Beruflich Dokumente
Kultur Dokumente
Abstract
This section covers sacrificial anode and impressed current cathodic protection
systems for the underside of tank bottoms. It discusses soil tests, foundation types,
design parameters, and cost analysis. Step-by-step design examples are given for
protecting single tanks, and larger systems that protect many tanks are discussed
briefly. (For very large systems, a cathodic protection contractor should be
consulted.) Retrofits for existing tanks are discussed, along with their limitations.
The ETD Materials Division or Mechanical and Electrical Systems Division can
provide additional support. Discussions of the corrosion mechanisms and whether or
not cathodic protection is needed can be found in Section 720 of this manual and in
the Tank Manual. Internal cathodic protection of tanks is discussed in Section 1600
of this manual.
Contents
Page
1300-3
1300-3
1300-6
1300-9
Chevron Corporation
1300-1
August 1999
1300-12
August 1999
1300-26
1300-26
1380 References
1300-26
1300-2
Chevron Corporation
Corrosion Activity
0-2,000
severe
2000-10,000
moderate
10,000-30,000
mild
>30,000
unlikely
For existing tanks, resistivity tests should be performed at a minimum of four locations around each tank at depths of 5 feet and 10 feet (Figure 1300-2). This can be
done using the Wenner four-pin method described in Section 1700. Tests should be
Chevron Corporation
1300-3
August 1999
August 1999
Fig. 1300-1 Flow Diagram for Design of External Cathodic Protection for Tank Bottoms
1300-4
Chevron Corporation
performed during the wet periods of the year. If tests cannot be performed during
wet periods, soil samples should be taken for analysis.
For new tanks with sand or special backfill material the resistivity of the backfill
should be measured using soil boxes in the as found and saturated states, and a
soil analysis of the backfill should be performed as described in Section 1700. For
new tanks with a membrane, resistivities should be measured, but a soil analysis is
not required.
Chevron Corporation
1300-5
August 1999
Corrosive
Very Corrosive
pH
5.0 - 6.5
<5.0
Chlorides
>300 ppm
>1000 ppm
Sulfates
>1000 ppm
>5000 ppm
August 1999
1300-6
Chevron Corporation
Chevron Corporation
1300-7
August 1999
August 1999
1300-8
Chevron Corporation
Limitations
Chevron Corporation
1300-9
August 1999
Practical only for small tanks (typically less than 40 feet in diameter)
Limitations
Various design parameters and site information are necessary to design the system,
including design current densities, design life of the structure and cathodic protection system, soil resistivity, tank configuration, and adjacent foreign structures.
August 1999
1300-10
Chevron Corporation
perimeter of the tank. Depending on the current required, the power source can vary
from a 12-volt storage battery to a 300-amp welding unit. Factors affecting current
requirement tests include the following:
Chevron Corporation
1300-11
August 1999
August 1999
1300-12
Chevron Corporation
Driving Voltage E,
Volts
Theoretical
Actual
% Efficiency
Magnesium
8.75
17.5
50
0.9(2)
0.7(3)
Zinc
23.5
25.8
90
0.25
Aluminum
6.46
7.08.0
90
0.25
Galvanic
Impressed
Durichlor 51
0.251.0
Graphite
0.52.0
(1) These values are for anodes surrounded by select backfill materials.
(2) Galvomag Alloy
(3) H-1 Alloy
Predesign phase. During the predesign phase (See Section 1320), basic information is obtained on the structure and its environment through field tests of
soil resistivity, potential measurements, soil analysis, etc., and through evaluation of the corrosion control performance of other installations in the general
area. The predesign phase determines the viability of cathodic protection as a
means of corrosion control.
Design phase. In the design phase cathodic protection system components are
selected. Initial iterations in the design phase are tentative. Technical and
economical life cycle costs are then calculated for the system components, and
the various alternatives are compared. Following design analysis, plans and
specifications are developed. The system is then installed.
Chevron Corporation
1.
2.
1300-13
August 1999
3.
Use soil resistivity data and current requirements for determining size and
number of anodes.
a.
b.
Impressed
Resistivity >5,000 ohm-cm
Current requirements >1.0 A
4.
5.
6.
7.
8.
9.
Conduct soil resistivity tests on sand/backfill foundation material for anode bed
design.
2.
3.
4.
5.
6.
7.
8.
9.
The following two simple examples illustrate the fundamentals of the cathodic
protection design procedure for tank bottoms. The formulas and considerations
required for complex system design are beyond the scope of this manual. Where
necessary, the references listed will explain the design formulas.
August 1999
1300-14
Chevron Corporation
Current Requirements
Current requirement tests were performed and the estimated current to provide
protection is 1.0 ampere. If current requirements were calculated using a current
density of 2.0 mA/ft2 the estimated current would be 1.41 amperes.
Ground Bed Resistance. Having determined current requirements from field
testing we next calculate a maximum allowable ground bed resistance. The total
series equivalent electric circuit must be considered (see Figure 1300-8). Kirchoffs
Voltage Law can be used to develop a relationship for estimating total circuit
resistance.
Ea Ec
I = --------------------------------R a + Rw + Rc
E
= ------Rt
(Eq. 1300-1)
where:
I = current required for cathodic protection, amps
Ea = anode-to-electrolyte (soil) open circuit potential, volts
(Figure 1300-8)
Ec = structure-to-electrolyte (soil) polarized potential, volts
(Figure 1300-8)
Ra = anode-to-electrolyte (soil) resistance, ohms
Rt = maximum ground bed resistance, ohms
Rw = anode lead wire resistance, ohms
Rc = structure-to-electrolyte (soil) resistance, ohms
E = driving voltage, volts
Another expression of Equation 1300-1 is:
E
R t = ------I
For this example a 32-pound prepackaged high potential magnesium anode has been
selected for the design. The driving voltage E for this anode is 0.9 volts (see
Figure 1300-7).
Chevron Corporation
1300-15
August 1999
So, using Equation 1300-2, the maximum permissible resistance Rt for 1.0 amps is:
0.9
Rt = ------- = 0.9 ohm
1.0
(Eq. 1300-2)
For galvanic cathodic protection the anode lead wire resistance (Rw) is usually small
and can be neglected. The structure-to-electrolyte resistance for uncoated structures
is also so small it can be neglected. Hence, for most cases Rt = Ra.
Fig. 1300-8 Cathodic Protection Equivalent Electric Current
Number of Anodes
The ground bed resistance of single and multiple anodes in parallel has been derived
by Dwight [2]. These equations can be used to determine the number of anodes
required to satisfy the maximum allowable ground bed resistance. In simplified
form, the resistance of one anode (R1) or of any number of vertically-placed anodes
(Rn) can be calculated using the following equations:
8L
0.0052
R 1 = -------------------- ln ------ 1
d
L
(Eq. 1300-3)
August 1999
1300-16
Chevron Corporation
0.0052
8L
2L
R n = -------------------- ln ------ 1 + ------- ln ( 0.656n )
nL
d
S
(Eq. 1300-4)
where:
= soil resistivity, ohm-cm
L = length of backfill column, ft (see Figure 1300-9)
d = diameter of backfill, ft (see Figure 1300-9)
Rn = combined resistance of n anodes, ohms
n = number of anodes
S = center-to-center spacing between anodes, ft
Equation 1300-5 is a simplified form of Equation 1300-4 and can be used if S is
greater than 6L and n is less than 15. If S is not greater than 6L or n is not less than
15, then Equation 1300-5 must be used.
8L
0.0052
n = -------------------- ln ------- 1
d
Rn L
(Eq. 1300-5)
From Figure 1300-9, The maximum ground bed resistance Rn is 0.9 ohm. Therefore, the number of anodes required for the system is:
8 ( 1.91 )
0.0052 ( 1800 )
n = --------------------------------- ln ------------------ 1
0.667
0.9 ( 1.91 )
=11.6 anodes (use 12)
It follows that twelve 32-pound high potential magnesium anodes are required to
keep total circuit resistance below 0.9 ohms. Once the number of anodes required
for current output has been determined we then must determine if the anodes will
provide the required design life, 20 years in this case.
Wn
D = --------QI a
(Eq. 1300-6)
where:
D = design life, years
W = weight of anode, lb. Use 32 lb (from Figure 1300-9).
n = number of anodes. Use 12.
Q = actual consumption rate, lb/amp-yr. Use 17.5 (from
Figure 1300-7).
Chevron Corporation
1300-17
August 1999
August 1999
1300-18
Chevron Corporation
These calculations show that a design utilizing twelve 32-lb magnesium anodes will
provide the desired current output for the proposed 20-year design life. If the design
life (L) is not met the engineer would rearrange Equation 1300-6 and solve for n to
achieve 20-year life. Lives for various sizes of magnesium anodes are shown as a
function of current output in Figure 1300-10.
The engineer must now produce design drawings (Figure 1300-4) and specifications for equipment. An engineering cost analysis is developed later in this section.
Fig. 1300-10 Magnesium Anode Life Versus Current Output
Chevron Corporation
1300-19
August 1999
(8)(7 )
ln ---------------- 1
0.833
= 0.429 ohms
Equation 1300-3
August 1999
1300-20
Chevron Corporation
where:
I = 8.32 amperes
Rt = Rn = 0.429 ohm
then:
V = (8.32)(0.429) = 3.57 volts
Therefore, the minimum rectifier output to provide adequate current and voltage is a
3.57-volt, 8.32-ampere unit. Other resistances, such as cable resistance (Rw), have
not been considered and should be determined in the final analysis. Whenever
possible, the rectifier rating should be determined by test after the ground bed is
installed. See Figure 1700-10.
Fig. 1300-11 Graphite Anode Dimensions and Shipping Weights (For reference only. Consult the anode manufacturer
for specific instructions.)
Figure 1300-4 shows a typical layout drawing with anodes placed around the perimeter of the tank 10 feet from the outside wall. The drawing also shows a No. 8
HMW/PE cable connecting the anodes around the perimeter. The calculated length
of No. 8 cable around the perimeter is approximately 380 feet. The resistance of
No. 8 cable is 0.000822 ohm/ft (See Figure 1300-12), resulting in a resistance (R)
equal to 0.312 ohms.
Chevron Corporation
1300-21
August 1999
Since the cable is looped and both ends terminate at the rectifier the actual resistance is R/2 or 0.156 ohms. If the cable resistance is added to R the total circuit
resistance is 0.585 ohm. Therefore, the new voltage requirement is 4.87 volts.
Sizes for various rectifiers can be obtained from manufacturers catalogues. Standard rectifiers are available in various outputs. The type of rectifier (i.e., air-cooled,
oil-cooled, explosion-proof) must be determined for cost analysis.
For the impressed current system a standard 8-volt, 12-ampere rectifier powering
ten graphite anodes with coke breeze backfill, placed vertically around the tank
perimeter should provide the necessary design life. A conceptual drawing of a
typical installation is shown in Figure 1300-4.
High-silicon cast iron anodes could also be used for this installation. Design information is given in Figure 1300-13.
August 1999
1300-22
Chevron Corporation
Chevron Corporation
1300-23
August 1999
The steel bottom surface area is 7854 ft2. Using a design current density of
2.0 mA/ft2 the estimate current required for cathodic protection is 15.7 amperes.
The anode in this design is a circular plate of 1/8-inch steel. Steel plate 1/8-inch
thick is much thicker than required, but is used to withstand construction vehicle
traffic during placement of backfill.
The resistance of the anode placed in this environment can be calculated using
Equation 1300-8.
t ( 0.002734 )
R = --------------------------------- + 0.10
A
(Eq. 1300-8)
where:
R = resistance of soil backfill
= soil resistivity, ohm-cm. Use 50,000 (given measurement).
t = thickness of backfill, in. Use 6 (assumed in this example. See
actual foundation design).
A = area of tank to be protected, ft2. Use 7854.
Note 0.1 ohm is used to compensate for resistance between anode and soil, resistance between tank bottom and soil, and cable resistances.
then:
( 50, 000 ) ( 6 ) ( 0.002734 )
R = ---------------------------------------------------------- = 0.204 ohms
7854
Now the rectifier voltage can be calculated using Equation 1300-7:
V = IRt = 15.7 (0.204) = 3.21 volts
Therefore the minimum rectifier output to provide adequate current and voltage is
3.21 volts at 15.7 amps. A cost analysis is provided later in this section.
August 1999
1300-24
Chevron Corporation
be placed into a deep well. Typically, 15 anodes is the upper limit for each well. See
Section 1200 for further discussion of deep-well ground beds.
Fig. 1300-14 Deep - Well Anode
The designer should be aware of subsurface geological strata in the area where the
deep-well anode is to be located. Areas having surface strata of high resistivity and
deeper strata of low resistivity (where the anodes are to be placed) may cause
shielding of the current from the deep anode to the steel tank bottom. See
Figure 1300-12. The design of deep-well anode systems requires more detailed
analysis than is presented in this manual.
Chevron Corporation
1300-25
August 1999
1380 References
August 1999
1.
Corrosion Control. Air Force Manual No. AFM88-9. United States Air Force,
1962.
2.
3.
1300-26
Chevron Corporation
Unit
Total
$102.00/ea.
$1,250.00
12 - Splice Kits
$25.00/ea.
$300.00
1 - Test Station
$18.00/ea.
$20.00
$0.25/ft.
$50.00
$80.00/ea.
$1000.00
$3.00/ft.
$600.00
$3,220.00
Maintenance Inspection
(1 manhour/month) x (12 months/year) x ($25.00/manhour) =
$300.00/yr
$200.00/yr
Unit
Total
$132.00/ea
$1,320.00
$560.00/ea.
$560.00
10 - Splice Kits
$25.00/ea.
$250.00
$0.25/ft.
$100.00
$80.00/ea.
$800.00
$3.00/ft.
$1,191.00
$4,200.25
Maintenance Inspection
$300.00/yr
$200.00/yr
Chevron Corporation
$15/yr
1300-27
August 1999
Unit
Total
$1.53/ft.2
$11,300.00
$0.25/ft.
$75.00
4 - Cadweld connections
$10.00/ea.
$40.00
$1000.00/ea.
$1,000.00
$200.00/400 ft.2
$3,695.00
$6.50/ft.
$1,950.00
4 - Cadweld connections
$50.00/ea.
$200.00
1 - Rectifier
$500.00/ea.
$500.00
7390 ft.
$18,766.00
Maintenance Inspection
$300.00/yr
$200.00/yr
$35.04/yr
August 1999
1300-28
Chevron Corporation