Cathodic Protection

Cathodic Protection
ME 472-061 Corrosion Engineering I ME, KFUPM Dr. Zuhair M. Gasem
Dr. Z. Gasem ME 472-061 KFUPM
References:

ASM Handbook, vol 13, pp. 466-477 Corrosion for Science and Engineering, K.R. Trethewey and J. Chamberlain, chapter 16 Handbook of Corrosion Engineering, P.R. Roberge Cathodic Protection in ARAMCOs Engineering Encyclopedia
Anodic and Cathodic Reactions of Iron in Acids

Acid Solution
H+
H2 H+
Corrosion Cell on a Metal Surface

Anode
Fe2+
H
Fe2+
Cathode
H+
H+
H+
H+
e
Metal
Electron Flow
Basic Physics of CP of Iron in Acids
Electrons from an external source are forced to flow into the structure to be protected resulting in:

Increased cathodic reaction (2H+ + 2e- H2) Decreased anodic reaction and hence reduced corrosion rate
H+ H+
Electrolyte
H+ H Fe2+
H2
H2
H2 H+
H2
H+ H+
H H+
H H+
H H H+ H+
H+ H+
e e
H+ H+
e e
e ee e e e e e e e e
Electrons from external source
Polarization Principle of CP of Iron in Acids
Before CP:

ianode = icathode = icorr E = Ecorr icorr = ia icathode = ic iapp = ic ia E = ECP

ECP
After CP:

Polarization Principle of CP of Iron in Water
The cathodic reaction for corrosion of steel and iron in aerated-water is usually (O2+2H2O+2e4OH-) under concentration polarization. Before CP:

After CP:

ianode = icathode = iL E = Ecorr icorr = ia icathode = ic = iL iapp = ic ia E = ECP
ECP
Cathodic Protection
CP makes the structures potential more negative which promotes cathodic reactions and slows anodic reaction Increases icathode Decreases ianode Need to supply iapp = icathode - ianode
Summary of cathodic protection:

Where CP is used? CP is often applied to coated structures, with the coat providing the primary form of corrosion protection and the CP system acts as a supporting protection. The main applications of CP include: Buried pipeline Acids storage tanks Offshore steel structures such as platforms and oil rigs Ships Concrete structures exposed to seawater such as bridges
CP of Buried Pipelines
Before CP is applied:

Anodes and cathodes are on the same surface of the pipe The soil is the electrolyte Ionic current flow b/w the anode and the cathode in the external surfaces Electrons flow in the metal from anode to cathode
After CP is applied: The structure to be protected becomes the cathode The anode is an external electrode: Amore active metal (sacrificial anode) An inert anode with impressed DC current (Impressed current) The soil is the electrolyte Ionic current flow b/w the anode and the cathode in the external surfaces Electrons flow between the anode and cathode through an insulated copper wire.
e-
cathode
+ve ions current in electrolyte
Sacrificial anode
10
Sources of current

Sacrificial anode system Impressed current system (note the - polarity from the rectifier)
Electrochemical reaction in sacrificial Anode CP System
11
Cathodic reactions on the steel structure:

In aerated wet soil
In aerated wet acidic soil
O2+2H2O+4e- 4OH-
In neutral seawater
O2+4H+ + 4e- 2H2O O2+2H2O+4e- 4OH-
In de-aerated soil or water
Anode reactions
2H2O+2e- 2OH- +H2
At active anode in sacrificial anode CP system (Mg, Al, Zn)
M M+n + ne-
CP of pipelines
12
Note that cathodic protection current will only protect external surfaces on buried structures, because the anode-electrolytecathode is at external surfaces. Above ground, structures cannot be protected by cathodic protection because the current discharged from the current source can not travel through the atmosphere (no electrolyte). CP is not usually used to protect internal surfaces of pipelines because of difficulty in placing anodes. internal surfaces of pipelines can be protected by: inhibitors, coatings, or by using a corrosion resistant alloy.
Protection Criteria
13
How

much current is needed to protect the pipeline?

Little current will lead to ineffective protection High current will lead to disbonding of coatings and hydrogen embrittlement (more power consumption and higher cost) Experience show that we should keep the pipeline potential less than a protection potential.
Protection Criteria
14
In less corrosive soil, E< -0.850 mV wrt Cu/CuSO4 reference electrode this reference electrode is used because it is less sensitive to temperature variation (0.318 s. SHE) In Saudis Aramco, the protection potential for cross-country pipeline is -1.1 V vs Cu/CuSO4 (due to highly corrosive soil) More ve potential means more current required and more operation cost.
Reference Electrodes
reference electrodes used in CP
15
Common
Cu/CuSO4 in soil

CuSO4 + 2e- Cu+SO42E vs. SHE 0.318 V AgCl + e- Ag + ClE vs. SHE 0.222 V
AgCl in seawater

Potential Protection
16
Why <-0.850 mV vs. Cu/CuSO4? From Pourbaix diagram, Fe is stable below -0.6 V vs SHE Cu/CuSO4 is more +ve than SHE by 0.318 V Hence, Fe is stable and corrosion is minimum if potential is (-0.6-0.318= -0.918 V vs Cu/CuSO4)
Potential and Corrosion of Buried Steel Corrosion condition Intense corrosion Corrosion Slow corrosion Cathodic protection Overprotection
Severe overprotection (disbonding of coatings, hydrogen blistering, HE)
17
Potential (V vs. Cu/CuSO4)
-0.5 to -0.6 -0.6 to -0.7 -0.7 to -0.8 -0.8 to -0.9 -0.9 to -1.1 -1.1 to -1.4
NACE Standards for CP
18
Saudi Aramcos Potential Requirements

Structure Minimum Required Potentials
19
Buried Cross-Country Pipelines Buried Plant Piping, Tank Bottom Externals, Isolated Buried Casings Water Tank Interiors
-1.10 volts versus CuSO4 electrode. -1.00 volt versus CuSO4 electrode. -850 mV versus CuSO4 electrode.
-0.90 volts vs. AgCl electrode
Marine structures
-0.90 volt or more negative versus AgCl electrode
Soil Corrosivity
20
Soil is composed mainly of mineral particles (mainly SiO2). Soil is composed of a mixture of:

The soil particles are covered with thin surface film of moisture with dissolved salts and gases. The total volume of soil consists of solid particles and pores filled with moisture and air. Soils with a high proportion of sand have very limited storage capacity for water whereas clays are excellent in retaining water Air in the pores contains 10-20 times as much CO2 as atmospheric air. Soils with high moisture content, high electrical conductivity, high acidity, and high dissolved salts will be most corrosive.
Fine sand (0.02-0.2 mm) Coarse sand (0.2-2 mm) Slit (0.002-0.02 mm) Clay (< 0.002 mm)
Soil Corrosivity
21
Variables affecting soil corrosivity:

Water is the electrolyte for electrochemical corrosion reactions Oxygen: the oxygen concentration decreases with increasing depth of soil pH: soils usually have a pH range of 5-8

Soil acidity is produced by decomposition of acidic plants, industrial wastes, and acid rain Alkaline soils tend to have high sodium, potassium, magnesium and calcium contents which form calcareous deposits on buried structures with protective properties against corrosion.
Chloride level: harmful for metals sulfate level: harmful for concreter
Soil Corrosivity
Soil Corrosivit resistivity y Rating (ohm cm) >20,000 Essentially noncorrosive Mildly corrosive Moderately corrosive Corrosive Very corrosive Dry sand
22
For CP design against corrosion, the most important property of a soil in determining its corrosivity is its electrical conductivity. The table shows soil corrosion severity ratings. Soil corrosion causes corrosion in underground petroleum storage tanks, pipelines, and water distribution systems. Soil resistivity is measured by Wenner 4-pin method
10,000 to 20,000 5,000 to 10,000 1,000 to 5,000 <1,000
Clay with saline water (sabkha)
Soil Corrosivity Seawater Resistivity
23
Progressively Less Corrosive 10,000
Electrolyte
Resistivity (ohm-cm)
Mildly Corrosive
Seawater (Gulf) Raw water Drinking water
16 200-2000 2000-5000
2,000 1,000 500 Moderately Corrosive Corrosive Very Corrosive
Ohm-cm
Current density required to reach Ecp for steel in moving and standing seawater and in soil
24
ASM Handbook Vol#13 p.476
Environment
Bare Steel (mA/m2)
Coated steel (mA/m2)
Initial CP Applied Initial CP current CP current current
Applied CP current
Moving seawater Stagnant seawater soil
325375 160270 43-54
75-105 45-75 11-16
32-54 11-32 5.4-11
11-16 5-11 1.1-0.54
Current Calculation for Design
25
Given a coated offshore structure with a surface area of 5,000 m2, 2/3 is immersed in seawater, calculate the amount of initial current and applied current necessary to cathodically protect the structure. The initial and applied current density requirement for coated seawater structures is 35 and 10 mA/m2. iinitial = 5,000*2/3*35= 116,666 mA = 117 A iapplied = 5,000*2/3*10 = 33,333 mA = 34 A
Example
26
Given a 150 m section of 0.75 m diameter steel pipe coated with fusion bonded epoxy (FBE), calculate the total amount of current required. Assume that 10% of the coating was damaged during installation. Assume that the required current density for FBE coated buried pipeline is 0.1 mA/m2 while for uncoated steel is 1 mA/m2 . surface area = DL=354 m2 iinitial = bare area*1 mA/m2 + coated area*0.1 mA/m2 = 354*0.1*1 + 354*0.9*0.1 = 67.3 mA Note that if the whole pipe is not coated, then the current requirement would be = 354*1=354 mA (5 times more than above)
Coatings in CP Systems
27
Bare structures require more current than coated structures Economical applications of CP for buried pipelines applied only for coated pipelines. Always assume 5-10% of coated area as bare due to damage during pipe installation.
Sacrificial Anode CP Systems
28
a more active metal than steels can act as a sacrificial anode. The galvanic series indicate that Mg, Zn, and Al are more active than steels. A number of anodes are electrically connected to the steel structure to be protected to provide the needed current. The amount of current output is increased by increasing the number of anodes. Usually applied in:

Low current requirement application Soil resistivity < 10,000 (.cm)
Sacrificial Anode CP Systems

No external power source needed Ease of installation, low maintenance, low cost Provides uniform distribution of current
29
Advantages of sacrificial CP:

Disadvantages

Limited current and power output High resistivity environments or large structures require a large number of anodes Periodic replacement of anodes
Galvanic Series in soil and seawater

Volts (referenced to Cu/CuSo4) -1.75 -1.6 -1.1 -1.1 -0.8 -0.5 to -0.8 -0.2 to -0.5 -0.5 -0.5 -0.2 -0.2 -0.2 -0.2 +0.3
30
Metal
Commercially pure magnesium Magnesium alloy (6% Al, 3%, Zn, 0.15% Mn) Zinc Aluminum alloy (5% Zn) Commercially pure aluminum Mild steel (clean and shiny) Mild steel (rusted) Cast Iron Lead Mild steel in concrete Copper, brass, bronze High silicon cast iron Mill scale on steel Carbon, graphite, coke
Sacrificial anodes
31
In soil, special backfills are used with sacrificial anodes to improve anode efficiency. Anodes are packaged in porous bags prefilled with backfill materials such as clay. Clay:
absorbs moisture from the soil and reduce anode resistance of anode/electrolyte distribute the anodic reaction all over the anode Increase the life of the anode
Sacrificial anodes
32
Anodes are packaged in bags filled with backfill material Commercial anodes (

60 inch in length 4 Kg
Anodes for buried structures (pipes, tanks): Pure Mg Mg alloy (Mg+6Al+3Zn+0.2Mn) Pure Zn For marine applications Al alloy containing 5% Zn is used Zn alloy
Design of Sacrificial Anode CP
33
Select Protection Criterion (depends on the environment)
Measure resistivity of environment (slide#34):

For buried steel (NACE standard gives protection potential = -850 mV vs. Cu/CuSO4 ) Soil resistivity ranges from (500-20,000 *cm) Seawater ranges from ( 10-50 *cm) Current requirement table (see slide#24) Current requirement test (see slide#35)
Estimate cathodic current requirement which depends on the environment and the surface area to be protected using either:

Select a suitable sacrificial anode and calculate the theoretical capacity and the driving voltage (slide#37 and 38) Estimate the number of anodes needed based on groundbed resistance (slide#41 and 42) Estimate anode life and replacement period
Wenner 4-pin Method to Measure Soil Resistivity
34
This method is done by placing four pins at equal distances from each other. A current is passed through the two outer pins using a power supply. the voltage across the two inner pins is measured using a voltmeter. the resistance can be calculated using Ohm's law (Resist = V/I). Soil resistivity = 191.2*V/I*d (d in feet) ohm-cm, where R is the soil resistance and d is the pin spacing in feet.
Power supply voltmeter
Current Requirement Test
35
The current may be increased gradually until the voltmeters at positions A and B reaches -0.85 V with respect to a copper sulfate reference electrode placed directly above the pipe. Current requirement test:

A small DC power system is used (10 A) A temporary anode ground bed is installed Potential loggers are installed at selected test locations to monitor potentials A current is applied and the potential is measured The current that brings the potential of the whole pipe below the protective potential is used the required current for protection
Sacrificial Anode
High driving potential to generate sufficient current Stable operating potentials over a range of current outputs (Eanode does not vary a lot with i) High capacity to deliver current per unit mass Does not passivate Theoretical capacity: the total charge in coulombs produced by the corrosion (dissolution) of a unit mass of the anode material [units in (A* hr)/Kg]. High Efficiency (efficiency = actual capacity/theoretical capacity*100)
36
Anodes must have:

Calculating the theoretical capacity
37
MW of Mg is 24.3 g/mol, density=1.74 g/cm3 MgMg+2 + 2e- (one mole of Mg produces 2 moles of electrons) Take 1 Kg of Mg as a basis:
1000g * mole/24.3g=41.2 mole of Mg # of e- mole= 2*41.2=82.4 moles of e82.4 moles of e- *96500 Coulomb/(mole e)= 795,1600 Coulomb/(Kg of Mg) 795,1600 Coulomb/Kg *1 hr/3600s=2,200 (A.hr)/Kg
Calculating driving potential
38
ED = Eanode Ep + Epolar ED = driving potential Eanode = anode potential Ep = protection potential Epolar = change in potential of anode due to current flow (polarization); usually taken as 0.1 V
ED
Driving Potential
39
Example:

calculate the driving potential for Mg in soil assuming:

Eanode = -1.75 vs Cu/CuSO4 Ep (buried pipeline cross country) = -1.0 V Epolar = 0.1 V ED = -1.75 (-1.0) +0.1 = -0.65 V
Example: calculate the driving potential for Al alloy (5%Zn) in soil assume Ep = -0.85 V and Epola=0 and Eanode=-1.1V
ED = -1.1- (-0.85) = -0.25 V
Sacrificial Anodes
Mg Zn 810 780 >90% Al 2980 2640 >90% -1.1
40
Theoretical capacity Actual capacity Efficiency potential
2200 (A*hr)/Kg 1232 50-60%
-1.75 V (vs -1.1 Cu/CuSO4)
Anode bed (groundbed) resistance
41
In both systems, the flow of current is analogous to a simple resistive circuit. The highest resistance to current flow is due to the anode/electrolyte resistance (Rab) RS (structure/electrolyte) resistance. RLW (lead wire) resistance. Rab = Resistance of anode/electrolyte; depends on the anode shape and the resistivity of the environment. Rtotal = Ra+RLW+RS (RS and RLW) can be neglected Rtotal Rab
Electric Circuit
E
Battery Resistor R total
Anode bed (ground bed) resistance
42
Dwights equation for single vertical anodes: Ra = /(2La)*(ln(8La/Da) -1) (for slender anodes mounted at least 0.3 m away from the steel structure)

La= length of anode (cm) = soil resistivity (.cm) Da = anode diameter (cm)
Rab
Anode current output i = ED/Ra
Anode bed (ground bed) resistance
43
1.
Example: Calculate the maximum current output for zinc anodes (L = 150 cm and D = 15 cm) in sacrificial anode CP system. Assume very corrosive soil (=1000 *cm) Calculate the driving potential assuming Epola = 0.1V, EZn = -1.1 vs Cu/CuSO4, Ep (buried pipeline) = -0.85 V Calculate the ground bed resistance

ED = -1.1 (-0.85)-0.1 = -0.15 V
2.
3.
Calculate the maximum current output from each anode i = ED/Ra = 0.15/3.6 = 0.042 A = 42 mA
Ra = /(2La)*(ln(8La/Da) -1) Ra = 1000/(2*150)*(ln(8*150/15)-1) = 3.6
Anodes distribution
44
Example: suppose you need 1 A to protect a steel structure by using Zn anodes as in the previous example. Each anode provides 0.042 A. Then, you need to have 1/(0.042) 24 anodes to give sufficient protection. Distance of anode to cathode:

Too far: high resistance in the soil leads to voltage drop Too short: current distribution is not uniform Needs experience (usually less than a meter)
Design Example
45
Example: design a CP system for a section of coated steel buried pipe assuming that the current required to shift the pipeline potential to the EP was approximated by a current requirement test to be 500 mA. Zn anodes (L=150 cm, D=15 cm) are available. (Density of Zn = 7.14 g/cm3). Assume Zn efficiency is 90% and =1000 *cm. From the previous example, each Zn anode produces 42 mA. Then, #anodes = 500/42 = 12 anodes. Total mass of anodes = 12*vol*density =12*3.14*D2*L/4*7.14 g/cm3= 2270 Kg Total charge available = efficiency*theoretical capacity*mass= 0.9*810*(A.hr/Kg)*2270 Kg= 1,593,540 (A*hr) Replacement period = 1,593,540 (A*hr)/0.5A= 189540 hr = 364 years
Sacrificial Anode CP System
46
Install 12 anodes evenly distributed along the pipeline. Keep each anode 30-100 cm away from the pipe. The system design life is indefinite. Monitoring Sacrificial CP
Measure the potential of the pipe and make sure it is -850mV Monitor the current flow from each anode at the junction box
Applications: buried tanks, pipelines, internal protection of heat exchangers and vessels, ship hulls, marine structures
47
Anodes
Aluminum alloy anode AA-036348
Impressed Current CP (ICCP) System
48
ICCP is used if:

high current is required high resistance electrolyte
ICCP
49
Components of ICCP system
A transformer: to reduce the voltage from high to low voltage A rectifier to convert AC to DC A current distributor (junction box) Anodes with backfills
Reactions
50
The anode potential is set at high +ve potential and the following oxidations reactions become possible:

Reactions at the cathode:

2H2O O2 + 4H++4e- (in water or in wet soil) 2Cl-Cl2 + 2e- (in salt or brackish water) C+2H2O CO2 + 4H++4e(in graphite anodes)
In aerated wet soil
In aerated acidic solution
O2+2H2O+4e- 4OH-
In neutral seawater
O2+4H+ + 4e- 2H2O O2+2H2O+4e- 4OH-
In de-aerated soil or water
2H2O+2e- 2OH- +H2
Cathode
anode
Advantages and Disadvantages of Impressed Current Systems

Advantages

51
Higher Current and power outputs Adjustable protection levels (controlled current) Large areas of protection Low number of anodes Can be used to protect poorly coated structure Complex equipment and installation costs Higher maintenance costs Possible interference problems with foreign structures Risk of incorrect polarity connections
Disadvantages

Components of ICCP external power source

AC transmission lines A solar power system
52
An

Anodes
are not necessarily more active than the structure to be protected

Two types of anodes
inert or non-consumable anodes: platinized anodes (a few micrometers thick coating of platinum on Ti or Niobium), graphite, consumable anodes (scrap steel, high-Si Cr cast iron)
Anodes for ICCP
53
Anodes are used with carbonaceous backfill called coke-breeze to:

Anode Coke-to-earth Resistance
increases the effective size of the anode lowers the anode-toground resistance. extends the life of the anode.
Anode to coke resistance Coke breeze
Soil
Anodes in ICCP
Material Consumption rate (Kg/(A*yr) applications
54
Platinized niobium (inert) Platinized Ti (inert) Graphite (inert) Scrap steel High Si-cast iron
8x10-6 8x10-6 0.1-1 7-9 1-0.25
Seawater, concrete, == Soil, Potable water Marine, soil Marine, soil
Applications
55
Ships (with coatings) Offshore platforms Buried pipelines (pref method) Oil well casing Concrete Structures (offshore bridges)
Buried pipelines
56
Well Casing
Junction Box Rectifier
57
Remote Surface Anode Bed
Producing Zone
Perforations
ICCP Design
58
1. 2.
Evaluation of electrolyte resistivity Estimating the current requirement

Current requirement test Current requirements theoretical estimation
3.
Selecting anode material and current distribution

Uniform current distribution Avoid interference (stray current)
4. 5. 6.
Determine the anode bed ground resistance Determine number of required anodes Select the power source capacity
1. Electrolyte Resistivity Survey
59
Measure soil resistivity along the pipeline The data from a soil resistivity survey along a 6 km section of pipeline is shown below. The lowest effective soil resistivity points are the most favorable anode bed locations.
2. Interruption Test for Bare Pipeline in Impressed Current System
60
In impressed current system for bare structure, the applied current is high and IR drop can not be neglected. Thus, protection Criteria for bare pipeline must check I*R effect. The protection criterion for bare steel pipeline uses interruption test where a negative (cathodic) change in potential of >300 mV must take place immediately after potential CP current is applied.
CP power on CP Power off 300 mV
time
3. Current distribution
61
Variation of electrolyte resistivity b/w anode and cathode (largest current flows along least resistant path) Defects in coatings: current concentrates at defects
Stray Currents
62
Stray Currents: currents flowing in the electrolyte from external sources other than the applied CP. Sources of stray currents: Subway system Interference with another CP system Welding equipment Electrical power transmission lines
4. Number of Required Anodes
63
N = Y*C*I/W
N = anodes Y = I = C = W = number of impressed current design life in years total current required in amperes anode consumption rate in kg/A-yr weight of a single anode in kg
5. Resistance calculation
equation for single vertical
64
Dwights
anode:
group of vertical or horizontal anodes (buried 6 ft below ground):

Ra = /(2La)*(ln(8La/Da) -1)
Vertical anodes ( Rv = *F/537) Each anode is 8-12 in in diameter and 10 ft in length Horizontal anodes (RH = *F/483) Each anode is 10 ft in length and 6 ft below surface F is called adjusting factor (F=1 for single anode)
F : Adjusting Factor
65
4. Power Source Selection
66
The

size of the power source is determined by:

the amount of current required to protect the structure (I) the voltage required to force the current through the anode ground bed resistance (R) E=I*R
Example: Design for ICCP
67
Design an impressed current system to protect a buried pipeline coated with fusion bonded epoxy (FBE) using the following information:
Horizontal anodes 6 ft below ground with 20 ft spacing Anode material: High silicon-cast iron ( C=0.5 Kg/(A*yr)) Anode dimensions with backfill: 25 cm dia. x 300cm, weight=50 Kg Pipeline length: 500 m and 115 mm in diameter
the anode to soil resistance is 0.24 ohm

Neglect cable resisitivity. Soil resistivity: 2,000 ohm-cm Required current density is 0.2 mA/m2 for FBE. Design life of 20 years
Example: Design for ICCP
68
Current required = surface area * current density = d L *i= 3.14*0.115*500 *0.2 = 36.1 A # anodes= Y*I*C/W = 20*36.1*0.5/50 = 7.2 anodes . Then use 8 anodes. To calculate the resistance: RH = *F/483 (for 8 horizontal anodes F=0.184) = 2000*0.184/483 = 0.76 Total R= 0.76+0.24=1 E = I*R=1*36.1 = 36.1 V Hence, use a DC power with a minimum current supply of 40 A and a minimum voltage of 40 V (1600 Watt rating).

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Cathodic Protection

ME 472-061 Corrosion Engineering I ME, KFUPM Dr. Zuhair M. Gasem

Dr. Z. Gasem ME 472-061 KFUPM

Dr. Z. Gasem ME 472-061 KFUPM

Anodic and Cathodic Reactions of Iron in Acids

Corrosion Cell on a Metal Surface

Dr. Z. Gasem ME 472-061 KFUPM

Basic Physics of CP of Iron in Acids

Electrons from external source

Dr. Z. Gasem ME 472-061 KFUPM

Polarization Principle of CP of Iron in Acids

ianode = icathode = icorr E = Ecorr icorr = ia icathode = ic iapp = ic ia E = ECP

Dr. Z. Gasem ME 472-061 KFUPM

Polarization Principle of CP of Iron in Water

ianode = icathode = iL E = Ecorr icorr = ia icathode = ic = iL iapp = ic ia E = ECP

Dr. Z. Gasem ME 472-061 KFUPM

Summary of cathodic protection:

Dr. Z. Gasem ME 472-061 KFUPM

Dr. Z. Gasem ME 472-061 KFUPM

+ve ions current in electrolyte

Dr. Z. Gasem ME 472-061 KFUPM

Dr. Z. Gasem ME 472-061 KFUPM

Electrochemical reaction in sacrificial Anode CP System

Cathodic reactions on the steel structure:

In aerated wet soil

In aerated wet acidic soil

O2+4H+ + 4e- 2H2O O2+2H2O+4e- 4OH-

In de-aerated soil or water

2H2O+2e- 2OH- +H2

At active anode in sacrificial anode CP system (Mg, Al, Zn)

Dr. Z. Gasem ME 472-061 KFUPM

Dr. Z. Gasem ME 472-061 KFUPM

much current is needed to protect the pipeline?

Dr. Z. Gasem ME 472-061 KFUPM

Dr. Z. Gasem ME 472-061 KFUPM

Dr. Z. Gasem ME 472-061 KFUPM

Dr. Z. Gasem ME 472-061 KFUPM

Potential (V vs. Cu/CuSO4)

Dr. Z. Gasem ME 472-061 KFUPM

NACE Standards for CP

Dr. Z. Gasem ME 472-061 KFUPM

Saudi Aramcos Potential Requirements

-0.90 volts vs. AgCl electrode

-0.90 volt or more negative versus AgCl electrode

Dr. Z. Gasem ME 472-061 KFUPM

Dr. Z. Gasem ME 472-061 KFUPM

Variables affecting soil corrosivity:

Dr. Z. Gasem ME 472-061 KFUPM

10,000 to 20,000 5,000 to 10,000 1,000 to 5,000 <1,000

Clay with saline water (sabkha)

Dr. Z. Gasem ME 472-061 KFUPM

Soil Corrosivity Seawater Resistivity

Progressively Less Corrosive 10,000

Seawater (Gulf) Raw water Drinking water

Dr. Z. Gasem ME 472-061 KFUPM

ASM Handbook Vol#13 p.476

Bare Steel (mA/m2)

Coated steel (mA/m2)

Initial CP Applied Initial CP current CP current current

Moving seawater Stagnant seawater soil

325375 160270 43-54

75-105 45-75 11-16

32-54 11-32 5.4-11

11-16 5-11 1.1-0.54

Ra = /(2La)(ln(8La/Da) -1) Ra = 1000/(2150)(ln(8150/15)-1) = 3.6