COURSE IN CP INSPECTION METHODS FOR CORROCEAN

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Part I Cathodic Protection Part II CP Inspection Methods

COURSE IN CP INSPECTION METHODS

Part I Cathodic Protection

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Offshore Corrosion
Corrosion: Based on the Latin word corrodere = to gnaw
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Wet corrosion in an electrolyte containing oxygen

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Electrode Potentials

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CATHODIC PROTECTION
PRINCIPLE:
The material to be protected is supplied with an external cathodic current The electrochemical potential of the protected material is moved in a negative direction to the immune area
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The material is completely protected when it reaches the Protection Potential

Pourbaix Diagram

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ELEKTROCHEMICAL REACTIONS
Corrosion of FE:
a) Fe2+ + 2 e- = Fe b) Fe3O4 + 8 H+ + 8 e- = 3 Fe + 4 H2O c) Fe3O4 + 8 H+ + 2 e- = 3 Fe 2+ + 4 H2O d) Fe2O3 + 6 H+ + 2 e- = 2 Fe 2+ + 3 H2O e) O2 + 4 H+ + 4 e- = 2 H2O f) 2 H+ + 2 e- = H2

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 Shows what reactions which can occur with

different pH and potential Indication on the composition of the corrosion/oxidation products Shows the changes of the environment (pH and potential) which are nessesary to avoid corrosion

Applications of the Pourbaix Diagram

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TECHNICAL SOLUTIONS
Sacrificial Anodes
Galvanic coupling to sacrificial anodes made of Al-alloy or Zinc Impressed Current Use of source for direct current (DC) and none corroding anodes

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Cathodic Protection

Impressed Cathodic Protection

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SACRIFICAL ANODE SYSTEMS

Advantages:
Disadvantages:

Robust system, reduced maintenance Used on every platform on the Norwegian continental shelf Limited driving voltage (0.25 V)

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More anodes necessary for protection More anodes necessary for securing long operating time

(Not suited for media with low conductivity, e.g. in soil)

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 Advantages:

IMPRESSED CURRENT

High driving voltage (30 V)

Disadvantages:

Few anodes reduced resistance

Vulnerable components Need for regulation/control system

Risk of overprotection of highly charged materials Coating damages cathodic accouplement

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Need for/recommended protection shield around the anodes Need for maintenance
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Example of Impressed Current Installation

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Applications of Impressed Current

Applied on steel in seawater or soil
Oil Platforms in steel and concrete Subsea Pipelines Hull Quay structures and sheet pile curtains Concrete bridges placed in seawater Pipelines buried in soil Vessels/tanks buried in soil
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 St eel

ELECTROCHEMICAL POTENTIALS

Corrosion potential ca. -650 mV Ag/AgCl Protected at ca. -800 mV Ag/AgCl

Al-anode and Zn-anode

Corrosion potential ca. -1050 mV Ag/AgCl

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CATHODIC PROTECTION
Anodic reactions: Zn = Zn2+ + 2eAl = Al3+ + 3e2 H2O = 4 H+ + 4OHO2 + 4 H+ + 4 e- = 2 H2O ---------------------------------O2 + 2 H2O + 4 e- = 4OH-

Cathodic reactions:

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2 H+ + 2 e- = H2 (g)
Anode and cathode reactions are always balanced, i.e congestion of electrons does not exist
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CRITERIA FOR CATHODIC PROTECTION

Potential Criteria: maximum -800 mV, ref Ag/AgCl minimum -1100 mV, ref Ag/AgCl

Demand for current: vary with O2 in the electrolyte solubility flow velocity temperature construction geometry geographical site
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Calcareous deposit reduces the demand for current:

Calcareous deposits reduce the effective cathodic surface area thereby lowering demand for current. The calcareous deposit is formed when MgOH2 and CaCO3 salts precipitate on the cathode (steel surface). The following changes the composition and quality of the calcareous layer: current density temperature pressure seawater quality flow velocity
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CATHODIC PROTECTION
The most commonly used sacrifical anode materials are: Al-Zn-In Zn Mg
Magnesium relatively expensive
low capacity of current because of high selfcorrosion may cause overprotection short operating time Often used where the electrolyte has low conductivity
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Zinc:
classical anode material low driving voltage (230 mV) low capacity of current results in high weight of anodes (780 A/kg) temperature limits < 40 Co Often used on subsea piplines and constructions buried in mud

Aluminium:
has to be alloyed otherwise it is passive high capacity of current (2500 Ah/kg) long operating time saves weight high driving voltage Al-Zn-In anodes most commonly used offshore
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PRACTICAL CP DESIGN
where will the construction be placed? what kind of environmental parameters should be taken into account (temp.,res.) areas to protect operating lifetime what kind of design standards should be used (DnV, NORSOK, NACE) what demand for current is expected will the construction be protected by coating, if so, what kind of coating degradation mechanisms for coating (Coating Breakdown) possible current drainage to e.g. wells, poles, other structure influence from other structures, pipelines etc. 24

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DEMAND FOR CURRENT

INITIAL DEMAND FOR CURRENT:
Demand for current to polarize the structure down to a safe protection potential ( -800 mV) and build a good calcareous deposit.

AVERAGE CURRENT:
Demand for current to maintain a safe protection potential after polarization of the structure. Used to calculate necessary anode weight.
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FINAL DEMAND FOR CURRENT:

Demand for current to repolarize the structure after a possible breakdown/damage of the calcareous deposit (after winter storms). It also gives the demand for current at the end of the operating lifetime.
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Illustration of design current density

Initial current density Current density (mA/m2)

Final (peak) current density Average current density

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Time
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REQUIREMENT OF CURRENT FOR PROTECTION

Bare steel in seawater: 100 - 200 mA/m2

Bare steel in soil: 10 - 20 mA/m2 Reinforced concrete: 1-3 mA/m2
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CATHODIC PROTECTION AND COATING

Reduces the requirement of current Lowers anode weight Easier to achieve good current distribution
and consequent protection of the entire structure
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CALCULATE CATHODIC PROTECTION

Structure: - calculate area to protect (m2) - calculate current requirement, I (A) - calculate anode weight requirement, W (kg)

Anode data: - anode material - anode type and dimensions - calculate anode weight, Wa (kg) - calculate anode resistance, Ra (ohm) - calculate driving voltage, DE, (mV) - calculate anode current output, Ia (A)
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CP DESIGN

Current requirement:

= i * Area
= I*L*8760 C*U = DE Ra = Voluma*d
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Anode weight requirement:W

Anode current output:

Ia

Anode weight:

Wa

REQUIREMENT OF ANODES
Calculate necessary number of anodes to meet the current requirement (initial and final current):
N1 = I Ia
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Calculate necessary number of anodes to meet the anode weight requirement for the total operating lifetime: N2 = W Wa
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