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TECHNICAL DATA
GENERAL
Corrosion Definitions:
Anode - An electrode at which oxidation of the surface or some component of the solution is
occurring. Practically, this is the electrode at which corrosion occurs.
Ampere - The practical unit of electrical current equal to that produced by one volt applied across a
resistance of one ohm.
Ampere-hour - The unit quantity of electricity equal to that produced by one ampere of current in a
one hour period.
Cathode - An electrode at which reduction is occuring. Practically, this is the electrode at which
protection occurs in a cathodic protection system.
Corrosion - The deterioration of material, usually metal, from a reaction with its environment.
Current Density - The applied electrical current per unit area.
Electrolyte - The common environment with which both a cathode and anode are in contact.
Practically, this is the soil or water to which a metal structure is exposed.
Galvanic Anode - A metal that provides cathodic protection when connected to other metals, as a
result of its relative position in the Galvanic Series.
Galvanic Series - A listing of metals in order of reactivity when exposed to an electrolyte.
Impressed Current Cathodic Protection - A cathodic protection system derived from the application
of external electrical energy from sources such as common electrical power, thermoelectric
generators, and solar panels.
Ohm - The practical unit of electrical resistance equal to the resistance of a circuit in which a potential
difference of one volt produces a current of one ampere.
Sacrificial Cathodic Protection - A cathodic protection system derived from the internal electrical
energy developed by coupling to more reactive metals such as aluminum, magnesium, and zinc.
Volt - The practical unit of electrical potential difference required to produce a current flow of one
ampere across a resistance of one ohm.
Introduction to Corrosion
Introduction
Corrosion is usually defined as the deterioration of a metal or its properties caused by a reaction with
its environment. Most metals occur naturally in the form of oxides and are usually chemically stable.
When exposed to oxygen and other oxidizing agents, the refined metal will try to revert to its natural
oxide state. In the case of iron, the oxides will be in the form of ferrous or ferric oxide, commonly
known as rust.
Metallic corrosion generally involves the loss of metal at a particular location on an exposed surface.
Corrosion occurs in various forms ranging from a generalized attack over the entire surface to a
severe concentrated attack. In most cases, it is impossible or economically impractical to completely
arrest the corrosion process; however, it is usually possible to control the process to acceptable
levels.
The U.S. government funded a detailed study of the annual cost of corrosion in 1975. The total cost
of metallic corrosion to the U.S. economy was estimated at 4% of the GNP ($70 billion dollars). Of
that, approximately 30% was defined as avoidable. Adjustment based on today's current economy
puts total current costs in the $300 billion range with over $100 billion of that avoidable.
Corrosion Process
3
Metallic corrosion is caused by the flow of direct current from one part of the metal surface to another.
This flow of direct current causes the loss of metal at the point where current discharges into the
environment (oxidation or anodic reaction). Protection occurs at the point where current returns to the
metal surface (reduction or cathodic reaction. The rate of corrosion is proportional to the magnitude of
the corrosion current. One ampere of direct current removes approximately twenty pounds of steel in
one year. Where corrosion occurs and to what extent depends upon the environment to which the
metal is exposed.
Four conditions must be met for corrosion to occur. Elimination of any of the four conditions will halt
the corrosion reaction.
Anode - the oxidation reaction occurs here. Current discharge into the environment and metal
loss are associated with this reaction.
Cathode - the reduction reaction occurs here. Current acceptance and metal protection are
associated with this reaction.
Electrolyte - the environment to which both the cathode and the anode are exposed. The
electrolyte must have the capacity to conduct electrical current through the flow of ions.
Metallic path - the anode and the cathode must be connected via a metallic connection that
conducts electrical current flow through the flow of electrons.
Causes of Corrosion
Corrosion is a natural process. The primary driving force of corrosion is based upon the
transformation of iron from its natural state to steel. The refining of iron ore into steel requires the
addition of energy. Steel is essentially an unstable state of iron and corrosion is the process of iron
returning to its natural state. The energy used in the refining process is the driving force of corrosion.
Corrosion cells are established on underground pipelines for a variety of causes. A primary cause of
corrosion is due to an effect known as galvanic corrosion. All metals have different natural electrical
potentials. Where two metals with different potentials are connected to each other in a common
environment, current will flow causing corrosion to occur. The coupling of steel to a different metal,
such as copper, will cause a corrosion circuit to be established. Direct coupling of copper to steel will
cause the steel to corrode much faster than normal. Another form of this is the coupling of rusty pipe
to new, clean steel. The natural difference in potential causes the new steel to corrode more rapidly
than the old steel. Other causes of pipeline corrosion cells include the effect of different soil types,
oxygen availability, stray current interference and microbiological growth.
Two other unique causes (and sometimes related) are stress and hydrogen.
Stress Corrosion occurs when even a very small pit forms in a metal under stress. The
concentrated stress either deepens and extends the pit, or cracks the protective film which
tends to form. Under continued exposure to the corrosive medium and stress, the crack
extends by alternate corrosion and stress failure.
Hydrogen Embrittlement and hydrogen attack results when atomic hydrogen penetrates into
the grain boundaries of steel producing microcracks, blistering and loss of ductility. The atomic
hydrogen combines into molecules and results in blistering and laminations.
Forms of Corrosion
Corrosion exhibits itself in a number of ways. A brief description of some of these is provided below.
General Corrosion is the most common form of corrosion. It exhibits itself in an overall attack
of the metal surface with no apparent concentrations. An example is the effect of atmospheric
corrosion.
Pitting Corrosion results in a localized, concentrated attack and has the appearance of holes
or craters.
Selective Leaching results in one constituent of an alloy being selectively removed, leaving a
porous replica of the original alloy. An example is the dezincification of brass or bronze and the
graphitization of cast iron where iron is removed selectively, leaving a replica composed of
carbon or graphite.
Control of Corrosion
The five general methods used in the control of corrosion are coating, cathodic protection, material
selection, environmental modification, and design practices. Control of underground corrosion is
primarily achieved by two methods: coating and cathodic protection. An effective external coating can
provide corrosion protection to over 99% of the exposed pipe surface. The protective coating is
usually applied to the pipe or tank before burial. The coating serves to electrically insulate the metal
from the soil. If the metal could be completely isolated, then the establishment of corrosion cells
would be prevented and no corrosion current would flow. However, no coating can be considered a
perfect coating. Damage to the coating as a result of handling, transportation, installation, thermal
stresses, and soil stresses will eventually create defects or "holidays" that expose the underlying steel
to the environment.
Cathodic protection is an electrochemical technique for preventing corrosion of a metal exposed to an
electrolyte. The process involves application of DC electrical current to the metal surface from an
external source. By forcing the metal surface to accept current from the environment, the
underground metal becomes a cathode and protection occurs. The external source can use outside
AC power through a rectifier and groundbed or by attaching sacrificial metals such as magnesium or
aluminum to the structure to be protected. It is used extensively in preventing corrosion to
underground and submerged steel structures; such as pipelines, production well casings, and tanks.
Effective application of cathodic protection can provide complete protection to any exposed areas for
the life of the structure. The combination of an external coating and cathodic protection provides the
most economical and effective choice for protection of underground and submerged pipelines. For
bare or ineffectively coated existing pipeline systems, cathodic protection often becomes the only
practical alternative for corrosion protection.
Cathodic protection is a mandated requirement of federal and state regulations governing
underground transmission pipelines, gas distribution systems, and underground fuel tanks. These
requirements include installation, monitoring, and maintenance of cathodic protection systems.
Introduction
Cathodic protection is an electrochemical technique for preventing corrosion of a metal exposed to an
electrolyte. The process involves application of DC electrical current to the metal surface from an
external source. The external source can be either a commercial power source or through connection
to sacrificial metals such as magnesium or aluminum. It is used extensively in preventing corrosion to
underground and submerged steel structures; such as pipelines, production well casings, and tanks.
Effective application of cathodic protection can provide complete protection to any exposed areas for
the life of the structure. The combination of an external coating and cathodic protection provides the
most economical and effective choice for protection of underground and submerged pipelines. For
bare or ineffectively coated existing pipeline systems, cathodic protection often becomes the only
practical alternative for corrosion protection.
Cathodic protection is a mandated requirement of federal and state regulations governing
underground transmission pipeline, gas distribution systems, and underground petroleum tanks.
These requirements include installation, monitoring, and maintenance of cathodic protection systems.
Three metals are commonly utilized for cathodic protection of steel. The selection of the anodic metal
is dependent upon resistivity and electrolyte. A general application guide for these metals are:
An advantage of sacrificial anode systems is the flexibility in application. Anodes can be installed in a
variety of applications and configurations. No outside power is required for cathodic protection to be
effective. Another advantage is the minimal maintenance required for these systems to function.
9
Disadvantages of sacrificial anode systems include the limited protection current available and limited
life. Sacrificial anodes are subject to rapid corrosion (consumption) and require replacement on a
regular basis. Typical design life of a pipeline system anode is five to ten years.
Impressed Current Cathodic Protection
Impressed current cathodic protection involves the application of an external DC current through longlasting anodes. A typical source of power for an impressed current system is AC power converted to
DC by a rectifier.
In order to be effective, impressed current anodes must be designed for long life at high current
output. This requires selection of materials with very low corrosion (consumption) rates. The typical
expectation of impressed current anode life is over twenty years. Anode materials that have proven to
be suitable for impressed current systems include treated graphite, high silicon cast iron, mixed metal
oxide, and to a lesser extent platinum and magnetite. Anodes are normally installed in grouped
configurations in the electrolyte. These groupings (both horizontal and vertical) in an underground
application are called groundbeds. The groundbeds are connected to the power by a positive cable to
the power source. A negative cable connects the power source to the structure.
Advantages of impressed current systems include the unlimited current opportunities and longer life.
Impressed current systems are typically installed where the structure to be protected is large,
requiring higher levels of current.
Disadvantages include the requirement for an outside power source and higher maintenance
requirements. Outside power might come from sources such as commercial AC converted to DC
through a rectifier, thermoelectric generator, or solar panels. A significantly higher monitoring and
maintenance effort is required by comparison to sacrificial anode systems.
10
Underground Pipelines are the primary market for cathodic protection. Both sacrificial and
impressed current systems are used. Federal and state regulations require cathodic protection
for most petroleum or gas pipeline systems.
Underground Storage Tanks (UST's) used for fuel are now required by EPA to either have
functional cathodic protection systems or to be of a non-corrosive material. Both types of
systems are widely used.
Aboveground Storage Tank (AST's) bottoms can be protected from soil-side corrosion with
cathodic protection. Most major tank operators include cathodic protection in their corrosion
control program. Unique problems involved with tank applications include the difficulty of
distributing current uniformly over the tank bottom and monitoring the effectiveness of the
systems.
Production Well Casings usually require impressed current systems due to higher current
requirements. The economics of cathodic protection are excellent until production volumes
decline and fields near the end of their effective life. This application of cathodic protection is
common; but tends to be concentrated in established fields with known corrosion history.
Internal surfaces of tanks and vessels are commonly protected by cathodic protection
systems. With some exceptions, most of these utilize sacrificial anodes. Possible applications
range from heater-treaters, heat exchangers, water storage tanks, and hot water heaters.
Offshore structures such as production platforms, docks, and pipelines are almost always
protected with cathodic protection systems. Sacrificial anode systems with aluminum anodes
are the most common application.
on the electrolyte near the structure. If the voltage difference is more negative than -0.850 volts, then
the structure is considered protected. If the value is more positive than -0.850 volts, the structure is
either unprotected or only partially protected. Normal values of unprotected steel in soil typically
range from -0.500 to -0.700 volts with respect to copper sulfate. The interpretation of pipe-to-soil
potentials requires consideration of the effects of measurement errors such as IR drop in the soil
between the pipe and the electrode. The most common consideration of this effect is through an
"instant off" measurement obtained by interrupting current sources. Other techniques include
potential measurement at permanent "coupon type test stations".
Design Considerations
There are four primary questions to be answered when designing a cathodic protection system.
Limitations of cathodic protection must be recognized during the design process. Cathodic protection
will be effective only on metal surfaces in continual contact to the electrolyte. Above-ground structures
will not be protected. The distribution of current to desired areas becomes difficult in congested or
remote areas. Examples include multiple pipeline right-of-ways and storage tank bottoms.
Multiple variables should be considered during the design process. Two primary factors include the
effectiveness of an external coating and resistivity of the electrolyte. The existence of a high quality
coating minimizes current requirements of a structure and greatly influences the design. Electrolyte
resistivity affects the choice between sacrificial and impressed current as well as the type of
groundbed.
Other design factors include foreign system interference, power availability, maintenance
requirements, and economics.
Volts
-1.75
-1.6
Zinc
-1.1
-1.05
-0.8
-0.5 to -0.8
12
-0.2 to -0.5
-0.5
Lead
-0.5
-0.2
-0.2
-0.2
-0.2
+0.3
Typical potential normally observed in neutral soils and water, measured with respect to copper/copper sulfate reference electrode.
Copyright 1991 by NACE International. Reprinted from Corrosion Engineers Reference Book with permission by NACE. All rights
reserved.
mA/m2
35,000
380,000
35 - 40
380 - 430
8 - 15
90 - 160
7 - 10
80 - 110
7-8
80 - 90
5-6
50 - 60
mmm Indonesia
5-6
50 - 60
Soil
1-3
10 - 30
0.1
0.003
0.03
0.0003 or less
0.003 or less
Environment
Copyright 1991 by NACE International. Reprinted from Corrosion Engineers Reference Book with permission by NACE. All rights
reserved.
Reference
Electrode
Copper/Copper
Sulfate
-0.850 volt
Silver/Silver
Chloride
-50 mv
-0.800 volt
Standard
Calomel
-70 mv
-0.780 volt
13
Zinc
-1100 mv
+0.250 volts
Where:
T is ppm dissolved solids
R is resistance in ohm-cm.
Resistance of a Single Rod Anode to Earth(1)
(1)
Corrosivity
Below 100
Extremely corrosive
100 - 1,000
Very corrosive
14
1,000 - 2,500
Corrosive
2,500 - 7,500
Moderately corrosive
7,500 - 15,000
Mildly corrosive
Over 15,000
Energy Capability
(Ah/lb)
Consumption Rate
(lb/Ay)
Potential vs CuCuSO4
(volts)
Zinc
95
335
23.5
-1.10
85
1150
6.5
-1.10
50
500
8.7
-1.45
50
500
8.7
-1.70
Anode
0.01% max
Manganese
0.50 - 1.3%
Copper
0.02% max
Silicon
0.05% max
Iron
0.03% max
Nickel
0.001% max
Others, each
0.05% max
Magnesium
Remainder
Element
Aluminum
5.3-6.7
5.3-6.7
5.3-6.7
Zinc
2.5-3.5
2.5-3.5
2.5-3.5
Manganes
e
.15 Min.
.15 Min.
.15 Min.
Silicon
.10 Max.
.20 Max.
.30 Max.
Copper
.02 Max.
.05 Max.
.10 Max
Nickel
.002 Max
.003 Max
.003 Max
Iron
.003 Max.
.003 Max.
.003 Max.
Other
Impurities
.20 Max.
.20 Max.
.30 Max.
16
Current Output
Current output is controlled by three factors:
Soil resistivity - Current output increases as soil resistivity decreases. Generally magnesium
anodes are installed in relatively low resistivity soils. Economic application decreases
significantly in soil resistivities exceeding 5,000 ohm-cm. Practically, magnesium anodes are
not effective above 10,000 ohm-cm.
Anode surface area - Current output is proportional to surface area. As the surface area
increases, current output increases. Increased surface area is usually achieved by increasing
the length of the anode.
Alloy potential - High potential anodes have open circuit potentials approximately 20-25%
higher than H-1 alloy. (-1.75 volts versus -1.40 volts). This creates a higher anode current and
results in a lower total anode requirement.
I = current in amperes
V = potential differential in volts
R = anode resistance in ohms
The voltage difference is the protected potential of -0.85 volts subtracted from the open circuit
potential of the anode. For high potential anodes, the difference is -0.9 volts. For H-1 alloy, the
difference is -0.55 volts.
Resistance to earth can be calculated by Dwight's Equation:
R = resistance in ohms
= soil resistivity in ohm-cm
L = anode length in feet
d = anode diameter in feet
Tefankjian, in his article "Application and Maintenance of Control Facilities" offers a simple process for
determining anode current output with consideration of coating, potential, and multiple anode
17
installation. The process involves calculation of anode current for a single high-potential anode
installed 10' away from a bare pipeline using the formula:
Step 1: For a well-coated pipeline, the constant of 150,000 should be reduced 20% to 120,000.
Step 2: Select anode size correction factor from Table 1.
Anode Weight
(pounds)
Standard
Anodes
Factor
(f)
3D3
(packaged)
0.53
5D3
(packaged)
0.60
9D3
(packaged)
0.71
17D3
(packaged)
1.00
20D2
(packaged)
1.60
32D3
(packaged)
1.06
48D5
(packaged)
1.09
Magnesium
-0.70
1.14
-0.80
1.07
-0.85
1.00
-0.90
0.93
-1.00
0.79
-1.10
0.64
-1.20
0.50
18
ADJUSTING FACTORS
Anode Spacing in Feet
5'
10'
15'
20'
1.839
1.920
1.946
1.964
2.455
2.705
2.795
2.848
3.036
3.455
3.625
3.714
3.589
4.188
4.429
4.563
4.125
4.902
5.223
5.411
4.652
5.598
6.000
6.232
5.152
6.277
6.768
7.036
5.670
6.964
7.536
7.875
10
6.161
7.643
8.304
8.679
As Tefankjian states in his article, the above process should be used only as a guide to estimate
current output.
D. A. Tefankjian in his article, "Application and Maintenance of Control Facilities" offers the following
formula for calculating anode life.
19
9D3
17D3
20D2
32D5
48D5
Soil
Resistivit Outpu Life Outpu Life Outpu Life Outpu Life Outpu Life
y
year
year
year
year
year
t
t
t
t
t
ohm-cm
mA
mA
mA
mA
mA
1000
122
3.6
163
260
166
208
11
2000
61
81
10
130
83
19
104
22
3000
41
11
54
15
87
11
55
28
69
34
4000
31
14
40
20
65
15
41
38
52
45
5000
24
18
33
25
52
19
33
47
41
56
6000
20
22
27
31
43
22
28
55
35
67
7000
17
25
23
36
37
26
24
65
30
78
8000
15
29
20
41
33
30
21
75
26
90
9000
14
32
18
46
29
33
18
86
23
101
10000
12
36
16
51
26
37
16
94
21
112
15000
54
11
77
17
56
11
141
14
168
20000
72
102
13
74
188
10
224
Design Process
Design of magnesium anode systems requires a thorough evaluation of the application with
consideration of the important variables. Once these variables are measured or assumed, the
process typically is divided into the following steps.
Calculate exposed surface area - This requires an assumption of coating quality. A high
quality coating can provide protection to over 99% of the total surface area. A conservative
assumption of coating efficiency is 95%.
Calculate total current requirements - This requires an assumption of current density. The
typical range of current density for steel in common soils is 1 to 3 milliamperes per square foot
of exposed surface. A conservative assumption is 2 milliamperes per square foot.
Calculate anode current output - Using previous discussed formulas, calculate anode output
considering the effect of coating, soil resistivity, alloy selection, and anode spacing. Several
anode sizes should be evaluated.
Select anode size based on life - Once anode current outputs have been calculated, the
appropriate anode size can be selected by evaluating the projected life. Typical design lives
range from 10 to 20 years.
20
Calculate total anode quantity - Divide the total current requirement in amperes by the
calculated anode output in amperes. The result is the estimated total number of anodes
required.
Determine anode location and configuration - This is primarily based on local site
conditions and an even distribution of current from the anodes.
Design Process
Design of magnesium anode systems requires a thorough evaluation of the application with
consideration of the important variables. Once these variables are measured or assumed, the
process typically is divided into the following steps.
Calculate exposed surface area - This requires an assumption of coating quality. A high
quality coating can provide protection to over 99% of the total surface area. A conservative
assumption of coating efficiency is 95%.
Calculate total current requirements - This requires an assumption of current density. The
typical range of current density for steel in common soils is 1 to 3 milliamperes per square foot
of exposed surface. A conservative assumption is 2 milliamperes per square foot.
Calculate anode current output - Using previous discussed formulas, calculate anode output
considering the effect of coating, soil resistivity, alloy selection, and anode spacing. Several
anode sizes should be evaluated.
Select anode size based on life - Once anode current outputs have been calculated, the
appropriate anode size can be selected by evaluating the projected life. Typical design lives
range from 10 to 20 years.
Calculate total anode quantity - Divide the total current requirement in amperes by the
calculated anode output in amperes. The result is the estimated total number of anodes
required.
Determine anode location and configuration - This is primarily based on local site
conditions and an even distribution of current from the anodes
Bare Pipe Chart
1K
Anode Recommendation
208 104 55
40
33
20 17 15 14 12
11
20
25
22 25 29 32 36
Pipe
inch
O.D.
inch
Surface
Area
Ft2/L.F.
Current
Reqmt.
mA/L.F.
2K
22
3K
28
4K
5K
6K 7K 8K 9K 10K
21
2.275
0.60
1.19
175
87
46
34
28
17 14 13 12
10
4.50
1.18
2.36
88
44
23
17
14
6.625
1.73
3.47
60
30
16
12
10
8.625
2.26
4.51
46
23
12
10
10.75
2.81
5.63
37
18
10
12
12.75
3.34
6.67
31
16
14
14.00
3.66
7.33
28
14
16
16.00
4.19
8.37
25
12
18
18.00
4.71
9.42
22
11
20
20.00
5.23
10.47
20
10
22
22.00
5.76
11.51
18
24
24.00
6.28
12.56
17
26
26.00
6.80
13.61
15
28
28.00
7.33
14.65
14
30
30.00
7.85
15.70
13
32
32.00
8.37
16.75
12
34
34.00
8.90
17.79
12
36
36.00
9.42
18.84
11
1K
2K
3K
5K
6K
7K
8K
9K 10K
Anode Recommendation
48#
48#
9#
9#
9#
9#
9#
208
104
55
40
33
20
17
15
14
12
11
22
28
20
25
22
25
29
32
36
O.D.
inch
Surface
Area
Current
Reqmt.
4K
Ft2/L.F.
mA/L.F.
2.275
0.60
0.06
3494 1747 924 672 554 336 286 252 235 202
4.50
1.18
0.12
1766
883
6.625
1.73
0.17
1200
600
98
87
81
69
8.625
2.26
0.23
922
461
89
75
66
62
53
10
10.75
2.81
0.28
739
370
71
60
53
50
43
12
12.75
3.34
0.33
623
312
165 120
99
60
51
45
42
36
14
14.00
3.66
0.37
568
284
150 109
90
55
46
41
38
33
16
16.00
4.19
0.42
497
248
131
96
79
48
41
36
33
29
18
18.00
4.71
0.47
442
221
117
85
70
42
36
32
30
25
20
20.00
5.23
0.52
397
199
105
76
63
38
32
29
27
23
22
22.00
5.76
0.58
361
181
96
69
57
35
30
26
24
21
24
24.00
6.28
0.63
331
166
88
64
53
32
27
24
22
19
26
26.00
6.80
0.68
306
153
81
59
49
29
25
22
21
18
28
28.00
7.33
0.73
284
142
75
55
45
27
23
20
19
16
30
30.00
7.85
0.79
265
132
70
51
42
25
22
19
18
15
32
32.00
8.37
0.84
248
124
66
48
39
24
20
18
17
14
34
34.00
8.90
0.89
234
117
62
45
37
22
19
17
16
13
36
36.00
9.42
0.94
221
110
58
42
35
21
18
16
15
13
Calculated values are based on current density of 2 milliamperes per square foot.
Calculated values based on a coating efficiency of 95%
through a test station. This configuration permits monitoring of anode performance. The
other method of installation is to directly connect the anode wire to the pipe.
Anodes may be installed either horizontally or vertically. A minimum separation distance
of 5' is desirable to maximize the performance of the anode. This separation can be
achieved either horizontally or vertically depending on local conditions. In most cases,
anodes should be installed no shallower than pipe depth. In dry soils, additional depth
may enhance anode performance by reaching lower resistivity soil. Wetting the anode
with approximately five gallons of water after installation will activate the anode faster
and provide initial current output data.
dimensionally stable anodes. These anodes include the precious metals and ceramic anode
materials. The development of new anode materials continues. Even today however; many of the
early anode materials are still in widespread use.
Reactions
Anodic reactions occur at the surface of anodes in a corrosion cell. Although there are several
possible reactions, gas evolution is the primary oxidation effect of impressed current systems. The
two primary anodic reactions in impressed current systems are chlorine evolution and oxygen
evolution. Chlorine evolution occurs when an anode is in the presence of chloride ions. This reaction
will predominate in seawater and high chloride environments.
The chlorine evolution reaction is:
2CL
Cl2 + 2eChlorine gas then reacts with water to form hypochlorous and hydrochloric acid.
Oxygen evolution occurs in low chloride ion concentrations or when sulfate ions are present. This
occurs in underground applications where chloride ion depletion and restriction of ion migration allows
the oxygen evolution reaction to dominate.
The oxygen evolution reactions are:
O2 + 4H+ + 4e&
2SO4 + 2H2O
2H2SO4 + O2 + 4eThese anodic reactions decrease the pH of the solution in the vicinity of the anode. Anodic
consumption of coke carbon particles also contribute to lowering pH of the anode environment.
Anodic environments with a pH as low as 1.0 have been observed. In order to be effective, anode
materials must be resistant to acid attack.
2H2O
Anode Material
Effective impressed current anodes should possess the following qualities:
Mechanically tough
Economical
Any material possessing these properties could be used as an impressed current anode. Materials
that have been utilized in commercial applications are:
Steel
25
Graphite
Cast Iron
Platinum
Conductive Polymer
Lead
Magnetite
Steel
The first known appearance of iron or steel as an anode were installations of iron
"wastage plates" in the early 1900's in condensers and boilers. Although unintentional,
steel acted as an anode on some early DC traction systems. Many of the corrosion
failures experienced on these systems were due to DC current discharge from the rails.
Probably the first planned use of steel as an anode was in the 1930's. Scrap steel was
commonly used, either in the form of old railroad rails or used pipe.
Steel anodes can take many forms. Scrap materials include buried structures which have
been abandoned in place; such as pipelines or well casings. Scrap pipe, tubing, or
railroad rails are commonly used. Any shape is capable of use; however, massive shapes
are more conducive to practical use.
26
Anodic corrosion product films may build up on anode surface, increasing the resistance to earth. This
effect may be partially overcome by installation in carbonaceous backfills.
Although most people would consider the use of steel as an anode as outmoded; there
are operators who currently use steel in groundbeds with successful results.
Graphite
Graphite anodes have been used for impressed current systems since the 1930's. Although the
development is not attributed to a specific application, it probably resulted from the early recognition
of carbon as a possible anode material.
Graphite anodes are made from ground petroleum coke mixed with a coal tar pitch binder. The
mixture is heated and extruded into cylinders. After extrusion, the cylinders are cooled in special vats,
placed in an oven, packed in a mixture of sand and petroleum coke, and heated to approximately 900
degrees Celsius to fully carbonize the pitch binder. The sand-petroleum coke packing material aids
heat transfer and supports the anode during its plastic stage. After cooling in a reducing atmosphere,
the anodes are stacked in an Atchison or graphite furnace between two electrodes, covered with
petroleum coke and an insulating sand layer, and single phase 60 Hz AC is passed through the pile.
This process raises the temperature of the anodes to approximately 2600 degrees Celsius and
completes the graphitization process.
The produced graphite material used for anodes typically has the following properties:
Electrical Resistivity Maximum resistivity 10
micro ohm-meters
Mechanical Strength Compression - 3000
27
requires specialized handling equipment. In addition, there are some toxicity problems with the resin
components. As a result, resin impregnation is normally only performed by the graphite manufacturer.
Fabrication
Each graphite anode is normally provided with an individual cable of varying length. There have been
numerous methods and procedures for connecting cable to graphite anodes. These range from a
simple tamped lead connection to threaded metallic connectors. One of the methods most commonly
used is a lead ferrule which is sized to the hole drilled in the anode. The ferrule is soldered to the
anode cable and inserted in the hole. The ferrule is then expanded by a pneumatic or hydraulic tool
which imposes a longitudinal force of up to 1800 pounds on the ferrule. This method results in
connections with pull-out strengths exceeding that of the cable.
Graphite anodes can be end connected or center connected. End connections are made by drilling a
6" to 8" deep hole from one end. Holes can be easily drilled with hand tools. Center connections are
accomplished by drilling a hole to the longitudinal center of the anode from one end. This procedure
requires more sophisticated gun drill type tools to maintain the hole in the center of the anode.
Following cable connection, the annular space around the cable must be filled with a high quality
electrical sealant. Common sealants are asphaltic electrical potting compounds. Care must be
exercised to insure the compound is at the proper pouring temperature and that there are no voids or
air pockets within the cavity. Anode caps such as epoxy or heat shrinkable caps are commonly used
for additional protection.
Graphite anodes can be prepackaged in steel canisters with carbonaceous backfill. Common canister
sizes are 8" x 72", 8" x 84", 8" x 96", 10" x 84", 10" x 96", 12" x 84", and 12" x 96".
Design Parameters
Published values of graphite consumption range from 0.25 pounds per ampere-year to 5 pounds per
ampere-year. Where oxygen evolution is the primary anode reaction, anode treatment should
decrease consumption rate by at least 20%. Where chlorine evolution is the primary reaction,
treatment should decrease consumption rate by at least 50%.
In free flowing seawater and in some other applications where chlorine is the primary gas evolved at
the anode, the graphite consumption rate should be in the 0.5 pound per ampere year range. In
neutral soil or fresh water service, consumption rates may increase to 2.0 pounds per ampere year.
Consumption rates are significantly lowered by surrounding the anode with a carbonaceous backfill.
The decrease in consumption can be in the order of 75%. A design consumption rate of graphite in a
coke breeze backfill is 1 lb/Amp-Year. The recommended maximum current density is 0.50 amperes
per square foot in a coke breeze backfill.
Applications
Graphite is one of the most commonly used impressed current anode material for underground
applications. Underground applications include deep, shallow vertical, or horizontal ground beds with
carbonaceous backfill.
29
Operation of anodes at higher than recommended outputs can cause an extremely low pH
environment at the anode surface; resulting in a breakdown of the coal tar pitch binder. When this
occurs, large sections of graphite can "slough" off the anode. Premature failures of untreated anodes
have been reported as a result of water penetration through the body of the anode to the metallic lead
wire connection. Electrolytic current flow between the connector and the anode will cause corrosion of
the connector; resulting in connection failure. Some early failures of graphite anodes occurred prior to
anode installation as a result of thermal expansion of the anode connector and/or the connection
sealing compound. These failures occurred under conditions that resulted in temperatures in excess
of 140 F. The majority of anode fabricators now use methods and materials that eliminate this
problem.
The use of carbonaceous backfill materials is highly recommended with graphite anodes. Accelerated
corrosion rates can occur when the oxygen evolution reaction predominates. Carbonaceous backfills
can act as an extended anode; minimizing the effects of increased consumption rates.
Cast Iron
Iron containing a high silicon percentage was developed in the early 1900's. The cast material was
extremely hard and brittle. It was first seriously considered for impressed current anode application in
the early 1950's. It was introduced as an anode material in 1954. A subsequent modification to the
alloy in 1959 produced better anode performance characteristics. This alloy consisted of the addition
of 4.5% chromium. This anode material has been widely used and accepted in the industry.
High silicon chromium cast iron is a solid, non-porous material. This alloy consists of a matrix of
silico-ferrite in which the majority of the carbon is in the form of graphite flakes at grain boundaries.
Adding chromium results in eliminating graphite.
The produced cast iron material used for anodes typically has the following mechanical properties:
Electrical Maximum resistivity 72
Resistivity: micro ohm-cm
Mechanical Compression - 100000
Strength: pounds per square inch
Flexural - 15000 pounds
per square inch.
Coefficient of 0.72 x 10-6/F
thermal expansion:
30
The standard metallurgical composition of cast iron anodes conforms to ASTM Standard A518-86
Grade 3 as follows:
Silicon: 14.20-14.75%
Chromium: 3.25-5.00%
Carbon: 0.70-1.10%
Manganese: 1.50% maximum
Copper: 0.50% maximum
Molybdenum: 0.20% maximum
This alloy is cast by several methods including sand mold casting, chill-casting, and centrifugal
casting. A variety of anode shapes and sizes are available. The most common anode shapes are
cylindrical tubes and solid bars in lengths up to 84", diameters from 1" to 6", and weights up to 280
pounds. The standard length for the solid bar anodes is 60". The standard length for tubular shapes is
84".
Fabrication
Each cast iron anode is normally provided with an individual cable of varying length. Cast iron anodes
are provided in both end-connected and center-connected configurations. The solid bar anodes are
cast with a hole at one end to accommodate a connecting cable. Center-connections are used for
cylindrical tube shapes. There have been numerous methods and procedures for connecting cable to
cast iron anodes. The most common connector for solid anodes is a poured and tamped lead
connection in the cast hole. Center-connected anodes utilize a one or two piece lead assembly
attached to the interior center of the anode.
Following cable connection, the annular space around the cable is filled with a high quality electrical
sealant. Common sealants are asphaltic electrical potting compounds. Care must be exercised to
insure the compound is at the proper pouring temperature and that there are no voids or air pockets
within the cavity. Anode caps such as epoxy or heat shrinkable caps are commonly used for
additional protection. Cast iron anodes can be prepackaged in steel canisters with carbonaceous
backfill. Common canister sizes are 8" x 72", 8" x 84", 8" x 96", 10" x 84", 10" x 96", 12" x 84", and
12" x 96".
Design Parameters
The reported consumption rate is between 0.2 and 1.2 pounds per ampere-year. The controlling
factor appears to be the environment. Manufacturer recommendations for anodes surrounded by
carbonaceous backfill is 0.7 pounds per amp-year. Current densities should be limited to
approximately 1 ampere per square foot.
Applications
High silicon cast iron anodes are widely used in underground applications in both shallow and deep
31
groundbeds. Although the performance is improved with coke breeze; its use is not critical. This
material is also widely used in freshwater and saltwater environments.
The performance of cast iron as an anode is dependent upon the formation of a thin layer of silicon
dioxide on the surface of the anode. Oxidation of the alloy is necessary to form this protective film.
Silicon-chromium cast iron is highly resistant to acid solutions. It does not perform particularly well in
alkaline environments or in the presence of sulfate ions.
There have been some reports of early failure when silicon iron anodes are exposed to environments
in which both sulfate and chloride ions are present. Other cases are reported where these anodes
increase significantly in resistance when exposed to drying conditions. It is thought that this condition
interferes with the formation of the conductive silicon dioxide film.
The mechanism of deterioration of a platinum based anode is consumption of the platinum coating.
Rate of consumption is controlled by many factors, primarily environment and current density. The
consumption rate of platinum in seawater is approximately 8 mg/A-yr. In fresh and brackish waters,
consumption is 2 to 3 times greater at low current densities (10 A/sq. ft). At high current densities,
consumption is much higher.
The use of platinum is now primarily limited to water environments. Its predominant use is probably in
fresh water tank applications; with secondary applications such as condenser water boxes, reinforced
concrete, process equipment, docks, etc. Anode manufacturers indicate that platinum can be
successfully used underground, both in surface beds and deep anode beds. However, most operators
experience has been negative. There have been numerous reports of anode failures when installed
underground. The primary failure mechanism is felt to be excessive consumption in small areas and
loss of substrate oxide. This could be a result of non-uniform electrolyte resistivities and/or non-linear
current distribution in the anode conductor core. Platinum has performed well in water applications. It
is probably the most widely used impressed anode material in fresh water applications such as
storage tanks and condensers.
amp year for a chlorine evolution environment such as seawater. For an oxygen evolution
environment, consumption rates are on the order of 5 mg per amp year.
Maximum recommended current densities for underground application with a coke breeze backfill
material is 100 A/sq. m (9.3 A/sq.ft). This current density relates to a design life of 20 years. Current
densities for muds and freshwater may be reduced by over half, depending upon temperature and
life.
Mixed metal oxide anodes are now commonly used in underground, and water environments. They
are also the predominant anode material used for protection of tank bottoms when installed with nonconductive secondary containment liners.
There have been some instances of bed drying which have resulted in increased groundbed
resistance. There have also been failures with anodes on strings where soil resistivity varied within
the groundbed. This may be more of a concern in deep anode bed applications. Variations in
resistivity can result in widely varying currents among the anodes. This has lead to accelerated
consumption of anodes that were operating at current densities exceeding manufacturer's
recommendation.
Generation of chlorine has led to attack of the standard cable insulation used for tubular anodes. In
these cases, a dual extrusion cable material is utilized.
Conductive Polymer
This anode material has been available since the early 1980's. The anode material consists of a
continuous semiconducting polymer material extruded on a copper wire. The active anode
component is carbon contained in a polymer matrix. It is a flexible wire-like anode and is provided on
continuous rolls. The material has an outer diameter of 1/2" with an inner core of #6 AWG stranded
copper wire. The anode is also provided prepackaged in carbonaceous backfill. The package is a
nylon sheath containing the anode and backfill, provided on continuous rolls. Connections of the inner
copper core to a main cable are normally with mechanical crimped connectors. The ends of the
anode and connections are normally sealed with manufacturer-provided heat shrink enclosures.
The manufacturers recommended maximum current density for the conductive polymer anode is 16
milliamperes per lineal foot, when installed underground. When this material is used in long-line
parallel applications, the attenuation of current in the conductor must be considered. Typically, a
heavy gauge parallel copper cable is installed with the anode and multiple connections are made at
regular spacings along the anode length. This material is used extensively for long line anode system
installed parallel to pipelines in areas where coating has deteriorated or where sub-surface conditions
do not permit efficient current distribution from conventional current sources. It is normally installed
with a surrounding carbonaceous backfill. Conductive polymer anodes have also been installed in
confined areas such as between tank bottoms and non-conductive secondary containment liners.
Conductive polymer anodes can provide uniform low-current density output over their entire lengths.
Reports have generally been very good. There are some reports of failures in areas where the wirelike anode was not installed in carbonaceous backfill and accelerated consumption of the carbon
occurred. These cases have almost all been related to excessive current discharge in low resistivity
wet areas such as creek or stream crossings.
34
Application Table
The selection of an impressed current anode should be based upon a thorough evaluation of the
application. Items of consideration include environment, current requirements, life requirements,
space, and economics. There is probably no anode material that is optimum or even capable of
effectively meeting the requirements of every situation. The anode materials developed within the
past 30 years certainly expand the arsenal of the corrosion engineer. However, for underground
application; the use of materials such as graphite and high silicon cast iron still far exceed those of
the newer materials.
IMPRESSED CURRENT ANODE APPLICATION CHART
Anode
Freshwater
Saltwater
Steel
Graphite
X
X
Platinum
X
X
Conductive Polymer
35
Environment Consumption
Rate
lb/amp-year
Design
Current
Density
Size
Weight Surface
pounds
Area
Sq Ft.
amps/SqFt
Steel
Graphite
Platinum
20.0
None
Soil
1.0
0.5
Freshwater
2.0
NR
Saltwater
0.5
2.0
Soil
0.7
1.0
Freshwater
1.0
2.5
Saltwater
0.5
2.5
Soil
NR
NR
36
Max*
Design
Output
(soil) Amps
3" x 60"
30
4.0
2.0
4" x 80"
72
7.3
3.6
1.5" x 60"
27
2.0
2.0
2" x 60"
44
2.6
2.6
2" x 60"
60
2.7
2.7
3" x 60"
110
4.0
4.0
4.5" x 60"
220
5.5
5.5
2.2" x 84"
50
4.2
4.2
2.6" x 84"
64
4.9
4.9
3.8" x 84"
95
7.0
7.0
4.8" x 84"
122
8.8
8.8
Conductive Polymer
Freshwater
8 mg/A-yr
50
Saltwater
8 mg/A-yr
50
Soil
5 mg/A-yr
10
Freshwater
5 mg/A-yr
10
Saltwater
1 mg/A-yr
50
Soil
16 ma per LF
Freshwater
3 ma per LF
Saltwater
NR
37
1.6 x 50 cm
NA
0.275
2.5
1.6 x 100 cm
NA
0.56
5.0
2.5 x 50 cm
NA
0.44
4.0
2.5 x 100 cm
NA
0.88
8.0