BUILDING SERVICES AND PROTECTION
DIPLOMA MODULE III
By Eng. Olwa T.V
CHAPTER 1
POWER PROTECTION
1.1 Protective Scheme
1.1.1 Susceptible Metals
Are metals that are easily corroded like Iron excluding;
Aluminum, Stainless steel, Brass, Bronze, Gold, Silver, Platinum etc
1.1.2 Corrosive Environment
Is Any Environment that promote rusting like Chemically affected area, Damped or Moist area.
Electrolytic Condition is affected by two factors; - Susceptible Metals; Corrosive Environment.
Terms;
Electrolysis- is the decomposition of a compound by passing an electric current through it.
Electrolytes- Aqueous solutions which conduct electric current; It can be a molten ionic
compound
Electrode- The rods e.g. graphite which carry the current into and out of the electrolytes
Unreactive metal electrodes such as platinum and copper can also be used as electrodes
Anode- The electrode connected to the positive terminal of the battery
Cathode- The electrode connected to the negative terminal
Oxidation- This is the increase in Oxidation State/ The loss of electrons
Reduction- This is the Decrease in Oxidation state/ The gain of electrons
Condensation- Is the process by which water vapor in the air is changed into liquid water as
observed in Cold Stores
1.1.3 Electrolysis Process
When an electrolytic cell is used to pass an electric current through a molten ionic compound or
an electrolyte aqueous solution with a connecting switch closed to complete the circuit, all +ve
ions move to the cathode and all -ve ions move to the anode. As the current flow, a chemical
reaction occurs at the electrodes. The ions lose the charge (they are discharged). Y– ions lose
electron(s) while X+ ions gain electron(s). The respective products are deposited on the surface
of each electrode
Liquids such as acidified water, sodium chloride solution, mineral acids and copper(II)
chloride solution conduct electricity. Aqueous solutions which conduct electric current are
called electrolytes. The current decomposes the electrolyte as it passes through it. Aqueous
solutions such as sugar and urea do not conduct electricity. These are known as non-
electrolytes.
Why non-electrolytes do not conduct electricity - Bonding in non-electrolytes is covalent.
When dissolved, there are no charged particles (ions) to carry an electric current. We learnt that a
covalent bond is formed when atoms share a pair of electrons. In this way they form discrete
molecules. Therefore, non-electrolytes exist in the form of molecules
Why electrolytes conduct electricity - Electrolytes are ionic compounds. They contain charged
particles called ions. In solid form the ions are not free to move, therefore a solid ionic
compound does not conduct electricity. The ions move if the solid is melted or dissolved in water
The positively charged ions are called cations and the negatively charged ions are anions. During
electrolysis the cations move to the negative electrode (cathode) and the anions move to the
positive electrode (anode)
Application of Electrolysis
1. Electroplating This is a method used in industries to coat (plate) a metal with another in
order to improve its appearance by making it more attractive or in order to prevent
corrosion. Examples • Gold-plated watches • Silver–plated utensils • Chromium plated
electric kettles, car bumpers. Items to be plated with nickel are first plated with chromium
because nickel does not adhere well to steel
The items e.g. spoons to be electroplated (coated with another metal) are always used as
the cathode, while the coating metal is the anode. The electrolyte is a salt of the metal to
be used as the coat. For example, to electroplate spoons with silver, use silver nitrate
solution
2. Purification of metals Impure copper can be purified by placing it at the anode. The
cathode is a sheet of pure copper and the electrolyte copper(II) sulphate solution.
3. Extraction of metals Copper metal is extracted from a rock by using the rock as the
anode and pure copper the cathode. The electrolyte is copper(II) sulphate solution.
Reactive metals like sodium and aluminium are extracted from their compounds by
electrolysis. Sodium is extracted from molten sodium chloride, while aluminium is
extracted from its molten oxide
Summary
1. A conductor (a metal or graphite) conducts an electric current but is not decomposed. Free or
delocalized electrons are responsible for the conduction of an electric current.
2. Electrolytes are compounds which conduct an electric current in molten or aqueous state and
are decomposed by the current into component elements in solid, or gaseous state.
3. Solutions of salts in water, solutions of acids and solutions of bases are electrolytes.
4. In an electrolyte ions carry the electric current as they move to the electrodes.
5. The positive electrode is called anode; the negative electrode is called cathode.
6. During electrolysis positive ions (metal ions or hydrogen ions) that move towards the cathode
are called cations; negative ions that move towards the anode are called anions.
7. During electrolysis, anions are discharged by losing electrons at the anode.
Therefore, electrons leave the electrolyte via the anode. Electrons enter the electrolyte via the
cathode where the cations gain these electrons.
8. Graphite is the only non-metal that conducts an electric current. It is mostly used because it
does not react with the electrolyte or the products formed.
9. When electroplating (coating) an item (spoon, fork, knife) note the following:
• The item to be coated should be the cathode e.g. spoon.
• The metal to coat should be the anode e.g. copper
• The electrolyte should be a salt of the metal to be used for coating.
10. An article is coated to prevent corrosion and make it attractive
1.2 Methods of Corrosion Protection
1.2.1 Cathodic Protection
Corrosion is an electrochemical process, normally occurring at the anode but not the
cathode. The principle of Cathodic protection is to connect an external anode to the
metal to be protected and to pass a DC current between them so that the metal
becomes Cathodic and does not corrode.
This can be achieved by employing two distinct types of Cathodic protection:
1) Sacrificial Anode Protection/Passive Cathodic protection
2) Impressed current Cathodic protection.
Passive Cathodic Protection
It’s also called Sacrificial Anode Protection – In Passive Cathodic protection systems,
the sacrificial anode or Galvanic Anode is connected directly or indirectly to the metal to
be protected.
The anode materials are alloys of either zinc, aluminium, or magnesium – all more active metals
than, for example, carbon steel.
These more active metals corrode preferentially to the steel when they are metallically
connected to the steel in an electrolyte.
The corrosion current of the anode material is the Cathodic protection current for the steel.
The current flows through the electrolyte onto the steel, controlling its corrosion. The current
returns to the anode in the metallic circuit
Power Impressed (Current Impressed)
In large structures, it may not be feasible to use passive Cathodic protection methods. The
number of sacrificial anodes required to deliver enough current to provide adequate protection
can either be unrealistic or impractical. To address this, an external power source is used to
assist in driving the electrochemical reactions. This technique is known as impressed current
Cathodic protection (ICCP).
ICCP systems are ideal for protecting lengthy structures, such as underground pipelines.
The negative pole is connected to the protected metal (‘negative drain point’), and the positive
pole is connected to the anode. As with GACP, the Cathodic protection current flows from the
anode, through the electrolyte and onto the metal being protected.
The anodes can be scrap steel, high silicon iron, or sophisticated ‘mixed metal oxides’ coated
onto titanium. Other materials, including graphite, magnetite, lead, platinum-coated titanium
and niobium, have also been used, though performance and cost have combined to reduce their
use.
Disadvantages of corrosion
1. It decreases the life span of metallic machines or objects.
2. A large amount of money is to be wasted on its prevention.
3. It wears out objects potentially causing malfunction of equipment.
4. It also varies the chemical properties of the compound hence a potential health hazard.
1.3 Prevention of Corrosion
i. Painting (Bituminized Paint)
When iron gate is painted, the layer of paint prevents the contact of iron with air and
moisture and so there is no rusting.
ii. Separation of Dissimilar Metals
When two dissimilar metals are in contact, they form a bimetallic couple (one metal being the
anode and the other being the cathode) due to their affinities for electrons. Their separation avoid
the formation of a bimetallic couple hence preventing corrosion.
The difference between the anode’s potential to be oxidized and the cathode’s potential to be
reduced is called the potential difference. This difference in potential allows for the free flow of
electrons between the anode and the cathode, and results in an electrical current.
Bimetallic (galvanic) corrosion occurs when two metals, with different electrode potentials, are
in contact with each other (directly or indirectly) in the presence of an electrolyte such as water.
Factors affecting Bimetallic (Galvanic) Corrosion
1. An electrolyte linking the two metals
2. Electrical connection between the metals
3. Sufficient potential difference between the two metals
Advantageous Situations of Bimetallic Corrosion
Under most circumstances, bimetallic corrosion is to be avoided and steps are usually taken to
prevent its occurrence. Despite its reputation as a destructive process, this electrochemical
phenomenon provides some advantages, which are listed below:
1. Voltage production in batteries
The principle of an electrical current produced by potential differences between dissimilar metals
is used in typical dry cell batteries. The anode usually consists of a zinc outer case while the
cathode may come in the form of a graphite rod. The electrolyte solution separates the two
metals and shuffles electrons between the anode and the cathode to produce electricity.
2. Galvanic/Cathodic protection of metals
Combing two metals with sufficient difference in potentials can be used to prevent corrosion of
the cathode by allowing the anode to corrode preferentially, therefore sacrificing itself. This very
same principle is used when galvanizing structural steel members, whereby the zinc coating is
used to galvanically protect the underlying steel.
Prevention of Dissimilar Metal Corrosion
Methods to prevent or mitigate the effects of bimetallic corrosion are focused mainly on
disrupting the electrical path in the metal or electrolyte part of the system. Some of the most
common methods of preventing bimetallic corrosion include:
1. Electrical insulation
By insulating the metals from each other, they are no longer in contact and the flow of electrons
between them is inhibited. This can be achieved through the use of a non-conductive material
between the two metals, such as plastic or rubber bushes, washers and gaskets.
2. Isolation from the electrolyte
The electrolyte is the medium responsible for the transfer of electrons via the potential difference
between the metals. Therefore, separating the metals from the electrolyte causes an interruption
in the electrical circuit and thus prevents galvanic corrosion. Come common measures used to
achieve this include the use of water-repellent compounds such as greases, paints, varnish,
plastic coatings and electroplating.
3. Using metals with similar electrode potentials
Metals that are closely matched in the galvanic series have lesser potential differences and
therefore less galvanic current. This ultimately results in a significant decrease in the probability
of bimetallic corrosion.
Conclusion
Bimetallic corrosion, though detrimental to metal components, can be prevented by proper
material selection and other insulation and separation techniques. However, despite its
destructive reputation, the principles that govern this type of corrosion can be used in a number
of beneficial applications.
\
iii. Soldering Operation
The soldering flux dissolves the oxygen compounds on the surface of the alloy. During the
dissolving process, the flux absorbs the oxides and prevents any further oxidation from
occurring.
Flux refers to an ingredient that is added to the surface before or added to the solder paste.
Soldering wire is also made of an alloy tin and lead metals that helps in corrosion prevention
since they are not susceptible metals.
iv. Metal sheath Protection (Lime and Cement)
The metal sheath that clads MI cable helps to protect the thermocouple wires from oxidation
when used in chemically active or wet environments. Corrosion resistance makes mineral
insulated cable ideal for use in areas where failure and replacement could be dangerous or even
impossible.
For example, MI cable is used in nuclear plants to monitor core temperatures. It would be
extremely dangerous if the temperature controllers were not receiving accurate readings, and it
would be difficult to repair or replace cables in that environment.
1.4 Regulation and Code of Practice for Corrosion Prevention
i. The Use of MI Cables
ii. The use of Metal Sheath Cables E.g. Lead Sheath
N/b
A Mineral insulated cable (MI cable) is a specialized type of cable used in high temperatures or
harsh environmental conditions because it has low flammability, even when operating at high
temperatures. It resists oxidation and enables precise measurement.
The mineral fillings in MI cables provide excellent non-reactive insulation, preventing the
thermocouple wires from contact with each other or with caustic substances such as oils, solvents
or water. This helps to ensure that the thermocouple probes remain accurate, critical in
applications such as heat treating or sintering where the quality of the product could be adversely
affected by temperature fluctuations.
The insulation of mineral insulated cables does not burn, which makes it ideal for
applications where fire could be catastrophic. Medical devices, power plants, and oil rigs are
examples of places where installation of MI cables makes operations safer.
1.5 KNEC QUESTIONS
1. State the Basic causes of Corrosion (2mks)
2. State two types of materials that causes Corrosion (2mks)
3. With an Aid of a Diagram, Describe impressed Current method of Cathodic
Protection (6mks)
4. With an aid of Diagram describe the Operation of Cathodic Impressed Current
method of protection (6mks)
5. Define the term Corrosion (2mks)
6. Describe the Process of Corrosion in Metals (4mks)
7. List two methods of Preventing Corrosion in metals (2mks)
8. Describe the process of Electrolytic corrosion and how it can be prevented (3mks)
9. Explain three ways of preventing corrosion in electrical Installation (2mks)
10. Define the term Building Protection (2mks)
KNEC 2023 APRIL
1. Describe impressed Current method of Corrosion Protection (6mks)
2. State three demerits of corrosion on infrastructure (3 mks)
KNEC 2023 NOVEMBER
1. With an aid of a labelled diagram, describe impressed Current method of Corrosion
Protection (7mks)