Cathodic Protection

Cathodic Protection
for On
for On
-
-
Grade Storage Tanks and
Grade Storage Tanks and
Buried Piping
Buried Piping
John Fitzgerald John Fitzgerald
Corrpro Corrpro
Freshwater Spills Symposium Freshwater Spills Symposium
April 6 April 6- -8, 2004 8, 2004

Preserve Assets
Preserve Assets

Reduce Maintenance Costs
Reduce Maintenance Costs

Governmental Compliance
Governmental Compliance

Preserve The Environment
Preserve The Environment
Why is Corrosion Control
Why is Corrosion Control
Important?
Important?
What I Will Cover.
What I Will Cover.
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-
Causes of Corrosion
Causes of Corrosion
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-
SPCC/State/OPS Regulations
SPCC/State/OPS Regulations
-
-
Cathodic Protection Applications
Cathodic Protection Applications
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-
Maintenance Requirements
Maintenance Requirements
Spill Prevention Control and
Spill Prevention Control and
Countermeasure (SPCC) Regulation
Countermeasure (SPCC) Regulation
(Implementation Required by 2/18/05 )
(Implementation Required by 2/18/05 )
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-
Provide buried piping that is installed or
Provide buried piping that is installed or
replaced after August 16th, 2002
replaced after August 16th, 2002
protective coating and
protective coating and
cathodic
cathodic
protection.
protection.
-
-
Should a section of line be exposed for any
Should a section of line be exposed for any
reason it must be inspected for deterioration.
reason it must be inspected for deterioration.
If corrosion damage is found you must take
If corrosion damage is found you must take
additional examination and corrective action.
additional examination and corrective action.
with a
with a
Federal Level
(Breakout Tanks)
a) Relieves surges in a hazardous
liquid pipeline system or b) receive
and store hazardous liquid transported
by a pipeline for reinjection and
continued transportation by pipeline
Breakout Tank Piping (DOT)
M
Main Line
Valve
OPS
Inspection
Meter
M
Product
Tank
(Breakout)
M
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-
Approximately 25% of States now
Approximately 25% of States now
require
require
cathodic
cathodic
protection be installed
protection be installed
and maintained on new, refurbished, or
and maintained on new, refurbished, or
repaired tanks in contact with soil or sand
repaired tanks in contact with soil or sand
foundations.
foundations.
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-
A number of other states are in the
A number of other states are in the
process of implementing regulations
process of implementing regulations
governing ASTs.
governing ASTs.
State Level
Terminal Tankage
Main Line
M
Valve
OPS
Inspection
Meter M
No OPS
Inspection
OPS Inspection Stops
(Enforcement Policy)
Loading
Terminal Product
Tank
(Terminal)
Product
Tank
(Terminal)
Corrosion Can be Defined as Either:
Practical
Tendency of a Metal to Revert
to its Native State
Scientific
Electrochemical Degradation
of Metal as a Result of a Reaction
with its Environment
IRON REFINING MILLING
IRON CORROSION IRON OXIDE
Corrosion - A Natural Process
OXIDE
1) ANODE
2) CATHODE
3) ELECTROLYTE
4) ELECTRICAL
CONNECTION
Anode
-600mV
Cathode
-550mV
-575mV
Corrosion
Corrosion
of
of
Metallic
Metallic
Structure
Structure
Anodic Area
( - )
Current Flow
Cathodic Area
( + )
Structure
SAND
CURRENT FLOW
Corrosion Cell on Tank
Bottom
CLAY
Steel Tank Floor
ANODE ANODE
CATHODE CATHODE
CATHODE CATHODE
DRY
SAND
MOIST SAND
WATER
Corrosion Caused by
Poor Water Drainage
New Bottom (Anode)
CURRENT FLOW
SAND
SAND
New Steel Coupled to Old Steel
Old Bottom (Cathode)
Galvanic Anode
Cathodic Protection
4 Current is obtained
from a metal of a higher
energy level
PRACTICAL GALVANIC SERIES
Material Potential*
Pure Magnesium -1.75
Magnesium Alloy -1.60
Zinc -1.10
Aluminum Alloy -1.00
Cadmium -0.80
Mild Steel (New) -0.70
Mild Steel (Old) -0.50
Cast Iron -0.50
Stainless Steel -0.50 to + 0.10
Copper, Brass, Bronze -0.20
Titanium -0.20
Gold +0.20
Carbon, Graphite, Coke +0.30
* Potentials With Respect to Saturated Cu-CuSO
4
Electrode
Structure
Magnesium
Anode
Current Flow
Galvanic Cathodic Protection on
Coated Pipeline
Cathodic Protection Test Station
Test
Station
Magnesium
Anode
Coated Pipe
FLANGE INSULATION KIT
INSULATING UNIONS
Typically limited to new piping, that has a
good quality coating and electrical isolation.
If the particular location is lacking any of the
above, an impresses current system may be
warranted.
Galvanic Anodes
Anode Cathode
Water / Sediment
Fuel Product
Internal Corrosion
Internal Corrosion
Coating
Anode
Bolt
Tank Bottom
Conventional CP Systems for
Conventional CP Systems for
ASTs
ASTs
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-
Shallow (Distributed) Anodes
Shallow (Distributed) Anodes
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-
Deep Anode
Deep Anode
Groundbed
Groundbed
Impressed Current Transformer Rectifier Unit
Impressed Current Transformer Rectifier Unit
Rectifier
Anode
Groundbed
( - ) ( + )
Pipeline
(Structure)
Current
Flow
Impressed Current System
Tank Tank
Anode
Splice
Typical Depth 20
Shallow Anodes
Rectifier
(-) (+)
Shallow Anodes
Tank
Rectifier
(-)
(+)
Anode
Anodes
J unction
Box
Rectifier
-
+
Directional Boring Under
Existing AST
ABOVEGROUND STORAGE TANK
CATHODIC PROTECTION
3 PVC 20%
Exposure
Anode Material
Anode Tube
10
Typical
Test/Access
Station
Grade
Aboveground
Storage Tank
New/Refurbished AST
Bottoms with or without
Secondary Containment
Secondary Containment
4 Environmental Protection
4 Minimize Liability
4 State and Local Regulations
New Tank Construction with Liner
New Tank Construction with Liner
Anode & Reference Cell Placement
Anode & Reference Cell Placement
in High Resistance Sand
in High Resistance Sand
Liner
Floor
Anode Conduit
CP Installation on Double Bottom Tank
CP Installation on Double Bottom Tank
New Floor Installation on Existing AST
New Floor Installation on Existing AST
CP Installation on
CP Installation on
Rebottomed
Rebottomed
Tank
Tank
Installation of CP System on
Lifted AST
Installation of CP System on
Installation of CP System on
Lifted AST
Lifted AST
Maintenance of Cathodic
Maintenance of Cathodic
Protection Systems
Protection Systems
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Conduct Annual Testing
Conduct Annual Testing
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Meet NACE Criteria/Standards
Meet NACE Criteria/Standards
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Conduct Bi
Conduct Bi
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-
Monthly Rectifier
Monthly Rectifier
Checks
Checks
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-
NACE Qualified Technicians
NACE Qualified Technicians
NACE Cathodic Protection Criteria
-850mV or more negative with current
applied
-850mV Instant off
-100mV shift between Instant off and
Native
Annual Cathodic Protection Survey
Tank
Rim Potential Measurements
Portable Reference Cell
Soil
(+)
?
? ?
?
- -850mV 850mV
Rim 25' Center 55' Rim
On -1411 -698 -404 -601 -1455
Off -902 -664 -402 -578 -911
Reference Cell
Bullseye

Monitoring
Tube
Test / Access
Station
boveground
torage Tank
ade
3
Typical
Potentials (mV)
Test
Station
Structure
Stray Current Monitoring Test Station
Stray Current Monitoring Test Station
Computerized Potential Logging Survey
Reference Cells
Pipeline
Test
Station
Backpack Computer
Unit
Chainer/Wire
Dispenser & Counter
Monitoring
Record volts and amps s
Compare values to target setting
Conduct annual cp survey by NACE engineer
Maintain cp records
every 30-60 day
Bi
Bi
-
-
Monthly Rectifier Check
Monthly Rectifier Check
Visual Check of Volts/Amps
Visual Check of Volts/Amps
Record Keeping
Record Keeping
-
-
Provides History
Provides History
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-
Computer Records/Data Collection
Computer Records/Data Collection
Remote Monitoring
Remote Monitoring
Hand Held Computers
Hand Held Computers
Close Interval Surveys
Close Interval Surveys
Data Printouts
Data Printouts
Flagging of Problem Areas
Flagging of Problem Areas
Prioritize Action Items
Prioritize Action Items
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As Built Drawings
As Built Drawings
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Store Data & Records for Life
Store Data & Records for Life
System Characteristics
Galvanic Impressed
8No external power 8 External power required
8Fixed driving voltage 8 Voltage can be varied
8Limited current 8 Current can be varied
8Small current requirements 8 High current requirements
8Used in lower resistivity 8 Used in almost any
environment resistivity environment
8 Usually negligible 8 Must consider interference
interference with other structures
Recommended Practices
API-651 - Cathodic Protection of Aboveground Petroleum
Storage Tanks:
Galvanic anodes method is not practical for
protection of large bare structures.
NACE RP0193-01 - External Cathodic Protection of On-Grade
Metallic Storage Tanks:
Galvanic protection systems can be applied to tank
bottoms where the metallic surface area exposed to
the electrolyte can be minimized through the
application of a dielectric coating or the area is small
due to the tank size or configuration.
Questions
Questions