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E. D. DOLAN*
ABSTRACT. Experimental work at BP Refinery (Kent) Limited is described. I n channel ends
and floating head ends of condensers, magnesium anodes (1) directly connected, (2) with
resistance control and (3) with aluminium sheathing were partially successful in preventing
corrosion; zinc anodes gave adequate protection when combined with coatings and stainless steel
facing of the flange mating with the tube plate. Present practice is outlined. A simple method of
protection is suggested, based on epoxy mastic coating and full-face iron anodes. A reliable tube
plate coating is required to increase the life of sacrificial anodes.
A section of 60 inch diameter cooling water main fabricated in steel has been protected
internally by impressed current; the optimum anode spacing is four diameters. At water velocities
up to 2% f.p.s. a current density of 5 m.A./sq.ft. gave protection. Zinc anodes gave barely
adequate protection at 48 spacing in an unlined section; zinc anodes at 98 spacing in a section
lined with coal tar paint gave over-protection.
Promising results were obtained with coatings of epoxy mastic, aluminium-bitumen paint, zinc
rich primer plus coal-tar top coats and a synthetic rubber/cement mastic.
RESUME. Des essais, effectus la Raffinerie BP (Kent) Ltd., sont dcrits dans cet article. Dans
la bote de circulation et la tte flottante de condenseurs, des anodes en magnsium 1) en contact
direct avec le mtal, 2) avec une rsistance intercale et 3) avec un revtement daluminium, ne
parviennent que partiellement viter la corrosion; des anodes en zinc ont fourni une bonne protection lorsque combines avec un revtement en acier inoxydable du rebord en contact avec la
plaque tubulaire, et avec des couches de peinture. La mthode utilise actuellement est dcrite dans
ses grandes lignes. On suggre une mthode simple de protection base sur lemploi dun revtement
d epoxy mastic et danodes en fer recouvrant totalement la section extrme de la bote de circulation. Un bon revtement de la plaque tubulaire est ncessaire pour diminuer la vitesse de
destruction des anodes.
Un tuyau dacier de lm.50 de diamtre pour le raffraichissement de leau a t protg
lintrieur par courant imprim; lcart optimum des anodes est de 4 diamtres. Pour une vitesse
deau de 0,75 m/s une densit de courant de 53 m.A/mJ a donn une bonne protection. Des anodes
en zinc espaces de lm.4 nont donn quune protection peine suffisante dans un tuyau nonrevtu; des anodes en zinc espaces de 3m. ont donn une protection excessive dans la partie du
tuyau revtu de peinture au goudron.
Des rsultats prometteurs ont t obtenus avec des revtements d epoxy mastic, de peinture
de goudron laluminium, une premire couche de peinture riche en zinc recouverte de couches de
goudron, et un mastic de caoutchouc synthtique et de ciment.
* Corrosion
Control Engineer, Refineries and Technical Dept., The British Petroleum Company Ltd.,
London, England.
1o9
110
Introduction
The British Petroleum Company Limited is interested in seven refineries with salt water cooling, of
which one is in England, three in Europe, two in the
Middle East and one in Australia. The refinery at
Abadan operated by BP up to 1951 was exceptional
in that it utilised a once-through cooling system of
non-aggressive water from the Shatt-el-Arab; consequently, prior to the post-war refinery development
programme, little direct company experience of salt
water cooling was available, although it was realised
that conventional materials would be subject to
corrosion.
The Isle of Grain Refinery (BP Refinery (Kent)
Ltd.), commissioned in 1953, was one of the first
post-war refineries built for salt water cooling. Plant
trials on methods of protection started as soon as the
first units came into operation. This paper describes
the results obtained on condenser ends and on a steel
salt water main; the general pattern of protection is
coating supplemented by cathodic protection.
The use of impressed current cathodic protection
for condensers has been given due consideration and
it has been decided that the wiring complications
and possible spark hazards render it undesirable in
the danger areas of operating plant.
General Considerations
CORROSION
and limitations should prove valuable aids in protection schemes in salt water. These devices are:
-Zinc alloy anodes.
-One coat linings of epoxy mastic.
-Aluminium-bitumen paint.
-Zinc rich primer sealed with heavy bituminous
paint.
The iron anode, also, is useful and will repay
further study.
TUBES
111
112
w
BARE 4 L B
ANODES
Coatings
Based on theoretical considerations and on observation, and with particular reference to the fact that
the anode and cathode areas in channels and floating heads are of the same order of magnitude, the
following opinions have been formed on coatings in
general :
I. Coatings alone on ferrous components such as
channels are dangerous. The underlying steel
will perforate rapidly at any fault in the coating; the tube ends receive negligible cathodic
protrction.
2. Coatings on non-ferrous components (tube
plates etc.) are useful and are not dangerous,
cxcept that there is some risk of encouraging
dczincification of brass in the absence of any
cathodic protection.
3. When used in conjunction with sacrificial
anodes, coatings on the tube plate and tube
ends would be more useful than coatings on
the ferrous components, since they reduce the
effective area of the more noble metal.
4. The highest grade of non-metallic coating is
imperfect by the time the coated part is installed in the unit. Therefore, coatings should
always be supplemented by cathodic protection.
The trials on coatings have been influenced by the
fact that over a thousand condensers must be maintained in various parts of the world, so that an
acceptable coating must be suitable for application by
STAGE
RESISTA
!3UDS
II
STAGE
4LB ANODES
SHEATHED IN
ALUMINIUM
STAGE I
S
!
8 LB AND 25 LB
ANODES SHEATHED
ALUMINIUM
FIG. 1-Types
of Magnesium Anodes.
EPOXY MASTIC
The one-coat, solvent free, epoxy mastic is a three
pack system; a liquid epoxy resin, originally developed as a casting resin, a solid hardener which is
melted before mixing, and silica flour filler. The mix
has a reasonable pot life and can be applied by
trowel or, with some difficulty, by brush. The adhesion to blast cleaned surfaces is excellent, although,
when the surface has been deeply pitted, it has been
deemed advisable to wet with a first coat of resin
and hardener without filler. The main coat is then
applied before the wetting coat is fully hardened.
Having no solvents, this epoxy mastic can be
worked in the open shop. The curing time in U.K.
temperatures is one to two days, after which the
coating may be exposed to water. I t is advisable to
shield the coating from dust and other fragments
during curing.
TUBEPLATECOATINGS
MAGNESIUM
ANODES
The four types of magnesium anode shown in Figure 1 were tried in channels, with the following
results :
i . Anodes direct o n the channel cover.
Single or multiple four-pound anodes bolted to
the channel cover gave more than adequate protection but the life was only about three month:.
2. Anodes on channel cover, with resistance control.
The anodes were bolted to the channel cover
through an insulating stalk carrying a resistance
wire. When the resistance was high enough to
make the anodes last one year, the current output
113
ANODES
114
FIG. 2-Zinc
Anode in 24 Channel.
115
IRONANODES
As stated earlier, non-corroding channels and floating head covers present a very real danger to tube
ends. After some unfortunate experiences, iron anodes
in non-ferrous or fully lined channels and floating
head covers are now regarded as esssential; the best
design of iron (mild steel) anodes has still to be
resolved. The requirements are:
A minimum life of 2% years, preferably five
years.
A low resistance contact, ultimately to the
tube ends.
Secure attachment throughout the life, bearing in mind that welding or brazing of mild
steel to non-ferrous metals is never simple and
can be very difficult in the case of some cast
copper alloys, such as high tensile brass, which
is liable to crack.
Anode corrosion products must neither block
the tubes nor encourage deposit attack inside
the tubes.
One cast steel 24 channel was lined with monel
sheet f/8 thick by welding. The channel cover was
not lined; a full-face iron anode [2] was fitted across
the channel with an external insulated cable to
ensure good connection between the anode and the
tube plate. The channel cover and the back of the
anode were lined with three coats of bituminous
ZINC ANODES
paint. The anode was sandblasted to remove millFULL WIDTH
scale, etc., and to reduce pitting.
When this channel end was inspected after approxiFLOATING HEAD END
CHANNEL END
mately two years in service, the tube plate, tube ends
and monel lining were in perfect condition. The
FIG. 3-Present Practice-Faced Flanges, Zinc Anodes,
full-face anode, originally 3/8 thick, was wasted
Painted Internally Including Tube Plate.
about 50% and was fit to return to service. There
was no wastage under the gaskets, indicating that
Figure 3 illustrates the latest practice on leakage at the anode joint will not be a problem
channel ends. I t shows the standard zinc anode, until the anode is in the last stages of exhaustion.
28 x 4 x 1%) weight 42 pounds, with mul- There was no evidence of tube blockage by corrosion
tiple welding tags; this anode fits 33 and 29 products.
I n the above experiment the anode area is equal
condensers and can be cut to fit smaller condensers. The shape and the galvanized insert to the tube plate area. Some non-ferrous floating head
are designed for easy casting in open-top covers were fitted with iron anodes only one quarter
moulds and this anode is now finding applica- of the tube plate area and after six months the anodes
tions outside refineries. The flanges are faced were almost exhausted. Circular plate anodes, dished
with stainless weld metal and the internal sur- to fit the floating head covers, can be purchased at
reasonable cost and are being tried in one refinery.
faces are painted.
116
Protection
WISKET
IRON
ANODE
FIG. 5-Pitting
117
118
COOLING WATER
CHANNEL.
CONCRETE
3.000 LONG
45 WIDE
IO DEEP
INTAKE
WMPHOUSE
paratus shown in Figure 7, in a length of 60 diameter Cooling Water Main. The most important information obtained was as follows:
1. The optimum spacing between anodes is four
times the pipe diameter, that is, 20 feet for
this main. At greater spacing the total power
demand increases due to excessively high potentials near the anodes.
2. At anode spacing of 8 diameters a protective
potential could not be maintained at the mid-
Chlorides
18350
19100 p.p.m.
23602600
Sulphates
Calcium
568713
Magnesium
6801040
Free Carbon Dioxide
414
Free Ammonia
Nil
Sulphate Reducing Bacteria
Present hut not active.
Samples become clear and colourless on
standing, with a buff coloured fine sandy
deposit.
Temperature Range (inlet 38-72F).
Design Outlet Temperature for Condensers.
llOF.
0.9
<
c /
w
z
0.8
O .7
AVERAGE CURRENT DENSITY 5 u*/%
ANODE5 20 FT APART
0.6
O
100
200
FT
300
HOUR5
FIG. &Effect
400
/SILVER
B PA1NTED
A BARE
1.0
POTENTIAL
JUNE 1957
0.6
SEPT
I
a
DEC
3-
MAR
l
-
lmd 2 -
t-
LL
VELOCITY
I-
1
0-
c;
u.
5-
<
CURRENT DENSITY
O
FIG. ,%Zinc Anodes in 6 0 Cooling Water Main.
119
..
120
FIG. 10-Zinc
FIG. 11-Zinc
121
Main Protection
122
TABLE II
COATINGS IN 60 C.W. MAIN
Tvpe of Coating
Aluminium-Bitumen Paint 2 coats
Surface
Preparation
Wirebrush
4 coats
2 coats Coal
N07niM.l
Thickness
Mils.
2
Barnacles
per sq. f t .
21
None
None
11
Tar Paint
Wax/Rubber Paint 2 coats
Wax/Rubber Mastic
brushed
1 coat, hot
Appearance after
11 months
Sand Blast
10
10
Breakdown starting.
260
67
250
current, by zinc anodes alone, or by zinc anodes plus to thank his colleagues who participated in its
a paint lining. The experiments continue, but it is preparation.
already evident that the method of cathodic protecReferences
tion may be chosen on economics, on ease of installa1. Gilbert, P. T., The Resistance to Failure of
tion and maintenance, and on the desirability or
Condenser and Heat Exchanger Tubes in Marine
otherwise of introducing large amounts of anode Service. Trans. Inst. Mar. Eng. 66 No. 1: 1-20
corrosion products into the system.
(January, 1954).
The bulk of the zinc anode corrosion product
2. Munro, J. D., Corrosion and Prevention-Heat
is retained on the anode at water velocities up to Exchangers in cooling water servi ce.^^ proc. A.P.I.
3% feet per second. It would be advisable to fit 34 (III) : 19-36 (1954).
permanent reference electrodes in any protected main
3. British Patent No. 699239.
to indicate, by falling potential, if the main should be
4. Crennell, J. T., and Wheeler, W. C. G., Zinc
entered to remove corrosion product.
Alloy Anodes. J. Appl. Chem. 8: 571 (1958).
Considering the selection of a protective lining to
5. The American Zinc Institute. New York. Cabe used in conjunction with zinc anodes, the choice thodic Protection with Zinc Anodes. (June, 1953).
seems to lie between the aluminium-bitumen ships
6. Tytell, B. H., and Preiser, H. S., Cathodic Probottom paint mentioned in Table II and the plas- tection of an Active Ship using Zinc Anodes. J. b.
ticized coal tar paint tried with the zinc anodes. The soCa
Nav. Eng. (November, 1956).
coal tar Paint was in a more advanced Stage of
7. Teel, R. B., and Anderson, D. B., The Effect of
breakdown than the aluminium-bitumen paint after rron in Galvanic Anodes in Sea Water. Corrcsion.
eleven months exposure. This supports the generally 12 N ~ 7:. 53-59
1956).
accepted opinion that heavy pigmentation with leaf8. U.S. Military Specification MIL-A-18001C.
ing aluminium increases the water resistance of the Anodes, Corrosion Preventive, Zinc: Plate, Slab,
medium in conditions of complete immersion. A Disc and Rod Shape& (October, 1956).
similar effect of aluminium pigmentation has been
9. Morgan, J. H., Lead Al:oy Anode for Cathodic
noted in other trials in which epoxy paints were Protection, Corrosion Technology. 5 No. 11: 347-352
employed.
(November, 1958).
10. Cotton, J. B., Platinum Faced Titanium for
Acknowledgements
Electro-Chemical Anodes. Platinum Metals Review.
The author wishes to thank the Chairman and 2 No. 2 : 45-47 (April, 1958).
Directors of The British Petroleum Company Limited
This paper was presented on June 2, 1959, by
for permission to publish this paper. He also wish=? E. D. DOLAN.
Discussion
A. J. VAN RIEMSDIJK
(Koninklijke Shell-Laboratorium, Amsterdam, The Netherlands). Mr. Dolan
has given us a very complete survey of ali modern
methods used for combating corrosion in salt water
cooling systems. I t is gratifying to notice that the
techniques used by the B. P. refineries have so much
in common with those used in the Royal Dutch/Shell
refineries; it goes to show that everywhere in the
oil industry the struggle against our common enemy
corrosion is being carried on with determination.
There are, of course, some technical differences
between the methods described by Mr. Dolan and
those applied in our refineries, of which I would
like to mention a few:
Mr. Dolan pointed out in his paper that coatings
are always to be supplemented by cathodic protection.
This is quite true for thin and brittle coatings: We
have found, however, that in the steam condensers
of a power house of one of our major refineries relatively thick layers of soft, rubber based materials
stand up perfectly, unaided by cathodic protection.
We think this to be the best protective measure for
cast iron and steel parts.
Concerning the use of sacrificial anodes; we agree
that the consumption of magnesium anodes is too
high; we are not keen on the use of zinc anodes,
having generally obtained poor results probably because of insufficient purity. It is rather difficult for a
refinery to check for trace metals! We prefer the use
of iron anodes; this choice is related to our preferred
constructional materials for coolers and condensers,
viz. :
Tubes : aluminium brass, inhibited with, e.g.,
arsenic to prevent dezincification (British specification 1464).
Tube sheets: aluminium bronze, ASTM B 171,
alloy E, which we order with a minimum aluminium content of 7% and a miximum aluminium
content of 10%.
Floating-head covers : aluminium bronze ASTM
B 148 alloy 9 D (with the same restrictions on
aluminium content as for B 171).
Channels and channel covers : tin bronze,
ASTM B 143 alloy 1 A.
123
124
125
126