Académique Documents
Professionnel Documents
Culture Documents
System
Agenda
Introduction
Working Principle of CP
CP Components
CP Techniques
CP Design
Anode Configuration
CP System at SGCPF
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Cathodic Protection
Introduction
Example
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Corrosion Cell
Anode
• Location where corrosion occurs
• Positive electrode in an electrolytic cell
• Metal loosing an electron and tends to degrade
Cathode
• Location where protection occurs
• Negative electrode in an electrolytic cell
• Chemical reaction is a reduction reaction
• The metal gaining electrons
Electrolyte
• Any material in contact with both the anode and the cathode which will allow ions to migrate
• Can be any soil or liquid adjacent to and in contact with the anode and cathode
Metallic Path
• Any conductor which allows electrons to flow from the anode to the cathode
• Electron flow must be present for electrochemical corrosion to occur
• In the case of a tank or pipeline, this can be the tank or pipe itself, or it can be a metallic bond to different
metallic structure
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Cathodic Protection
Working Principle
• Principle of cathodic protection is, connecting an external
anode to the metal to be protected and the passing of an
electrical current so that all areas of the metal surface
become cathodic and therefore do not corrode
• Corrosion moves to external anode from structure to stop
further corrosion from occurring
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Cathodic Protection
Corrosion Rate Vs. Current
Cathodic Protection
Corrosion Rate Vs. Current
• Corrosion rate drops as we apply CP current
• Corrosion rate goes to nearly zero and the structure is considered
cathodically protected
• For some metals, if you apply too much current, you can cause damage
to the metal
• Too much current can damage some metals such as stainless steel and
titanium
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Cabling
Galvanic Anodes
Electro- potential of common metals buried in soil
Potential in mV relative to Cu/CuSO4 reference electrode
Anodes Electro-Potential
Magnesium -1700
Aluminum -1150
Zinc -1100
Copper -200
Silver +200
Gold +800
Platinum +1000
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ICCP Anode
The most commonly used materials for impressed current anodes
are graphite and high-silicon cast iron
The best materials is one which has a low rate of weight loss per
ampere-year
Comparison of CP Techniques
Anode System Advantages Disadvantages
Simple & reliable Low output
Sacrificial Anodes
No need of external power Short life
Often lower cost No power switch
Little to no maintenance Difficult to test
Limited Use
Additional anodes to
increase current output
Anode Configurations
Remote Anode Systems
• Used to project current over a wide area
• Placed a distance away from the structure being protected
• Deep anode beds or remote horizontal ground beds
Linear Anode
• Installed parallel to the structure being protected
• Used for new construction pipeline & plant applications
• Low power system
• Easy to install
• Very reliable
• Long Life: 50-100 years
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Rectifier
• Increase the potential of the electrons from the anodes in order to provide
the desired protective current
• Convert alternating current into controlled direct current
Test Station
• Used to measure the current applied to pipeline
• Direct connection with pipe line
Reference Electrode
• Fixed potential electrode of know potential,
• Buried near the test stations and find the potential applied to pipeline
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CP System at SGCPF
Sacrificial CP system
ICCP System
• Sujjal-1 Pipeline
• Condensate Storage Tank 3 & 4
• Fire Water Tank
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CP Design at SGCPF
Sacrificial CP for Condensate Storage Tanks
Tank diameter (O.D) 5m= 16.41 ft
Surface Area 211 sq. ft
Soil Resistivity 2000 Ohm-cm
CP system Life (Y) 20 years
Estimated Current Density 1.2mA/sq.ft.
Sacrificial Anode Magnesium
Soil resistivity measured with resistivity meter using four pin method at
location near condensate tank which was 2000 ohms-cm at 6 ft. depth
It was proposed to use 7.7 Kg magnesium anodes packed in backfill
constituting 75% gypsum, 20% bentonite & 5% sodium sulphate resistivity
of 5 ohm-cm
Protection Current Requirement
𝟏𝐦𝐀
Current 𝐑𝐞𝐪𝐮𝐢𝐫𝐞𝐝 = 𝐒𝐮𝐫𝐟𝐚𝐜𝐞 𝐀𝐫𝐞𝐚 (𝐟𝐭 𝟐 ) 𝐗 𝐂𝐮𝐫𝐫𝐞𝐧𝐭 𝐃𝐞𝐧𝐬𝐢𝐭𝐲 ( )
𝐟𝐭 𝟐
= 1.2 X 211
=253 mA =0.253 A
Required Driving Potential =0.75 V
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No. of Anodes
Based on Magnesium Weight
𝐈𝐦 𝐱 𝐘 𝐱 𝐀𝐧𝐨𝐝𝐞 𝐂𝐨𝐧𝐬𝐮𝐦𝐭𝐢𝐨𝐧 𝐑𝐚𝐭𝐞
Weight (W) =
𝐔𝐥𝐭𝐢𝐥𝐢𝐱𝐚𝐭𝐢𝐨𝐧 𝐅𝐚𝐜𝐭𝐨𝐫
Where,
W= Total weight of Mg anodes in kg required to supply required protection current
Y= Life of CP system=20 Year
Im= Total average current required to protect the structure in Amp
Consumption rate = 7.90 Kg
Utilization factor = 0.85
𝟎.𝟐𝟓𝟑𝐗𝟐𝟎𝐗𝟕.𝟗𝟎
Weight (W) = 𝟎.𝟖𝟓
W= 47.03 kg
No. of 7.7 kg Magnesium Anodes = 47.03/7.7
=6.1
Sacrificial CP System
Tank-1 Tank-2 Fire Water Pipeline Glycol Tank Slope Vessel
Spread One:5
Present Status of Anode 6 6 3 5
Spread Two:4
ICCP at SGCPF