Fundamentals

of
Cathodic Protection
David H. Kroon, P.E.
September, 2000
Corrpro Companies Inc.
For Every Corner of Your World

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How Cathodic
Protection Works

Corrosion occurs where

current discharges from metal
to electrolyte

The objective of cathodic

protection is to force the entire
surface to be cathodic to the
environment

Soil/Water/Tank Pad
Cathode

Anode
Tank

Cathodic Protection
introduces an external DC
current which makes the
entire structure a cathode.

Anode

Tank
Cathode

Anode
Cathode

Cathodic Protection Theory

Concept of Cathodic Protection
Current Requirements
Polarization
Reference Electrodes
Criteria for Cathodic Protection

Microscopic View of a
Corrosion Cell

Cathode

Anode

Microscopic Corrosion Cell on

the Surface of a Pipeline

Corrosion of the Metal Will Cease Once

the Applied Cathodic Protection Current
Equals the Corrosion Current

Cathode

Electrolyte

Metallic
Connection
Anode

Cathodic Protection
Current
Cathodic Protection Anode

Corrosion

3) ELECTROLYTE
4) METAL PATH

Ste el -6 00 m V

2) CATHODE

C opp er -3 00 m V

1) ANODE

1) ANODE

2) CATHODE

3) ELECTROLYTE

4) METAL PATH
M a gn e siu m -1.7V

Ste e l -6 00 m V

C op p er -3 00 m V

Corrosion

3) ELECTROLYTE
4) METAL PATH

M agn e sium -1.7V

2) CATHODE

Ste el -6 00m V

1) ANODE

C op per -3 00m V

Cathodic Protection

Cathodic Protection

4) METAL PATH

An od e

3) ELECTROLYTE

C atho d e

2) CATHODE

C atho d e

1) ANODE

Cathodic Protection
Current Requirements
Surface area to be protected
Polarization behavior of the structure
in its environment
Presence of barrier coatings

Coatings Reduce
Exposed Metal Area

Cathodic Protection Systems

Galvanic Anode
Impressed Current

Galvanic Anode
Cathodic Protection

Current is generated
from a metal at a higher
energy level.

Tank Floor

Soil
Wire
Anode

Galvanic Anode

Types of Galvanic Anodes

Magnesium

Zinc

Aluminum

Cast, Packaged and

Extruded Magnesium
Anodes

Magnesium Alloy Specifications

Element

High Potential

AZ 63 H-1 Alloy

Mg-Mn

Grade A

Grade B

Grade C

Al

0.010% Max

5.3 - 6.7%

5.3 - 6.7%

5.0 - 7.0%

Mn

0.50 - 1.30%

0.15% Min

0.15% Min

0.15% Min

Zn

.......

2.5 - 3.5%

2.5 - 3.5%

2.0 - 4.0%

Si

.......

0.10% Max

0.3% Max

0.3% Max

Cu

0.02% Max

0.02% Max

0.05% Max

0.1% Max

Ni

0.001% Max

0.002% Max

0.003% Max

0.003% Max

Fe

0.003% Max

0.003% Max

0.003% Max

0.003% Max

Other

0.05% each or 0.30% Max

0.30% Max
Total

0.30% Max

0.30% Max

Magnesium Anodes

-1750 mV to CSE
1.2 volt CP driving potential
High Potential Alloy
NOT AZ 63 or H-1 Alloy
550 amp-hours/pound
17 pounds/amp-year

Magnesium Anode

Anode Backfill
Material
75% gypsum
20% bentonite
5% sodium sulfate

Purpose
low resistivity (<50 ohm-cm)
absorbs water
uniform environment

Cast Zinc Hull, Ballast

Tank,
& Condenser Anodes

Zinc Soil & Ribbon

Anodes

Zinc Alloy Specifications

TM

Hi-AMP

Mil. Spec.

Element

Zinc

A-18001-H

Al

0.1 - 0.4%

Cd

0.025 0.06%

ASTM B-418-73
Type I

Type II

0.10 - 0.50% 0.10 - 0.50% 0.005% Max

0.025 0.15%

TM

HI-PURE
Zinc
.......

0.03 - 0.10% 0.003% Max 0.003% Max

Fe

0.005% Max 0.005% Max 0.005% Max

Pb

0.006% Max 0.006% Max 0.003% Max 0.003% Max 0.003% Max

0.0014%
Max

0.0014%
Max

Cu

............

0.005% Max

..........

...........

...........

Si

............

0.125% Max

..........

...........

...........

Zn

Remainder

Remainder

Remainder

Remainder

Remainder

Application

Seawater & brackish water

(Temp. <60 C)

Soil & fresh water

CP and ACIM

Zinc Anodes

-1100 mV to CSE
0.55 volt CP driving potential
ASTM 418, Type II
NOT Type I or Hi-Amp
354 amp-hours/pound
25 pounds/amp-year

Aluminum Anodes
Cast Aluminum Anodes

Aluminum Bracelet Anodes

Aluminum Anodes Offshore

Pipeline Bracelets

Aluminum Anodes

-1150 mV to CSE
0.60 volt CP driving potential
Aluminum-Zinc-Indium
For Salt and Brackish Water
1150 amp-hours/pound
7.6 pounds/amp-year

Impressed Current
Cathodic Protection (ICCP)
Current is generated from
a transformer-rectifier
energizing a relatively inert
ground electrode.

Impressed Current
Cathodic Protection System
Anodes
Rectifier
Wiring

ICCP Anodes

Graphite
Silicon Chromium Iron
Polymer Anode
Platinized Titanium/Niobium
MMO Coated Titanium

Three Primary Anode

Reactions
Metal Oxidation
M

M+ + e-

Oxygen Evolution
2H2O

O2 + 4H+ + 4e-

Chlorine Evolution
2Cl- Cl2 + 2e-

Graphite Anodes
Advantages
Performs well in coke
Best under dry conditions
Long history

Graphite Anodes
Disadvantages

Oxygen evolution increases consumption

Soft - erodes in flowing water
Brittle
Porous (treatment recommended)
End effects (center connections are advised)
Large size
Single U.S. manufacturer

Graphite Anodes

Silicon-Chromium-Iron Anodes
Advantages

Performs well in coke

Best under wet conditions
Can be installed without backfill
Acid resistant
Proven

Silicon-Chromium-Iron Anodes
Disadvantages

Poor performance in sulfates

Poor performance under dry conditions
Brittle
Large and heavy

Silicon-Chromium-Iron Tubulars

Conductive Polymer Anodes

Advantages
Easy installation
Good where continuous, distributed
anode is required
Light weight, easy to handle

Conductive Polymer Anodes

Disadvantages
Low surface current density limit
Limited to temperatures
below 66oC (150oF)

Lack of performance data

Polymer Anode

Platinized Titanium/Niobium
Advantages
Performs well with chlorine evolution
Proven in seawater
Size varies, light weight

Platinized Titanium/Niobium
Disadvantages

Performs poorly with oxygen evolution

Not recommended for underground use
Breakdown voltage cannot be exceeded
Attacked by low frequency ripple
Wear rate increases for deep anodes

Mixed Metal Oxide Anodes

Advantages

Fully oxidized surface

Low consumption rate
Resistant to acid attack
High performance characteristics
Size varies, light weight
Economic - low life cycle cost

Mixed Metal Oxide Anodes

Disadvantages
Somewhat higher first costs

MMO Anodes

MMO Tubular Anode

MMO Ribbon & Conductor Bar

ICCP Anode Installation

Importance of Sealed Splices

Tensioned
String
Anode (TSA)
System

Rectifier Schematic Diagram

AC Power Input
Step-Down
Transformer

AC Breaker Switch

Adjusting
Taps on
Secondary
Winding

Housing

Rectifying Stacks
+

Current Shunt
Output Voltmeter

To Structure

A
V

Output Ammeter
Grounding

+
To Anodes

Transformer-Rectifier

Wind Generator

Solar Power

Thermoelectric Generator

Engine Generator

System Characteristics
Galvanic

ICCCP

No external power

External power required

Fixed driving voltage

Voltage can be varied

Limited current

Current can be varied

Small current requirements

High current requirements

Used in lower resistivity Used in almost any

environment
Usually negligible
interference

resistivity environment
Must consider interference
with other structures

Cathodic Protection
Monitoring

Cathodic Protection
Monitoring
Read transformer-rectifiers every 60 days
Obtain potentials on both impressed
current and galvanic systems annually

DC Voltmeter & Ammeter

CP System Life
With the actual cathodic protection
current output recorded, the actual
system design life can be calculated

Structure-to-Soil
Potential Measurements
High Input Impedance Voltmeter
Copper/Copper Sulfate Reference Electrode
Underground and Fresh Water Applications
Silver/Silver Chloride Reference Electrode
Seawater Applications

Copper-Copper Sulfate
Reference Electrode
Copper Rod
Window

Porous Plug

Saturated Copper
Sulfate Solution
Copper Sulfate Crystals

Tank to Soil Potential Measurements

Polarization Decay Criterion

Coupon Test Stations

Cathodic Protection
Design Considerations

Safety
Codes
Economics
Performance
System Life
Interference
Monitoring
Maintenance

Water Tank Coating

Economics of Cathodic
Protection

Impressed Current System

Rectifier

(-)

(+)

Anodes
(Groundbed)

Pipeline
(Structure)
Current
Flow