Cathodic Protection RP 651 Sand Pads, Inspections and Pitfalls

Louis Koszewski US Tank Protectors

API 651 Rev. 3 January 2007 Rev

New Tank foundation/RW construction Sand Pad Material Sand Pad Construction Inspection of Sand Pad and CP p

New Foundations slabs

NEC 501 REV. 2008 REV
Rebar in the concrete ringwalls and slabs must be bonded into electrical grounding system.

Will cause galvanic couple Rebar /Tank Become a significant draw to the CP
system t Shielding or De-coupling of the rebar Deshould be considered.

Sand Pad
Chemical and Electrical Properties of Sand
Values listed are from solution Sand pad is not a solution

Resistivity Measures the dissolved salts

ASTM G57 Wenner 4 pin method Samples measured as received Samples measured after saturation ASHTO Extracts /washes out contaminants

Sand Pad
pH very time sensitive
pH < 4.5 very corrosive to steel p y

Chlorides -10 PPM or less

Depolarizer

Sulfate > 200 PPM organic matter S lfid reduced sulfate by bacteria Sulfide d d lf t b b t i Sand should be tested at the source

Sand Pad Construction

Section 5.3.2.2 Discussing new tank pad
(b) Sand is often installed by loose lifts in ( ) y maximum layering of 6 8 thickness..

Does not mean minimum sand pad to be p

6 or more. Refers to compaction of the sand pad to be 6 8 between lifts.

12 12 Sand Pad
7.2.4.3 General concerns in this section
Less than 12 successful operation and p monitoring shorting out of anodes.

Installing plastic mesh (rock shield) will gp ( )

solve shorting problems. Consider the cost of extra sand vs. cost of plastic mesh over anodes. Consider spacing anodes closer together. together

Inspection Testing & p g Maintenance of CP Facilities

11.3.2.5
Examination for bottom-side corrosion may bottomy be achieved by making coupon cutouts..

11.3.2.6
Repair, replacement or adjustment of CP Provide supplemental CP Reference cell replacement

Great opportunity to inspect the Pad & CP

Inspection Testing & p g Maintenance of CP Facilities

Why Spend the time to inspect Pad & CP?
You wont have the opportunity for 10 yrs. pp y y Internal inspections show overall corrosion Corrosion is usually averaged over time Corrosion may have just started p y Sand pad may have become contaminated Confirms the chemical and electrical Properties of the sand pad Only requires a few hours to complete

What Information Will I Need To Perform ECDA?

Internal inspection report Tank bottom construction plans
Cone up/down

Tank Pad specifications

Previous tank pad electrical/ chemical tests

CP system design/configuration t d i / fi ti
Anode configuration sizes/ratings (if present) CP operating reports

What Equipment Will I Need?

Tank crew (1-2 men) (1 Cut sample coupons (holes or patches)

Soil resistivity meter (soil box)

Distilled water (high resistivity) ( g y)

2 good locations 2 corroded locations (if present)

pH paper or test kit SRB test kit Soil sample jars (bags) S il l j (b ) Very High Impedance voltmeter & Cell
Meter > 20 M M

Tank Pad Electrical / Chemical Test

NACE RP0502 Has testing procedures Tank Pad Resistivity Static, Saturated
Use high resistivity distilled water Soil box 4 pin method in some cases

pH pH paper or field test kit SRB test kit Send samples to lab for verification p

Anode Testing
Sacrificial Systems
Visual test color, shape, % corrosion Check anode/cable connection Anode potential Anode end effect / Attenuation

Impressed Current Anodes

Visual Anode potential Anode end effect / Attenuation

Ohio Tank
90 Diameter Flat bottom Gasoline Service Bottom Failure 4 years of service Zinc anode system No cathodic protection reports Sand pad with no chemical/electrical
reports

Ohio Results
Poor sand pad used Poor electrical connections Owner decided to install new clean sand

with good electrical /chemical properties properties, and properly connect the sacrificial anodes Next Inspection 10 years

Illinois Tank
200 diameter Hot service 200 F 200 Bottom Failure 3 years Zinc anode system No CP reports No Sand pad electrical/chemical tests

Illinois Results
Poor sand pad used Improper anode selection Owner decided to:
Install new bottom with RPB IC system High temperature

N t iinspection 10 years Next ti

Florida Tank #1

100 Diameter Gasoline Service Minor corrosion 10 years service Impressed Current MMO Loop system Annual CP reports Silica sand Sand tests
pH 7.4 Chlorides 8 PPM Sulfides <.1 PPM Resistivity 146,000 -CM (dry)

38,000 -CM saturated

Florida #1 Results
Very good sand pad used Very good IC System Patches where no contact and return to
service Next Inspection 10 years

Florida Tank #2

90 Diamter Gasoline Service Minor corrosion 10 year inspection Zinc anodes Annual CP reports Silica sand Sand tests
pH 8.4 Chlorides 28 PPM Sulfides <.1 PPM Resistivity 864,000 -CM (dry)

136,000 -CM saturated

Florida #2 Results
Very Good Sand Pad Used Effective CP System Installed patch plates and returned to
service Next Inspection 10 years

New Jersey Tank y

120 Diameter Gasoline Service 10 year inspection minor corrosion Tank leaked 2 years after placed back in service Zinc Anode system CP Annual surveys y No sand pad electrical/chemical tests

New Jersey Results

Good sand pad used Maybe? Poor CP system selection Owner decided to:
Replace tank bottom with RPB Install IC system Anode attenuation Anode end effect Pad became contaminated with sea water

Conclusion
Causes of Tank Bottom Corrosion
No Cathodic Protection CP Not Connected Insufficient Current Applied Hot tanks
Sacrificial anodes Zinc anodes/hot tank Do not use Magnesium anodes in low resistivity tank pad,
rapid anode consumption

Conclusion
ECDA For Tank Bottoms Will:
D t i th cause(s) of past corrosion Determine the ( ) f t i
Determine the electrical/chemical tank pad condition

D t i th potentiall f f t corrosion on Determine the t ti for future i

the tank tested and like service tanks Confirm the condition of the CP (if present) Establishes a baseline for future inspections M t importantly - prevent very costly re-entry Most i t tl t tl re- t into the tank before the next internal inspection