small increments, or in
some cases offer complete control from zero to
100% of rated DC output.

51

CP System Testing

52

A CP system can be evaluated by obtaining a

reference cell potential. This potential
determines the amount of cathodic polarization
the structure is receiving.
Adequate protection is indicated by obtaining a
value more negative then the established criteria.
This criteria is specific to the reference cell used
to obtain potentials.