12730729302.0 Impressed Current Cathodic Protection Section

IMPRESSED CURRENT CATHODIC PROTECTION
2.0 CONTENTS
2.1 Silicon Iron Anodes
2.1.1 Silicon Iron Rod Anodes
2.1.2 Silicon Iron Tubular Anodes
2.2 Mixed Metal Oxide Anodes
2.2.1 Mixed Metal Oxide Tubular Anodes
2.2.2 Mixed Metal Oxide Ribbon Anodes
2.2.3 Mixed Metal Oxide Wire Anodes
2.2.4 Mixed Metal Oxide Mesh & Ribbon Mesh
Anodes
2.2.5 Mixed Metal Oxide Anode Accessories
2.2.6 Mixed Metal Oxide Ribbon Mesh Canister
Anodes
2.2.7 Mixed Metal Oxide Discrete Mesh Anodes
2.3 Other ICCP anodes
2.3.1 Magnetite Anodes
2.3.2 Graphite Anodes
2.3.3 Platinised Titanium Anodes
2.4 Transformer Rectifiers
2.4.1 Air Cooled / Oil Cooled TR's
2.4.2 Remote Monitoring For TR's
2.5 Junction Boxes
2.5.1 Positive / Negative / Bond Junction Boxes
2.6 ICCP Accessories
2.6.1 Wellhead Assemblies
2.6.2 Carbonaceous Backfill
2.6.3 Cable XLPE/PVC
2.6.4 Cable XLPE/PVC/SWA/PVC
2.6.5 Cable PVDF / HMWPE
2.6.6 Cable Halar / HMWPE
2.6.7 Cable HMWPE
2.6.8 Vent Pipe
2.6.9 Casing Pipe
2.6.10 Splice Kits
2.6.11 Solar Power Units
2
S
E
C
T
I
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OPENER Impressed Current 6/8/08 13:34 Page 1
SILICON IRON ROD ANODES
IMPRESSED CURRENT CATHODIC PROTECTION DATASHEET 2.1.1
REVISION 1
Venture Way, Grantham, Lincs NG31 7XS UK. Tel: +44 (0)1476 590666 Fax: +44 (0)1476 570605
Email: cpc@cathodic.co.uk Website: www.cathodic.co.uk
Registered Office: Minalloy House, Regent Street, Sheffield S1 3NJ, UK VAT No. 116 8408 71, Regd in England No. 478098
DATASHEET
2.1.1
APPLICATION
Marine Structures, Seawater Intakes, Deepwell Groundbeds, Horizontal Groundbeds, Distributed Anodes, Tank
Internals & Tank Bottoms. Suitable For Use In Soils, Mud, Carbonaceous & Petroleum Coke Backfill; Fresh, Brackish
and Sea Water.
CHEMICAL COMPOSITION
CONSUMPTION RATES
CABLE CONNECTION
SILICON IRON ANODE DATA
Silicon
Manganese
Carbon
Chromium
Iron
Normal
14.50%
0.75%
0.85%
Remainder
Chrome
14.50%
0.75%
0.95%
4.50%
Remainder
Normal Alloy
Chrome Alloy
0.5 kg/Amp/year
0.2 kg/Amp/year
Typical Rates
Anode/Cable Connection : Connection less than 0.001 Ohm
With Heatshrink Sleeve With Heatshrink Cap
Type
36/2.0
36/2.5
36/3.0
48/2.0
48/2.5
48/3.0
60/2.0
60/2.5
60/3.0
60/4.5
SILICON IRON ROD ANODES
REVISION 1
DATASHEET
2.1.1
CABLE TYPES
Available cable types include : XLPE/PVC, HMWPE, PVDF(Kynar), XLPE/PVC/SWA/PVC, EPR/CSPE
STANDARD ANODE TYPES AND WEIGHTS
CANISTERED ANODES
A
(in)
36
36
36
48
48
48
60
60
60
60
B
(in)
2.0
2.5
3.0
2.0
2.5
3.0
2.0
2.5
3.0
4.5
C
(in)
3.0
3.5
4.0
3.0
3.5
4.0
3.0
3.5
4.0
4.5
(m
2
)
0.16
0.20
0.23
0.20
0.25
0.30
0.25
0.32
0.38
0.55
(ft
2
)
1.70
2.1
2.50
2.20
2.70
3.30
2.70
3.40
4.0
5.90
(kg)
14.50
22.30
31.40
19.10
28.60
40.90
22.70
35.90
50.00
99.10
(lbs)
32
49
69
42
63
90
50
79
110
218
Surface Area Approx Wt
Standard Sizes
150mmDia x 1500mm L
200mmDia x 2000mm L
250mmDia x 2000mm L
300mmDia x 2000mm L
Standard Gauges
1.0mm 20bg
1.2mm 18bg
1.5mm 18bg
2.0mm 14bg
SILICON IRON
TUBULAR ANODES
REVISION 1
DATASHEET
2.1.2
APPLICATION
Marine Structures, Seawater Intakes, Deepwell Groundbeds, Horizontal Groundbeds, Distributed Anodes, Tank Internals
& Tank Bottoms (not recommended for large diameter tanks). Suitable For Use In Soils, Mud, Carbonaceous & Pet Coke
Backfill; Fresh, Brackish and Sea Water
TECHNICAL DATA
SILICON IRON TUBULAR ANODE DATA
Silicon Iron ASTM A518 86 Grade 3
Silicon
Manganese
Carbon
Chromium
Copper
Molybdenum
Iron
14.20 14.75%
1.50% Max
0.75 1.15%
3.25 5.00%
0.50% Max
0.20%Max
Remainder
Tensile Strength (1/2Dia bar)
Compressive Strength
Brinell Hardness
Density
Melting Point
15,000 psi
100,000 psi
520 bhn
7.0 gr/ml
2,300 F
Consumption Rate
Anode/Cable Connection
Cable Types
Typical rates Chrome: 0.2kg/A/yr
For CP design a current density of not more than 30A/m
2
of
anode surface is recommended
Centre connection less than 0.001 Ohm resin encapsulated
XLPE/PVC, HMWPE, PVDF(Kynar); XLPE/PVC/SWA/PVC, EPR/CSPE
SILICON IRON
TUBULAR ANODES
REVISION 1
DATASHEET
2.1.2
STANDARD ANODE TYPES, WEIGHTS, DIMENSIONS AND OUTPUTS
Average Wt Type Approx
Area
Outside
Dia
Inside
Dia
Length
31
46
63
85
110
MS-1
MS-2
MS-3
MS-4
MS-5
14.1
20.9
28.6
39.2
49.9
2.4
4.0
4.9
6.9
8.7
0.2
0.4
0.5
0.6
0.8
71
58
71
96
124
2.8
2.3
2.8
3.8
4.9
45.7
35.6
45.7
74.4
99.0
1.8
1.4
1.8
2.9
3.9
1067
2134
2134
2134
2134
42
84
84
84
84
1.5-2.0
3.0-4.0
3.5-5.0
6.0-7.0
6.0-8.5
lbs kgs ft
2
m
2
mm in mm in mm in
Nominal
Discharge
Amps
Substrate Titanium ASTM B338 Grade 1 or 2
Coating IrO
2
/Ta
2
O
5
Coating Method Multi pass thermal decomposition of precious metal salts technique
Diameter 25.4mm
Wall Thickness 0.90mm
Consumption Rate 0.5 - 4.0 mg/A/yr depending upon CP application conditions
Utilisation Factor Dimensionally Stable
Working Environment Suitable for Cl
2
& O
2
or combination of both
Operating Characteristics
Coating loading can be adjusted for specific lifetime/current density requirement

Cable Types HMWPE/PVDF(Kynar); XLPE/PVC/SWA/PVC; EPR/CSPE
Maximum 1Cx50mm
2
Anode/Cable Connection Centre connection less than 0.001 Ohm, resin encapsulated & helium tested
to prove effective seal
MIXED METAL OXIDE
TUBULAR ANODES
REVISION 1
DATASHEET
2.2.1
APPLICATION
Marine Structures, Seawater Intakes, Deepwell Groundbeds, Horizontal Groundbeds, Distributed Anodes, Tank Internals
& Tank Bottoms Suitable For Use In Soils, Mud, Carbonaceous & Pet Coke Backfill; Fresh, Brackish and Sea Water
TUBULAR MMO ANODE DATA
Environment
Carbonaceous Backfill
Calcined Petroleum Coke
Freshwater
Brackish Water
Seawater
Max Current Density
(A/m
2
)
50
100
100
100-300
600
Life
(Years)
20
20
20
20
20
MIXED METAL OXIDE
TUBULAR ANODES
REVISION 1
DATASHEET
2.2.1
STANDARD ANODE TYPES, DIMENSIONS AND OUTPUTS
Soil (with carbon backfill)
S-2.5/50
S-2.5/100
Fresh Water
FW-2.5/50
FW-2.5/100
Sea Water
SW-2.5/50
SW-2.5/100
Mud (*)
M-2.5/50
M-2.5/100
Brackish Water (**)
BW-2.5/50
BW-2.5/100
mm
25
25
25
25
25
25
25
25
25
25
inches
1
1
1
1
1
1
1
1
1
1
mm
500
1000
500
1000
500
1000
500
1000
500
1000
inches
19.7
39.4
19.7
39.4
19.7
39.4
19.7
39.4
19.7
39.4
(Amps from 5-70C)
4
8
4
8
25
50
2 - 4
4 - 8
(Amps from 10-70C)
412
824
(Amps from 0-5C)
2
4
2
4
5
10
1.5
3
(Amps from 0-10C)
26
412
Type OD Length
Current Output
(Typical)
Current Output
(Typical)
(*) Current outputs in mud depend on site conditions (sea mud or river mud, etc)
(**) Current outputs in brackish water depend on site conditions & chloride concentrations.
NOTES
Coating loading may be adjusted to suit a particular current density or design life
Standard anodes are designed for 20 year life, however, design life of up to 50 years can be catered for.
Tubular MMO anode strings can be supplied to Clients specific requirements.
Other tube diameters are available on request,16mm dia & 32mm dia.
MIXED METAL OXIDE
RIBBON ANODES
REVISION 1
DATASHEET
2.2.2
APPLICATION
Reinforced Concrete Structures & Tank Bottoms
APPLICATION
RIBBON MMO DATA
Substrate
Coating
Coating Method
Width (Nom)
Thickness (Nom)
Standard Coil Length
Standard Coil Weight
Surface Area of Ribbon
Consumption Rate
Utilisation Factor
Working Environment
Operating Characteristics
Titanium Conductor Bar
Substrate
Sand & Concrete
Titanium ASTM B338 Grade 1
IrO
2
/Ta
2
O
5
Multi pass thermal decomposition of precious metal salts technique
0.25 (6.35mm)
0.025 (0.635mm)
250 (76.22m)
2.5lbs (1.12kg)
0.014m
2
/m
0.5 - 4.0 mg/A/yr depending upon CP application conditions
Dimensionally Stable
Suitable for Cl
2
& O
2
or combination of both
CURRENT OUTPUT IN FINE SAND
12.8mA/ft (42mA/m) when operating at a current density of
0.278A/ft
2
(3A/m
2
).
50 year design life when operating at a current density of
0.278A/ft
2
(3A/m
2
).
CURRENT OUTPUT IN CONCRETE
0.45mA/ft (1.5mA/m) when operating at a current density of
10.19mA/ft
2
(110A/m
2
).
100 year design life when operating at a current density of
10.19mA/ft
2
(110A/m
2
).
Width: 0.50 (12.7mm); Thickness: 0.035 (0.9mm)
Coil length: 250 (76.22m); Coil Weight: 8.5lbs (3.8kg)
Titanium ASTM B 265 Grade 1
Datasheet 2.2.2 6/8/08 13:18 Page 1
MIXED METAL OXIDE
WIRE ANODES
REVISION 1
DATASHEET
2.2.3
APPLICATION
Tank Bottoms, Tank Internals, Pipeline Internals, Canistered Anodes, Continuous Horizontal Groundbeds,
Discontinuous Horizontal Groundbeds, Shallow Vertical Groundbeds, Deep Anode Groundbeds.
Available in two standard sizes, with two standard current ratings. Other sizes and rating are available upon request.
MMO Wire Anode consists of solid titanium wire which meets ASTM B348 Grade 1 or 2 standards, that has been
coated with Mixed Metal Oxide.
PIGGYBACK WIRE ANODE SYSTEMS
For use on pipelines, the product comprises Mixed Metal Oxide Wire Anode material piggybacked to a cable at
predetermined intervals (to aid current distribution and attenuation). The wire and cable is contained within a cotton
sock filled with calcined petroleum coke breeze backfill. The Piggyback Sock Anode is placed alongside the pipeline with
suitable lengths of cable at each end of the loop allowed for termination into a junction box.
PIGGYBACK WIRE SOCK ANODE SYSTEMS
For use on pipelines, the product comprises Mixed Metal Oxide Wire Anode material piggybacked to a cable at
predetermined intervals (to aid current distribution and attenuation). The wire and cable is contained within a cotton
sock filled with calcined petroleum coke breeze backfill. The Piggyback Sock Anode is placed alongside the pipeline with
suitable lengths of cable at each end of the loop allowed for termination into a junction box.
WIRE ANODES ELECTRICAL RESISTANCE
1.5mm diameter : 75,537 microhms/ft / 247,821 microhms/m
3.0mm diameter : 18,884 microhms/ft / 61,954 microhms/m
Approximate electrical resistance @ 25C. Mechanical properties are based on typical room temperature.
Datasheet 2.2.3 6/8/08 13:18 Page 1
MIXED METAL OXIDE
WIRE ANODES
REVISION 1
DATASHEET
2.2.3
TYPICAL CABLE TO WIRE SPLICED CONNECTION
TYPICAL WIRE SOCK ANODE ARRANGEMENT
TYPICAL CONCENTRIC PATTERN WIRE ANODE ARRANGEMENT
Datasheet 2.2.3 6/8/08 13:18 Page 2
ANODE PERFORMANCE
Current rating @ 110 mA/m
2
(10 mA/ft
2
)
Expected life (NACE Standard TM02944-94)
Catalyst
Maximum anode concrete interface current density
FHWA limit
Short-term limit
NOMINAL DIMENSIONS
Width
Coil length
Actual anode surface per unit length of anode
Expanded thickness
Diamond dimensions
Shipping weight per coil
SUBSTRATE
Composition
Coefficient of thermal expansion
Thermal conductivity @ 20C
Electrical resistivity
Modulus of elasticity
Tensile strength
Yield strength
Elongation
CURRENT DISTRIBUTOR
Width
Thickness
Coil length
ELECTRICAL PROPERTIES
Anode ribbon mesh resistance lengthwise
Current distributor resistance lengthwise
MIXED METAL OXIDE
ELGARD 85 RIBBON MESH
REVISION 1
DATASHEET
2.2.4
ELGARD Anode ribbon mesh is composed of a precious metal oxide catalyst sintered to an expanded Titanium
mesh substrate. The Anode Ribbon Mesh is used as a key component in the Cathodic Protection of Reinforced
Concrete Structures.
MATERIAL SPECIFICATIONS
2.8 mA/m (0.85 mA/ft)
75 Years
Iridium Based Mixed Metal Oxide
110 mA/m
2
(10 mA/ft
2
)
220 mA/m
2
(20 mA/ft
2
)
10 mm (0.4 ")
76 m (250 ft)
0.025 m
2
/m (0.082 ft
2
/ft)
1.30 mm (0.051 ")
2.5 x 4.6 x 0.6 mm (0.10 " x 0.18 " x 0.025 ")
1.4 kg (3.1 lbs)
Titanium, Grade 1 per ASTM B265
8.7 x 10
-5
/K (0.0000048/in/in/K)
15.6W/ m
2
- K (9.0BTU/hr/ft
2
/F/ft)
0.000056 Ohm-cm (0.000022 Ohm-in)
105 GPa (14,900,000 PSI) minimum
245 MPa (35,000 PSI) minimum
24% minimum
12.70 mm (0.5 ")
0.90 mm (0.035 ")
76 m (250 ft)
3.9 kg (8.6 lbs)
0.49 Ohm/m (0.15 Ohm/ft)
0.049 Ohm/m (0.015 Ohm/ft)
Datasheet 2.2.4 85 6/8/08 13:19 Page 1
ANODE PERFORMANCE
2
(10 mA/ft
2
)
Catalyst
Maximum anode concrete interface current density :
FHWA limit
Short-term limit
NOMINAL DIMENSIONS
Width
Coil length
Expanded thickness
Diamond dimensions
SUBSTRATE
Composition
Tensile strength
Yield strength
Elongation
CURRENT DISTRIBUTOR
Width
Thickness
Coil length
3.5 mA/m (1.05 mA/ft)
75 Years
110 mA/m
2
(10 mA/ft
2
)
220 mA/m
2
(20 mA/ft
2
)
13 mm (0.5 ")
76 m (250 ft)
0.032 m
2
/m (0.105 ft
2
/ft)
1.30 mm (0.051 ")
2.5 x 4.6 x 0.6 mm (0.10 " x 0.18 " x 0.025 ")
1.8 kg (4 lbs)
8.7 x 10
-5
/K (0.0000048/in/in/K)
15.6W/ m
2
- K (9.0BTU/hr/ft
2
/F/ft)
0.000056 Ohm-cm (0.000022 Ohm-in)
24% minimum
12.70 mm (0.5 ")
0.90 mm (0.035 ")
76 m (250 ft)
3.9 kg (8.6 lbs)
0.39 Ohm/m (0.12 Ohm/ft)
0.049 Ohm/m (0.015 Ohm/ft)
MIXED METAL OXIDE
REVISION 1
DATASHEET
2.2.4
Datasheet 2.2.4 100 6/8/08 13:20 Page 1
5.28 mA/m (1.61 mA/ft)
75 Years
110 mA/m
2
(10 mA/ft
2
)
220 mA/m
2
(20 mA/ft
2
)
19 mm (0.75 ")
76m (250 ft)
0.048 m
2
/m (0.157 ft
2
/ft)
1.30 mm (0.051 ")
2.5 x 4.6 x 0.6 mm (0.10 " x 0.18 " x 0.025 ")
2.7 kg (6 lbs)
8.7 x 10
-5
/K (0.0000048/in/in/K)
15.6W/ m
2
- K (9.0BTU/hr/ft
2
/F/ft)
0.000056 Ohm-cm (0.000022 Ohm-in)
24% minimum
12.70 mm (0.5 ")
0.90 mm (0.035 ")
76 m (250 ft)
3.9 kg (8.6 lbs)
0.26 Ohm/m (0.08 Ohm/ft)
0.049 Ohm/m (0.015 Ohm/ft)
ANODE PERFORMANCE
2
(10 mA/ft
2
)
Catalyst
FHWA limit
Short-term limit
NOMINAL DIMENSIONS
Width
Coil length
Expanded thickness
Diamond dimensions
SUBSTRATE
Composition
Tensile strength
Yield strength
Elongation
CURRENT DISTRIBUTOR
Width
Thickness
Coil length
MIXED METAL OXIDE
REVISION 1
DATASHEET
2.2.4
Datasheet 2.2.4 150 RIBBON 5/3/08 12:11 Page 1
ANODE PERFORMANCE
2
(10 mA/ft
2
)
Catalyst
FHWA limit
Short-term limit
NOMINAL DIMENSIONS
Width
Coil length
Expanded thickness
Diamond dimensions
SUBSTRATE
Composition
Tensile strength
Yield strength
Elongation
CURRENT DISTRIBUTOR
Width
Thickness
Coil length
5.3 mA/m (1.62 mA/ft)
75 Years
110 mA/m
2
(10 mA/ft
2
)
220 mA/m
2
(20 mA/ft
2
)
20 mm (0.8 ")
76 m (250 ft)
0.05 m
2
/m (0.082 ft
2
/ft)
1.30 mm (0.051")
2.5 x 4.6 x 0.6 mm (0.10 " x 0.18 " x 0.025 ")
2.9 kg (6.38 lbs)
8.7 x 10
-5
/K (0.0000048/in/in/K)
15.6W/ m
2
- K (9.0BTU/hr/ft
2
/F/ft)
0.000056 Ohm-cm (0.000022 Ohm-in)
24% minimum
12.70 mm (0.5 ")
0.90 mm (0.035 ")
76 m (250 ft)
3.9 kg (8.6 lbs)
0.25 Ohm/m (0.07 Ohm/ft)
0.049 Ohm/m (0.015 Ohm/ft)
MIXED METAL OXIDE
REVISION 1
DATASHEET
2.2.4
ANODE PERFORMANCE
2
(10 mA/ft
2
)
Catalyst
FHWA limit
Short-term limit
NOMINAL DIMENSIONS
Width
Coil length
Expanded thickness
Diamond dimensions
SUBSTRATE
Composition
Tensile strength
Yield strength
Elongation
CURRENT DISTRIBUTOR
Width
Thickness
Coil length
7.0 mA/m (2.13 mA/ft)
75 Years
110 mA/m
2
(10 mA/ft
2
)
220 mA/m
2
(20 mA/ft
2
)
25 mm (0.8 ")
76 m (250 ft)
0.062 m
2
/m (0.203 ft
2
/ft)
1.30 mm (0.051 ")
2.5 x 4.6 x 0.6 mm (0.10 " x 0.18 " x 0.025 ")
3.6 kg (7.9 lbs)
8.7 x 10
-5
/K (0.0000048/in/in/K)
15.6W/ m
2
- K (9.0BTU/hr/ft
2
/F/ft)
0.000056 Ohm-cm (0.000022 Ohm-in)
24% minimum
12.70 mm (0.5 ")
0.90 mm (0.035 ")
76 m (250 ft)
3.9 kg (8.6 lbs)
0.20 Ohm/m (0.061 Ohm/ft)
0.049 Ohm/m (0.015 Ohm/ft)
MIXED METAL OXIDE
REVISION 1
DATASHEET
2.2.4
ANODE PERFORMANCE
2
(10 mA/ft
2
)
Catalyst
FHWA limit
Short-term limit
NOMINAL DIMENSIONS
Width of roll
Length of roll
Area per roll
Actual anode surface per unit area of concrete
Expanded thickness
Diamond dimensions
SUBSTRATE
Composition
Tensile strength
Yield strength
Elongation
Anode mesh resistance lengthwise
Resistance width wise c/w current distributor
18.8 mA/m
2
(1.71 mA/ft
2
)
75 Years
110 mA/m
2
(10 mA/ft
2
)
220 mA/m
2
(20 mA/ft
2
)
1.22 m (4ft)
76 m (250 ft)
92.9 m
2
(1000 ft
2
)
0.17 m
2
/m
2
(0.17 ft
2
/ft
2
)
1.415 mm (0.056")
34 x 76 x 0.64 mm (1.33 " x 3.0 " x 0.025 ")
26 kg (56 lbs)
8.7 x 10
-5
/K (0.0000048/in/in/K)
15.6W/ m
2
- K (9.0BTU/hr/ft
2
/F/ft)
0.000056 Ohm-cm (0.000022 Ohm-in)
24% minimum
0.085 Ohm/m (0.026 Ohm/ft)
0.049 Ohm/m (0.015 Ohm/ft)
0.023 Ohm/m (0.007 Ohm/ft)
MIXED METAL OXIDE
ELGARD 150 ANODE MESH
REVISION 1
DATASHEET
2.2.4
ELGARD Anode mesh is composed of a precious metal oxide catalyst sintered to an expanded Titanium mesh
substrate. The Anode Mesh is used as a key component in the Cathodic Protection of Reinforced Concrete Structures.
Datasheet 2.2.4 150 6/8/08 13:20 Page 1
ANODE PERFORMANCE
2
(10 mA/ft
2
)
Catalyst
FHWA limit
Short-term limit
NOMINAL DIMENSIONS
Width of roll
Length of roll
Area per roll
Expanded thickness
Diamond dimensions
SUBSTRATE
Composition
Tensile strength
Yield strength
Elongation
Resistance widthwise c/w current distributor
24.4 mA/m
2
(2.22 mA/ft
2
)
75 Years
110 mA/m
2
(10 mA/ft
2
)
220 mA/m
2
(20 mA/ft
2
)
1.22 m (4 ft)
76 m (250 ft)
92.9 m
2
(1000 ft
2
)
0.22 m
2
/m
2
(0.22 ft
2
/ft
2
)
1.981 mm (0.078")
34 x 76 x 0.89 mm (1.33 " x 3.0 " x 0.035 ")
33kg (73 lbs)
8.7 x 10
-5
/K (0.0000048/in/in/K)
15.6W/ m
2
- K (9.0BTU/hr/ft
2
/F/ft)
0.000056 Ohm-cm (0.000022 Ohm-in)
24% minimum
0.046 Ohm/m (0.014 Ohm/ft)
0.049 Ohm/m (0.015 Ohm/ft)
0.016 Ohm/m (0.005 Ohm/ft)
MIXED METAL OXIDE
REVISION 1
DATASHEET
2.2.4
Datasheet 2.2.4 210 6/8/08 13:22 Page 1
ANODE PERFORMANCE
2
(10 mA/ft
2
)
Catalyst
FHWA limit
Short-term limit
NOMINAL DIMENSIONS
Width of roll
Length of roll
Area per roll
Expanded thickness
Diamond dimensions
SUBSTRATE
Composition
Tensile strength
Yield strength
Elongation
Resistance width wise c/w current distributor
37.8 mA/m
2
(3.44 mA/ft
2
)
75 Years
110 mA/m
2
(10 mA/ft
2
)
220 mA/m
2
(20 mA/ft
2
)
1.22 m (4 ft)
76 m (250 ft)
92.9 m
2
(1000 ft
2
)
0.34 m
2
/m
2
(0.34 ft
2
/ft
2
)
1.981 mm (0.078 ")
25 x 51 x 0.89 mm (0.923 " x 2.0 " x 0.035 ")
43 kg (95 lbs)
8.7 x 10
-5
/K (0.0000048/in/in/K)
15.6W/ m
2
- K (9.0BTU/hr/ft
2
/F/ft)
0.000056 Ohm-cm (0.000022 Ohm-in)
24% minimum
0.027 Ohm/m (0.008 Ohm/ft)
0.049 Ohm/m (0.015 Ohm/ft)
0.013 Ohm/m (0.004 Ohm/ft)
MIXED METAL OXIDE
REVISION 1
DATASHEET
2.2.4
Datasheet 2.2.4 300 6/8/08 13:23 Page 1
MIXED METAL OXIDE
ANODE ACCESSORIES
REVISION 1
DATASHEET
2.2.5
APPLICATION
A range of accessories are available to assist with the successful installation of our Mixed Metal Oxide anode systems.
SPOT WELDERS FOR UNDER TANK SYSTEMS
ANODE CENTRALISERS
For connection of Titanium conductor bars to Mixed Metal Oxide
Ribbon Anodes (see data sheet 2.2.2.)
For connection to tubular anode systems allowing them to centralise
within the casing / borehole. Available in a range of sizes and
materials to suit the application. When ordering please specify
metallic or non metallic type and the size of borehole / casing the
are being passed through.
CABLE TIES AND CLIPS
A full range of cable ties and clips are available to secure multiple
anodes chains in place for ease of installation. Please specify the
required length, thickness and material when ordering.
Datasheet 2.2.5 6/8/08 13:23 Page 1
MIXED METAL OXIDE
ANODE ACCESSORIES
REVISION 1
DATASHEET
2.2.5
END WEIGHTS
End weights are secured to bottom of an anode string / chain configuration to ensure cables remain straight during installation.
Weights are calculated according to the anode cable and ground bed arrangement.
Datasheet 2.2.5 6/8/08 13:23 Page 2
MIXED METAL OXIDE
RIBBON MESH CANISTER ANODES
REVISION 1
DATASHEET
2.2.6
APPLICATION
Horizontal Groundbeds, Shallow Vertical Groundbeds.
MESH STRIP ANODES are manufactured using titanium expanded mesh substrate, which meets ASTM B265
Grade 1 or 2 standards
MESH STRIP ANODES are 1.25" wide x 48" long and are rated 5 Amps for a 20 year design life in calcined petroleum
coke. The MESH STRIP ANODE can be packaged in a spiral wound, galvanized steel canister or a fabric sleeve.
Anode size and rating is calculated as follows,
Max Operating current density of anode = 100A/m
2
Titanium Surface Area of 1.25 (32mm) Width x 48 (1220mm) Length Strip Mesh Anode = 0.05m
2
Titanium is coated with a proprietary MMO coating with a sufficient loading to last a minimum of 20 years at the
specified current density.
Surface area of anode is 0.05m
2
and at current density of 100mA/m
2
gives output 5A for minimum 20 years (or
equivalent of 100 Amp/years at max current density of 100A/m
2
)
CABLE TYPES & CONNECTIONS
Anodes are factory assembled with a fully encapsulated cable connection.
Method of Connection : A stud bolt is passed through the mesh onto which a suitably sized cable lug is placed and then
tightened with nuts and steel washers to create an electrical connection between mesh anode and cable. Electrical
resistance test performed : Maximum connection resistance of 0.001 Ohm
Connection encapsulated with heat shrink sleeve
Datasheet 2.2.6 6/8/08 13:24 Page 1
Standard Gauges
1.0mm 20bg
1.2mm 18bg
1.2mm 18bg
1.5mm 18bg
2.0mm 14bg
Standard Sizes
150mmDia x 1500mm L
150mmDia x 2000mm L
200mmDia x 2000mm L
250mmDia x 2000mm L
300mmDia x 2000mm L
MIXED METAL OXIDE
RIBBON MESH CANISTER ANODES
REVISION 1
DATASHEET
2.2.6
CABLE TYPES & CONNECTIONS
Standard Cable types included HMWPE, XLPE/PVC, PVDF/HMWPE, When ordering please specify cable type,
length and size (mm
2
)
CANNISTER TYPES AND DIMENSIONS
Datasheet 2.2.6 6/8/08 13:24 Page 2
Maximum Current Density (CD) @ Anode 216mA/m
2
(20mA/ft
2
)
Mesh Length, L, mm (ft) 100 (.325) 150 (.492) 200 (.658) 250 (.817) 300 (.983) 350 (1.125
Anode Surface Area, m
2
(ft
2
) .020 (.215) .030 (.325) .040 (.430) .050 (.545) .061 (.660) .071 (.770)
Current Rating @ Max CD, mA 4.6 6.8 9.1 11.4 13.7 15.9
Expected Life 50 Years
Anode Coating Iridium Oxide, Mixed Metal Oxide
25.4mm (1 in)
31.75mm (1-1/4 in)
Variable See Table Below
1.30mm (0.051 in)
2.5mm x 4.6mm (0.1 in x 0.18 in)
0.6mm (0.025 in)
8.7 x 10
-5
/K (0.0000048/in/in/K)
15.6W/ m
2
- K (9.0BTU/hr/ft
2
/F/ft)
0.000056 Ohm-cm (0.000022 Ohm-in)
24% minimum
6.35mm (1/4 in)
0.63mm (0.025 in)
Anode Diameter
Installation Hole Diameter
Lengths
Expanded Mesh Thickness
Diamond Dimensions
Strand Thickness
Composition
Tensile strength
Yield strength
Elongation
Width
Thickness
MIXED METAL OXIDE
DISCRETE MESH ANODES
REVISION 1
DATASHEET
2.2.7
APPLICATION
The Elgard Discrete Mesh Anode compliments the existing line of Elgard anodes for Cathodic protection of reinforced
concrete structures. The anode is composed of a precious metal oxide catalyst on an expanded titanium mesh substrate.
The anodes are available in 100mm, 150mm, 200mm, 250mm, 300mm and 350mm lengths and can be combined to
meet specific requirements.
DIMENSIONS
SUBSTRATE
CURRENT DISTRIBUTOR
ANODE PERFORMANCE
Datasheet 2.2.7 6/8/08 13:24 Page 1
MIXED METAL OXIDE
DISCRETE MESH ANODES
REVISION 1
DATASHEET
2.2.7
OUTLINE DRAWING
ANODE WELDMENT
ELTECH
PART No.
0670EA03-1
0670EA03-2
0670EA03-3
0670EA03-4
0670EA03-5
0670EA03-6
100
150
200
250
300
350
400
450
500
550
600
650
DIM. L1 DIM. L2
Datasheet 2.2.7 6/8/08 13:24 Page 2
MAGNETITE ANODES
REVISION 1
DATASHEET
2.3.1
APPLICATION
Magnetite is a natural mineral with a high corrosion resistance making it an excellent anode material. The anodes are
cast cylindrical and hollow. Cables are centre connected to give a uniform dissipation of current from the anode
surface. The anode to cable connection is electrically sealed with a dielectric compound and an anode cap.
Suitable for use in Horizontal Groundbeds, Deep Well Groundbeds, Fresh Water Installations, Seawater Installation
(1) depends on environment
MAGNETITE ANODE DATA
Specific gravity
Brinell hardness (WB5/187.5/15)
Bending strength
Density
Melting point
Coefficient of linear expansion
4.74.8
344
5
4,71
1500
6.4x10-6
kg/dm3
kN/cm2
g/cm3
C
1/C (0-100C)
Consumption rate
Current density (1)
Efficiency
0.02 kg/A year
0.70 mA/dm2
90%
FeO
Fe3O4
Balance
28 - 32%
60 - 64%
4 - 12%
Datasheet 2.3.1 6/8/08 13:25 Page 1
MAGNETITE ANODES
REVISION 1
DATASHEET
2.3.1
EXPERIENCE
Lifetime comparison - Basis: anode current load 5 A
Surrounding electrolyte:
neutral soil and water
without chlorine and
sulfate content
Applications:
shallow groundbeds,
deep groundbeds
CHLORINE CONTAINING SOIL
SEAWATER AND DEEP GROUNDBEDS
STANDARD ANODE TYPES WEIGHTS AND OUTPUTS
TYPE MA-U
Diameter 60 mm
Total length 720 mm
Effective length 670 mm
Total weight 6.0 kg
Min. effective mass 4.7 kg
Surface area 13.4 dm
2
Max. current load 3.0 A
chlorine and/or sulfate
containing soil or
stagnant water
Applications:
shallow groundbeds,
deep groundbeds
TYPE MA-CS
Diameter 60 mm
Total length 720 mm
Total weight 6.0 kg
2
Datasheet 2.3.1 6/8/08 13:25 Page 2
MAGNETITE ANODES
REVISION 1
DATASHEET
2.3.1
flowing seawater or
brackish water
Applications:
platforms, jetties,
harbours
STANDARD ANODE TYPES WEIGHTS AND OUTPUTS
TYPE MA-SEA
Diameter 60 mm
Total length 760 mm
Total weight 6.0 kg
2
CANISTER FOR MA-U & MA-CS
COKE BACKFILL
Minimum carbon content 90%
Maximum moisture content 5%
Maximum resistivity 1m
Density 700-950 kg/m
3
Particle size (dia.) 20 mm max.
chlorine containing soil or
stagnant water
Applications:
deep groundbeds open
hole, deep groundbeds
closed hole, water tank
TYPE MA-CHAIN
Diameter 60 mm
Total length 740 mm
Total weight 6.2 kg
2
Max. current load (groundbeds) 6.0 A
Max. current load (tanks) 16.0 A
Standard canister Diameter (mm) Length (mm) Total weight (kg)
CAN 10 160 1000 22
CAN 15 300 1500 85
CAN 20 300 2000 110
Datasheet 2.3.1 6/8/08 13:25 Page 3
GRAPHITE ANODES
REVISION 1
DATASHEET
2.3.2
APPLICATION
Plain graphite anodes are used in dry soil conditions installed in groundbeds containing compacted carbonaceous
backfill. Linseed oil impregnated anodes can be used in moist saline soils, in fresh and brackish water, and for
seawater applications. Graphite anodes can be installed as horizontal or deepwell groundbeds to protect buried
pipelines or due to their lightweight nature they can be suspended into the electrolyte to protect water tank internal
surfaces or marine structures.
Cathodic Protection Co Ltd graphite anodes are manufactured in two standard sizes - 3 dia up to 60 long & 4
dia up to 80 long. There are two types of graphite anodes - plain & linseed oil impregnated. Plain graphite
anodes are used for ordinary soil conditions and linseed oil impregnated anodes are usually used for saline soil
or seawater environments.
GRAPHITE ANODE DATA
CONSUMPTION RATES
Datasheet 2.3.2 6/8/08 13:25 Page 1
GRAPHITE ANODES
REVISION 1
DATASHEET
2.3.2
TYPICAL CHARACTERISTICS
ANODE TO CABLE CONNECTION
Cable for Graphite Anodes is supplied according to customer requirements. We can offer the following insulation and
sheathing types PVC. XLPE/PVC, HMWPE, KYNAR, HALAR, EPR/CSPE.
Datasheet 2.3.2 6/8/08 13:25 Page 2
PLATINISED TITANIUM ANODES
REVISION 1
DATASHEET
2.3.3
APPLICATION
Underwater steel structures - Wharves, jetties, sheet pile walls and piers. Usually rod type anodes distributed
throughout the structure to be protected to give a good overall protective current distribution. Anodes should be
installed in areas not liable to cause Anode damage i.e. out of the way of berthing vessels, mooring ropes, chains etc.
Exterior protection of ships hulls - anodes in the shape of plates, discs or strips. Housed in chlorine resistant plastic as
the anode operates at high current densities in seawater which produces chlorine.
Water tank internal protection - usually distributed rod anodes are used for this type of installation by suspending from
the tank roof.
Internal protection of plant - large diameter water pipelines such as cooling water can be protected using rod or wire
shaped anodes.
PLATINISED TITANIUM ANODE DATA
Platinised Titanium anodes are manufactured from a commercially pure titanium substrate plated with a very thin coating
of platinum. The titanium serves simply as the anode body and the conductor, the active anode element being the
platinum coating.
The usual thickness of the platinum coating is approximately 2.5 microns, however, this coating thickness should be
increased to 5.0 microns for harsher environments. The base metal is available in a wide variety of standard shapes -
rods, tubes, mesh, etc - which can be fabricated into non-metallic mounts for attachment to the structure to be
cathodically protected.
The thickness of the platinum coating and the current density at which the anode is operated determine the useful life
of the anode. The maximum voltage at the anode to electrolyte interface should not exceed 8 Volts in electrolytes
containing chloride as voltages greater than this value could cause local corrosion on any unplatinised portions of
the anode.
Platinised titanium anodes should not be used in electrolytes containing fluoride as titanium oxide dissolves in fluoride.
Anodic passivation does not protect the titanium substrate in such electrolytes.
The advantage of platinised titanium anodes is that they can be operated at high current densities with very low
consumption rates.
Datasheet 2.3.3 6/8/08 13:26 Page 1
REVISION 1
DATASHEET
2.3.3
CURRENT DENSITY AND CONSUMPTION RATES
FEATURES
Anodes can work at high current densities without decomposition or dissolving.
Favourable strength to weight ratio.
Anodes can be smaller and more compact than comparable conventional anodes.
Can be manufactured in a wide variety of shapes and sizes.
Lightweight support tube installation for Pt Ti anode installation.
ANODE INSTALLATION EXAMPLES
Datasheet 2.3.3 6/8/08 13:26 Page 2
REVISION 1
DATASHEET
2.3.3
APPLICATION
Underwater steel structures - Wharves, jetties, sheet pile walls and piers. Usually rod type anodes distributed
throughout the structure to be protected to give a good overall protective current distribution. Anodes should be
installed in areas not liable to cause Anode damage i.e. out of the way of berthing vessels, mooring ropes, chains etc.
Exterior protection of ships hulls - anodes in the shape of plates, discs or strips. Housed in chlorine resistant plastic as
the anode operates at high current densities in seawater which produces chlorine.
Water tank internal protection - usually distributed rod anodes are used for this type of installation by suspending from
the tank roof.
Internal protection of plant - large diameter water pipelines such as cooling water can be protected using rod or wire
shaped anodes.
PLATINISED TITANIUM ANODE DATA
Platinised Titanium anodes are manufactured from a commercially pure titanium substrate plated with a very thin coating
of platinum. The titanium serves simply as the anode body and the conductor, the active anode element being the
platinum coating.
The usual thickness of the platinum coating is approximately 2.5 microns, however, this coating thickness should be
increased to 5.0 microns for harsher environments. The base metal is available in a wide variety of standard shapes -
rods, tubes, mesh, etc - which can be fabricated into non-metallic mounts for attachment to the structure to be
cathodically protected.
The thickness of the platinum coating and the current density at which the anode is operated determine the useful life
of the anode. The maximum voltage at the anode to electrolyte interface should not exceed 8 Volts in electrolytes
containing chloride as voltages greater than this value could cause local corrosion on any unplatinised portions of
the anode.
Platinised titanium anodes should not be used in electrolytes containing fluoride as titanium oxide dissolves in fluoride.
Anodic passivation does not protect the titanium substrate in such electrolytes.
The advantage of platinised titanium anodes is that they can be operated at high current densities with very low
consumption rates.
Datasheet 2.3.3 6/8/08 13:26 Page 1
REVISION 1
DATASHEET
2.3.3
CURRENT DENSITY AND CONSUMPTION RATES
FEATURES
Anodes can work at high current densities without decomposition or dissolving.
Favourable strength to weight ratio.
Anodes can be smaller and more compact than comparable conventional anodes.
Can be manufactured in a wide variety of shapes and sizes.
Lightweight support tube installation for Pt Ti anode installation.
ANODE INSTALLATION EXAMPLES
Datasheet 2.3.3 6/8/08 13:26 Page 2
TRANSFORMER RECTIFIERS
REVISION 1
DATASHEET
2.4.1
APPLICATION
Onshore, Offshore and Marine applications.
A wide and varied range of high quality transformer rectifiers are designed and manufactured at our Grantham works to
meet the market requirement for all land and marine structures necessitating an Impressed Current Cathodic Protection
system or a Marine Growth Anti Fouling system.
The products have been developed to satisfy the most arduous environmental
conditions, giving safe operational reliability with minimal maintenance at
competitive price levels.
Two main types of transformer rectifiers are available ie: Air Cooled and Oil
Cooled, the selection of which may be specification derived or personal
choice. The final selection invariably being the environmental conditions and
relative to output rating, these will determine the physical size and cost of the
unit. Our engineers are able to assist you with this selection.
1 Phase and 3 Phase supplies to 660Volts, 50/60Hz are readily catered for
within our standard arrangements
Voltages: 6 to 120Volts DC (British Standards state 50Volts DC output max)
Currents: 5 to 800Amps (Multiples of transformer rectifiers should be
considered for greater than 12kWatt)
Input Power Supply
Output Rating @
Ambient Temperatures -
10 to 55C
TRANSFORMER RECTIFIER UNIT DATA
Datasheet 2.4.1 6/8/08 13:27 Page 1
REVISION 1
DATASHEET
2.4.1
Switch Control via control panel facia switches to select transformer
tappings, 15 and 63 step control available as standard
Auto transformer (Variac) control indefinitely from 0 to 100%.
Electronic thyristor control from panel facia mounted potentiometer giving
indefinite variable adjustment from 3Volts to maximum rating.
All auto systems operate from 3Volts to maximum rating and are fitted with a
manual override facility.
Constant current maintains the output current at the preset value
irrespective of supply and output circuit changes.
A permanent reference electrode(s) controls the output current to maintain a
constant potential at the surface of the protected structure subject to
compensate for changes in electrolyte resistivity, coating efficiency, power
supply voltage variation, tidal conditions etc.
A wide range of standard and purpose built arrangements up to IP66
protection levels.
Mild steel, Stainless Steel, Aluminium and Glass Reinforced Polyester are
available.
Epoxy/Polyurethane paint finishes on prepared shot blast, cleaned and zinc
chromate primed/Zinga base as standard. Options include Zinc flame
sprayed, natural bead blast finishes, etc.
Selected to meet the specification requirement with particular emphasis on
high efficiency transformers and generously rated semi-conductors
OUTPUT CONTROL
Manual
Switched
Auto Transformer
Electronic
Auto (Electronic)
Constant Current
Constant Potential
Enclosures
Material
Finishes
Electrical/Electronic
Components
Datasheet 2.4.1 6/8/08 13:27 Page 2
REVISION 1
DATASHEET
2.4.1
Supply/Output Monitoring
Limit and Alarm (high and low)
Local/Remote indication facilities
4-20mA re-transmission signals
RCCD/MCB and fuse protection
Surge suppression
Lightning Arrestors
Metering
Instant Off timers
Synchronous timing
All transformer rectifiers undergo works testing to include the following as a
minimum:
Wiring connection integrity
Circuit continuity and compliance
Operation at full output current and voltage far a minimum of 12 hours
High voltage insulation resistance test
In addition new designs are subjected to a 12-24 hour heat run test at full
load to ensure that the temperature rises are within permitted limits for the
materials used in construction.
FACILITY AVAILABLE
TESTS
Datasheet 2.4.1 6/8/08 13:27 Page 3
REVISION 1
DATASHEET
2.4.1
TYPICAL TRANSFORMER RECTIFIER GENERAL ARRANGEMENT
(Model Shown Oil Cooled 75V / 125A)
TYPICAL TRANSFORMER RECTIFIER / POSITIVE JUNCTION BOX SITE ARRANGEMENT
Datasheet 2.4.1 6/8/08 13:27 Page 4
REMOTE MONITORING
FOR TRS
REVISION 1
DATASHEET
2.4.2
Bullhorn i-series ICP Information
American Innovations Bullhorn
i-series ICP is a satellite

based remote monitoring device that provides scheduled
and by exception inbound reporting as well as two-way
communication for on-demand reads and
activating/deactivating ancillary equipment. The device can
be field upgraded to include a MicroMax
GPS80 current
interrupter enabling the collection of IR-free cathodic
protection (CP) reads in the most efficient, economical way
possible. The ICP uses the OrbComm satellite system and
enables equipment monitoring and control in very remote
locations. It is ideal for international use.
The ICP monitors many different kinds of equipment in the
cathodic protection industry including rectifiers, test points
and critical bonds. It is also ideal for monitoring equipment
in a number of other industries. The ICP provides automatic
notifications of alarm events via email, cell phone or pager.
With secure access, data can be viewed on the internet
from anywhere in the world, day or night.
The ICP unit is available in 2 and 4 analog channel versions. The 5th analog channel is used internally when a MicroMax
is utilized and is not available for other purposes. Both versions have 6 digital inputs and 6 digital outputs. For CP
applications, analog inputs are available with filtering and surge protection. The ICP is easy to install since all
configuration of the device takes place via the satellite system, so there is no need for a laptop computer in the field.
It accepts customer supplied AC or DC line power or DC solar power. In the event of power loss, an internal
rechargeable battery provides backup power.
Remote interruption by adding MicroMax GPS80 Interrupter
Easy to install
Configure via the web
Up to 4 analog channels for external inputs
Satellite for global coverage
Datasheet 2.4.2 11/8/08 16:17 Page 1
REMOTE MONITORING
FOR TRS
REVISION 1
DATASHEET
2.4.2
Up to 5 Analog channels
Available input ranges:
0-100V
0-10V
0-100mV
Analog inputs are isolated
Inputs specified at time of order
1 digital input available
Remaining digital inputs:
Available for use with MicroMax GPS
Current Interrupter
Available for use with MicroMax GPS current interrupter
Configuration via web interface
MicroMax GPS80 Interrupter, AC Present Sensor,
Interruption Verification Sensor
AC (Line Power Supplied by Customer) w/ Nominal Voltage of 110VAC.
DC (line power supplied by customer) 15-36VDC.
Backup battery has a Nominal Voltage of 12 VDC and 7AH Capacity.
Solar Power Option Available for an additional fee.
Aluminum or Fiberglass enclosure available:
Height- 13.5 inches, Width- 11.5 inches, Depth- 7.125 inches
Data stored in non-volatile (EEPROM) memory
Temp: -40 degrees C to +85 degrees C; Humidity: 0-95% non-condensing
UL/CUL General Classification (pending); FCC Part 15; Enclosure: NEMA 4
compliant for all Bullhorn types
Bullhorn secure website. Standard web browsers.
AI Network operations center
Orbcomm satelite
Data Inputs
Outputs
Config. Parameters
Supporting Products
Power Supply
Physical Description
Data Integrity
Environmental
Compliance
Software Interface
Communications
I - series ICP Product Information
Datasheet 2.4.2 11/8/08 16:17 Page 2
JUNCTION BOXES
REVISION 1
DATASHEET
2.5.1
Stainless Steel 316L & 304, Aluminium Explosion Proof
Painted Mild Steel Plastic GRP
Galvanised and Painted Cast Iron Custom Finishes
Please also specify IP, NEMA or Hazardous area classification required.
APPLICATION
Junction boxes for positive and negative current distribution and control , and for resistance bonding are available to
meet exact client specifications.
Suitable for onshore and marine environments in safe and hazardous areas.
When specifying a CPC Junction Box assembly please clarify specific hardware and components required.
ENCLOSURES
Resistors Metering Diodes
Shunts Monitoring Labelling
Support Frames Transducers Switches
Copper Links Terminals Security / Locking
ACCESSORIES
Datasheet 2.5.1 6/8/08 13:28 Page 1
JUNCTION BOXES
REVISION 1
DATASHEET
2.5.1
Cable entry can be made by any type of proprietary cable gland, or by conduit and hub assemblies allowing the safe
passage of multiple cables into the enclosure.
CABLE ENTRY
TYPICAL JUNCTION BOX
ARRANGEMENT
TYPICAL JUNCTION BOX SUPPORT ARRANGEMENT
TYPICAL INTERNAL LAYOUT OF ANODE
JUNCTION BOX
Datasheet 2.5.1 6/8/08 13:28 Page 2
WELLHEAD ASSEMBLIES
REVISION 1
DATASHEET
2.6.1
APPLICATION
Suitable for onshore and marine environments in safe and hazardous areas. For the termination and support of anode
cables at deep well ground bed locations and for the safe ventilation of gases produced by high chlorine environments.
Cathodic Protection Co Ltd can manufacture a custom range of well head assemblies to suit your exact requirement.
We can provide well head structures manufactured from a range of materials including GRP, Steel and Concrete. The
well head design will generally incorporate the support and termination of anode cables, sufficient ventilation of gases
generated in deep well ground bed locations and security / ingress protection to prevent tampering and
environmental damage.
TYPICAL LAYOUT OF WELLHEAD STRUCTURE
Datasheet 2.6.1 6/8/08 13:29 Page 1
CARBONACEOUS BACKFILL
REVISION 1
DATASHEET
2.6.2
APPLICATION
Impressed current cathodic protection groundbeds and packaged impressed current anodes.
CARBONACEOUS BACKFILL DATA
TYPICAL ANALYSIS
Chemical Composition (%) DBW SP
Ash 0.2 12 max
Volatiles 0.3 1.5 max
Moisture 0.3 10
Fixed Carbon 99.2 86.5 min (dry basis)
Sulphur 1.0 1.5 max
Silicon 168 ppm 1.0
Iron 83 ppm 1.1
Size Grading 0.25 - 1mm 0 -10mm
Resistivity @ 150psi 0.1 0hm cm 0.5 0hm cm
Products supplied in 25kg multi walled paper bags, stacked on pallets and
shrinkwrapped. Alternatively 1 tonne bulk bags on pallets and shrinkwrapped
CABLE XLPE/PVC
REVISION 1
DATASHEET
2.6.3
APPLICATION
Surface wiring & buried if protected by clean sand. Suitable for use as anode cable tails, positive feed cable,
negative return cable and test cable.
XLPE/PVC CABLE DATA
Single core XLPE insulated/PVC sheathed 600/1000V
BS7889 6181XY
Conductors: Plain annealed copper
Insulation: XLPE (Cross linked Polyethylene)
Sheath/Jacket: PVC (Polyvinyl-Chloride)
Colours: Black/Black, Red/Red
Voltage: 600/1000v
Operating temperature: Maximum 90C, minimum bending 0C
Standard: BS7889 & IEC60502
Minimum bending radius : Diameter up to 25mm, 4 x OD; Diameter over 25mm, 6 x OD
STANDARD CABLE SIZES DIMENSIONS AND WEIGHTS
Size
(mm
2)
6
10
16
25
35
50
70
95
120
150
185
240
Maximum Dia
Over Conductor
(mm)
3.12
4.05
5.10
6.40
7.50
8.90
10.70
12.60
14.98
15.96
17.78
20.52
RT of
Insulation
(mm)
0.7
0.7
0.7
0.9
0.9
1.0
1.1
1.1
1.2
1.4
1.6
1.7
Dia over
Core
(mm)
4.5
5.5
6.5
8.2
9.3
11.1
13.2
15.0
17.6
19.0
21.3
24.3
RT of
Sheath
(mm)
1.4
1.4
1.4
1.4
1.4
1.4
1.5
1.5
1.6
1.7
1.7
1.9
Nominal
Overall Dia
(mm)
7.3
8.3
9.3
11.0
12.1
14.2
16.4
18.3
21.2
22.8
25.1
28.4
Weight
(Kg/km)
104
150
214
317
420
560
787
1050
1450
1650
2030
2660
Datasheet 2.6.3 11/8/08 16:18 Page 1
CABLE XLPE/PVC/SWA/PVC
REVISION 1
DATASHEET
2.6.4
APPLICATION
Surface wiring & buried if protected by clean sand. Suitable for use as anode cable tails, positive feed cable,
negative return cable and test cable.
XLPE/PVC/SWA/PVC CABLE DATA
Single Core BS5467 600/1000V
Conductors: Plain annealed stranded copper
Insulation: XLPE (Cross linked polyethylene)
Core identification: Brown
Bedding: PVC (Polyvinyl-Chloride)
Armour/Protection: SWA (Galvanised steel wire armour)
Sheath/Jacket: PVC (Polyvinyl-Chloride)
Colour: Black
Voltage: 600/1000v
Operating temperature: Maximum 90C, minimum bending 0C
Standard: BS5467
Minimum bending radius : 6 x Outside Diameter
Size
mm
2
10
16
25
35
50
70
95
120
Maximum Dia
Over Conductor
mm
4.05
5.10
6.40
7.50
8.90
10.70
12.60
14.98
RT of
Insulation
mm
0.7
0.7
0.9
0.9
1.0
1.1
1.1
1.2
Dia of
Armour Wire
mm
0.9
0.9
0.9
0.9
0.9
1.25
1.25
1.25
Approx Dia
under Armour
mm
10.4
10.8
11.4
12.0
12.9
14.9
16.6
18.3
Nominal
Overall Dia
mm
13.5
14.2
15.2
16.3
17.7
20.4
22.3
24.0
Weight
Kg/km
495
535
585
640
730
980
1270
1540
Datasheet 2.6.4 6/8/08 13:30 Page 1
CABLE PVDF/HMWPE
REVISION 1
DATASHEET
2.6.5
APPLICATION
Surface wiring & buried if protected by clean sand. Suitable for open hole deep well groundbeds and anode cable tails
where H2S and high levels of chloride ion species and where oxygen and/or chlorine gases may be evolved.
PVDF/HMWPE CABLE DATA
Single core PVDF insulated/HMWPE sheathed 600/1000V
Conductors: Tinned annealed copper
Insulation: PVDF Fluoropolymer (Radiation cross linked polyvinyldene fluoride)
Sheath/Jacket: HMWPE (High Molecular Weight Polyolefin) to ASTM Spec D-1248
Colours: Clear/Black
Voltage: 600/1000v
Operating temperature: Maximum 150C, minimum bending minus -15C
Minimum bending radius : 10m x OD of cable
Size
mm
2
6
10
16
25
35
50
Maximum Dia
of Conductor
mm
3.12
4.05
5.10
6.40
7.50
8.90
RT of
Insulation
mm
1.0
1.0
1.0
1.2
1.2
1.4
Dia over
Core
mm
5.12
6.05
7.10
8.80
9.90
11.70
RT of
sheath
mm
1.65
1.65
1.65
1.65
1.65
1.65
Nominal
Overall Dia
mm
8.42
9.35
10.40
12.10
13.20
15.00
Weight
Kg/km
96
135
197
312
398
541
NOTE: The Polyolefin sheath protects the PVDF insulation from damage during installation. The HMWPE sheath will
deteriorate under aggressive environmental conditions leaving the PVDF to withstand the surrounding media.
Datasheet 2.6.5 6/8/08 13:31 Page 1
CABLE HALAR/HMWPE
REVISION 1
DATASHEET
2.6.6
APPLICATION
HALAR/HMWPE cable is designed for anode lead wires in a wide range of environments. Due to its dual insulation
construction, it can be installed directly in native soils or submerged in fresh, brackish, or salt waters. The cable is ideal
for deep anode bed installations where chlorine and hydrogen gases are generated. The HALAR insulation will not
embrittle at temperatures down to (-80F) and will maintain dimensional stability and dielectric strength at temperatures
up to 250F. It is highly resistant to notch propagation.
One of the major causes of deep anode failures is the failure of cable insulation. This is especially evident in areas where
brackish water is present in the ground. In this environment, anodes generate reactive gases such as chlorine and
nacent oxygen. These gases cause rapid deterioration of conventional HMWPE insulation.
Cathodic protection cable insulated with HALAR fluoropolymer, is especially suited for deep anode lead wires. HALAR
fluoropolymer is inert to reactive compounds and has an outstanding ability to prevent the passage of gases. Laboratory
and field evaluations indicate that HALAR fluoropolymer insulated lead wire can extend the life of deep anode
installations. The cable is composed of stranded copper wire covered by two layers of insulation. The outer insulation
layer is made from high molecular weight polyethylene (HMWPE). It exhibits superior dielectric and tensile strength, and
provides mechanical protection to the cable.
The material is also resistant to water intrusion and is not affected by most organic or inorganic substances. The inner
or primary insulation is composed of HALAR, a fluoropolymer. This insulating material demonstrates exceptional chemical
resistance. In the presence of chlorine, hydrochloric acid, sulfuric acid, or other strong oxidizing agents the material
remains stable. Further, it will not deteriorate when exposed to petroleum hydrocarbons which are encountered in
numerous cathodic protection applications.
The dual extrusion HALAR cable is made specifically for cathodic protection applications. It can withstand considerable
abuse during installation.
Conductor : Stranded bare copper conductor conforms to ASTM Specification B-3 and B-8.
Insulation : A homogeneous wall of natural ECTFE fluoropolymer (HALAR) shall be extruded over the conductor.
Jacket : Insulation is high molecular weight polyethylene conforming to ASTM-D-1248, Type 1, Class C, Category 5,
Grades E5 & J1. Tensile Strengths Jl, J3.
Available with high density polyethylene (Types II, III, IV) Class B and C (all colors). Surface printed. Custom printing available.
HALAR/HMWPE CABLE DATA
STANDARDS
Datasheet 2.6.6 6/8/08 13:31 Page 1
CABLE HALAR/HMWPE
REVISION 1
DATASHEET
2.6.6
CABLE DATA
Size
#8
#6
#4
#2
No. of
Strands
7
7
7
7
Circular
Mils
16,510
26,240
41,740
66,360
AWG
Diameter
Inches
.142
.179
.225
.283
HALAR
Thickness
Inches
.020
.020
.020
.020
HMWPE
Thickness
Inches
.065
.065
.065
.065
Nominal
Diameter
Inches
.32
.36
.41
.46
Weight
Lbs per
1000 ft
81
116
170
254
DC Ohms
per Mft
at 20 C
.652
.411
.258
.162
Specifications for HALAR/HMWPE Cathodic Protection Cable
This specification describes a special single conductor size 8 AWG-2 AWG, HALAR insulated, High Molecular Weight
Polyethylene jacketed cable designed for use as a direct burial feeder in deep anode ground-bed cathodic protection
systems. The cable is ideally suited for use in harsh chemical environments involving brackish water, sour gas, chlorine,
acids, alkalis, and petroleum based solvents. The cable is suitable for use at voltages up to 600 volts ac or dc.
Applicable Standards (The following standards form a part of this specification to the extent specified herein:)
ASTM Specification B 3, latest edition, for Soft or Annealed Copper Wire
ASTM Specification B 8, latest edition, for Concentric-Lay Stranded Copper Conductors
ASTM Specification D 1248, latest edition, for Polyethylene Plastics Molding and Extrusion Materials.
ICEA Standard S-61-402/NEMA Standard WC5 for Thermoplastics Insulated Wire and Cable
Conductor
The copper conductor shall be Class B stranded, compressed, annealed, uncoated cooper in accordance with ASTM B 3
and B 8
Insulation : The conductor shall be insulated with an extruded layer of natural HALAR ECTFE fluoropolymer as a primary
insulation. The average thickness shall be 20 mils. The minimum thickness at any point shall be not less than 90% of
the specified average thickness. The insulation shall be applied tightly to the conductor and shall be free-stripping.
Jacket : A black High Molecular Weight Polyethylene jacket having both insulating and jacketing properties shall be
extruded over the primary insulation. The jacket, before extrusion, shall comply with the physical and electrical
requirements of ASTM Specification D 1248 for Type1, Class C, Category 5, Grade E-5 and J-1 material.
The average jacket thickness shall be 65 mils. The minimum thickness shall be not less than 80% of the specified
average thickness.
Identification : The cable shall be surface ink printed with: "Conductor Size AWG, CU, Manufacturer, HALAR/HMWPE
CATHODIC PROTECTION CABLE".
Tests : The completed cable shall be tested in accordance with the requirements of ICEA S-61-402, Part 6.
Datasheet 2.6.6 6/8/08 13:31 Page 2
CABLE HMWPE
REVISION 1
DATASHEET
2.6.7
APPLICATION
Surface wiring & buried if protected by clean sand. Suitable for use as anode cable tails, positive feed cable, negative
return cable and test cable.
The cable utilized in cathodic protection systems is a critical component of any cathodic protection system. The industry
standard cable for direct burial is a stranded copper conductor covered with an insulation of high molecular weight
polyethylene (HMWPE). The thick insulation provides both electric isolation and mechanical protection. During installation,
this cable can withstand considerable mechanical abuse without compromising the conductor. The HMWPE insulation is
chemically resistant and protects against most organic and inorganic substances.
STANDARDS
Conductor : Stranded copper conductor conforms to ASTM Specification B-8.
Insulation : Insulation is high molecular weight polyethylene conforming to ASTM D-1248, Type 1, Class A, Category 5,
Grades E4 & E5. Tensile Strengths Jl, J3. Available with high density polyethylene (Types II, III, IV) Class B & C (all colors).
Tests : The completed cable shall be tested in accordance with the requirements of ICEA Pub. No. S-61-402, Part 6.
INSULATION
THICKNESS
NOMINAL O.D. NUMBER OF
STRANDS
AWG
mm
2
Inches mm No Inches mm
14 2.5 0.11 2.794 7 0.299 7.59
12 4 0.11 2.794 7 0.31 7.87
10 6 0.11 2.794 7 0.34 8.64
8 10 0.11 2.794 7 0.36 9.14
6 16 0.11 2.794 7 0.41 10.41
4 25 0.11 2.794 7 0.46 11.68
2 35 0.11 2.794 7 0.52 13.21
1 45 0.125 3.175 19 0.59 14.99
1/0 50 0.125 3.175 19 0.63 16
2/0 70 0.125 3.175 19 0.67 17.02
4/0 120 0.125 3.175 19 0.78 19.82
WIRE SIZE NOMINAL OD
HMWPE CABLE DATA
STANDARD SIZE AND DATA
Datasheet 2.6.7 6/8/08 13:31 Page 1
VENT PIPE
REVISION 1
DATASHEET
2.6.8
APPLICATION
Deep well groundbeds, undertank systems.
1" PVC SCHEDULE 80 PIPE
Schedule 80 is available in grey and is for socket or threaded fittings. It has a wide variety of uses in the chemical field
and resistance, also in industrial plants. PVC material is Type 1 according to the American Society for Testing Material
D-1784. Pipe is round and smooth on the inside and out, resistant to cracking, and made from premium virgin PVC resin.
Sch. 80 socket fitting ASTM D-2467. Pipe- ASTM D-1785.
SOLID PIPE
Standard lengths: 3m
Wall thickness: 4.5mm
Diameter ID: 24.0mm
OD: 33mm
PERFORATED PIPE
Standard lengths: 3m
Wall thickness: 4.5mm
Diameter ID: 24.0mm
OD: 33mm
Perforations: 1mm slots x 32mm long, Slotted on alternate sides @ 40mm spacing
Screen: Monofilament Braided
COUPLER/SOCKET
1 Plain socket for glued connection of pipes.
END CAP
1 End cap to seal bottom of vent pipe.
Datasheet 2.6.8 6/8/08 13:32 Page 1
CASING PIPE
REVISION 1
DATASHEET
2.6.9
APPLICATION
These uPVC casings are ideal for the installation of open hole deep well groundbeds in areas where a static water level
can be reached. This also allows for the retrieval and replacement of anodes strings at the end of their life.
Casings are supplied with threaded joints for convenient on-site assembly
CASING PIPES DATA
CASING (SOLID)
Casing Material : PVC DIN4925
Notch Impact @ 200C : 4.5 + 0.5kJ/m2
Elasticity Coefficient : 2943 N/mm2
Tensile Strength : 45-55N/mm2
Thread : DIN 4925 Part 2 Table 4, Trapezoidal Without O Ring
Diameter : 225mm (246mm At Internally Threaded End)
Wall Thickness : 13mm
Pipe Length : Overall Length 5775mm (+35 / -10mm Tolerance)
Effective Length 5700mm (+35 / -10mm Tolerance)
SCREEN (SLOTTED)
Material Spec as above
Slot Width : 3mm Width Slots
Open Area : 20% Of Slottable Outside Diameter Of Pipe.
Slot Ends : Rounded
Mesh : Woven Polyethylene Filter Mesh To 300 Micron Sieve Analysis
Fitted Over Slotted Section Protected By Heavy Duty PE Outer
PE Outer Mesh & Secured At Ends By Heat Shrink Tape.
ACCESSORIES
Wooden casing clamps
Sump Pipes
Centralisers
Lifting hoists
End Caps
Datasheet 2.6.9 7/8/08 13:47 Page 1
CASING PIPE
REVISION 1
DATASHEET
2.6.9
OUTLINE DRAWING OF CASING / SCREEN PIPES
Datasheet 2.6.9 7/8/08 13:47 Page 2
SPLICE KITS
REVISION 1
DATASHEET
2.6.10
APPLICATION
Onshore and Marine
SPLICE KIT DATA
Suitable for plastic or rubber insulated cables 600/1000 V (without armour).
FEATURES
Strong clear plastic mould body with Snaplock connection for tight seal.
Stepped cable entry cut-off points for all cable diameters.
Large mould shell enables crimp or split bolt / line tap connectors to be used.
Resin 2-year shelf life.
APPLICATIONS
Used on Cathodic Protection applications including pipelines, tanks and buried structures.
Ideal for single core unarmoured Tee or Branch jointing rated up to 1kV, above or below ground. To suit mains
cable single core max size up to 95 sq mm. Branch single core up to 35 sq mm.
RESIN SEALING COMPOUND
Resin sealing compound is suitable for all climate conditions.
High quality resin sealing compound has a high resistance to moisture absorption, is mixed in a clear pack and
stored in an aluminium protective bag.
The long-term electrical properties of resin sealing compound result in a more reliable connection without any
associated maintenance costs.
MAJOR USERS
Specified by leading oil, gas and water companies and consulting engineers.
QUALITY
Designed to meet the requirements of BS 7888:1998.
Datasheet 2.6.10 6/8/08 13:33 Page 1
SPLICE KITS
REVISION 1
DATASHEET
2.6.10
RESIN PACK
FEATURES
The pack has been specifically designed and fabricated to offer the user a quick, clean and efficient method of mixing
and pouring.
The pack consists of a two part polyurethane resin correctly proportioned into pouches separated by a divider.
The user simply breaks the divider, amalgamates the two components and pours.
Dual system of packaging ensures that the pack is sealed against the atmosphere.
The outer aluminium packaging provides added protection against the atmosphere to give a shelf life of 2 years.
The inner transparent plastic packaging provides a visible reference for the user when mixing.
During mixing the user does not come into contact with the resin but gloves are provided for extra safety.
Each pack has its own unique batch number and use by date to provide an easy reference for the user.
Full safety labelling.
Controlled curing temperature designed to be compatible with PVC, XLPE, EPR, polythene and PILC cables.
Odour free.
Detailed storage instructions.
No special labelling required for transportation by road, sea or air.
Designed to meet requirements of BS 7888-3:1998 and CENELEC HD623 S1
Datasheet 2.6.10 6/8/08 13:33 Page 2
SPLICE KITS
REVISION 1
DATASHEET
2.6.10
TECHNICAL PROPERTIES
Resin Hardener Mixed
Colour Black Brown Black
Specific gravity (gm/cubic cm) 1.58 1.23 1.51
Viscosity (poise) 70-100 1-2 50-60
Gelation time 20-30 minutes 200 gram mass @ 21C
Full cure 24 hours @ 23C / 1 hour @ 80C
Shelf life 2 years (24 months) when stored between 10-25C. Packaging must remain intact.
Peak exotherm 75.2C based on 5 ltr placed in a container 200mm diameter conditioned at 21C.
Measurements taken at 5 minute intervals at the centre of the resin mass.
Thermal conductivity 0.46 w/mk
Tensile strength 47 Mpa
Shore hardness 80 A
Elongation 40%
Dialectric strength (solid) Greater than 5 MV/m
Operating temperature Provided resin is mixed correctly based on a static environment with gradual rise and
fall in temperature is -40C to +110C.
TYPE
PC5581
PC5581
PC5581
PC5581
PC5581
PC5581
PC5581
USABLE VOLUME OF PACK
200ml
450ml
500ml
1000ml
1200ml
1500ml
2000ml
HEALTH & SAFETY
Each pack contains mixing instructions and carries health and safety warnings in accordance with BS 7888:1998.
MIXING DETAILS
Datasheet 2.6.10 6/8/08 13:33 Page 3
SPLICE KITS
REVISION 1
DATASHEET
2.6.10
CABLE CONNECTORS
Datasheet 2.6.10 6/8/08 13:33 Page 4
In remote areas, providing AC power for impressed current cathodic protection systems can be
a major constraint. Solar electricity is a solution to this problem.
Solar generators provide a reliable and low maintenance source of power that can
be used for cathodic protection.
The control equipment is an integral part to the reliability and performance of the Solar
generator. We use world leaders in the design, manufacture and supply of
these controls to cover an extensive range of requirements. The CP controller
utilises high-speed pulse width modulated switching technology to ensure the
highest conversion efficiency fully maximising the power from the SGU.
The controller which is a DC-DC converter is suitable for connection to 12, 24 or 48Volt DC
systems with output current options of 25A and 50A. The controller is capable of controlling the
power delivered to the load to a maximum of 1V below
the input voltage.
CONTROLLER FEATURES
Control - Operating parameters are set by multi-turn controls with LED and volt free contacts for indication of control mode
Constant Output Voltage Mode
Constant Output Current Mode
Constant Reference Electrode Voltage
Low Current Alarm LED and Volt-Free Contacts
High Current Alarm LED and Volt-Free Contacts
Crystal Controlled Interrupt Timer (1-999 seconds ON and 1-999 seconds OFF)
Output Circuit Breaker to protect the unit and allow the user to isolate the output.
METERING & DISPLAY VIA LCD DISPLAY
Voltage Set Point
Output Voltage
Current Set Point
Output Current
Reference Electrode Set Point
Reference Electrode Voltage
Low Current Alarm Set Point
High Current Alarm Set Point
TERMINATIONS
2 Power Input Terminals (M8 Studs)
Positive and Negative Output Terminals (M8 Studs)
2 Input Terminals to connect the Reference Electrode/Pipeline with an input impedance of 1M
ENCLOSURE
Stainless Steel to IP66 as defined in BS EN 60529:1992 (alternatives available)
Dimensions: 600H x 400W x 200D (mm)
OUTPUT
Voltage to within 1Volt of the Battery Voltage
Current to the Maximum stated
Output Resistance 0.25
SOLAR POWER UNITS
REVISION 1
DATASHEET
2.6.11
APPLICATION
Onshore pipelines and plant in safe and hazardous areas.
SOLAR GENERATING UNIT DATA
Datasheet 2.6.11 6/8/08 13:34 Page 1
SOLAR POWER UNTIS
REVISION 1
DATASHEET
2.6.11
ENVIRONMENT
The controller will operate in the following conditions:
99% relative Humidity
-100 to +550C Ambient Temperature
REMOTE MONITORING & CONTROL
Optional Remote Monitoring
Optional Remote Control
Optional Radio Synchronisation of Interrupt Timer
Optional RS 232 Port
SOLAR ARRAYS
SOLAR ARRAY FEATURES
We offer a wide range of different solar array types to meet the specific application and
site where they are intended to be used. Solar modules are usually the traditional mono-
crystalline cells but other high density cells are also available. The mono-crystalline solar
cells deliver maximum power even under reduced light conditions. All modules are
assembled into robust weatherproof sub-arrays including cabling.
Mono-crystalline solar cells deliver maximum power even under reduced light conditions
Dense packing of cells provides more power where space is a limitation and creates a
uniform aesthetic
Tight electrical specifications guarantee industry leading energy yield performance
Highly transparent tempered glass delivers more power and ensures high impact
resistance and protection against hail, snow, ice and storms
Long and reliable service life backed by a 25 year warranty.
BATTERIES
MAIN CHARACTERISTICS
The batteries we offer are Dryfit type which are sealed, maintenance free lead acid batteries.
It is no longer necessary to refill with water.
Lead Acid System
Sealed Units
Rechargable
Maintenance Free
Pb-Ca-Sn Alloy
Immobilised Gel Electrolyte (preventing acid layer formation)
Extremely Economical and Efficient
Datasheet 2.6.11 6/8/08 13:34 Page 2

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