Protection Course

cathodic
4. Conception
Marcel ROCHE
Generalities and selection criteria

Galvanic anode Forced current system

Installation simple complex
Energy source not necessary indispensable
Distribution of current on the Homogeneous given the field often heterogeneous
structure action of an anode
Dimension of the structure to be protected important surcharge in weight for Large dimensions, large
large-scale structures, lengths
unsuitable for large lengths
Influence of the resistivity of the medium not conceivable if resistivity too high no difficulty
big
Current by anodes weak raised
Number of anodes important weak
Flexibility in the conditions of none big
operation in particular
variation in current demand
Risk of overprotection almost null except in the case of anodes of possible
magnesium
Interferences with others weak Strong possible influence
structures
Human risks no possible
Surveillance / maintenance weak regular surveillance and
requiring technicians
specialized
 Systems energized by imposed current

Transformer -
Rectifier
220V power supply

Cables D > 50 Overflow composed of

of m old rails
copper ferrosilicon
16 mm² graphite
magnetite
titanium + precious metals

The backfill decreases the

resistivity of the medium
around the anode

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 Protection by galvanic anodes

5 mA < I < 20 mA
Point soil < 50 Ohm.m
of
distance anode/canalisation >
measure 3m

Cables
of Magnesium anode
copper or in zinc
16 mm²

The backfill reduces the

resistivity of the medium
around the anode

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Sizing of cathodic protection

The design of the protection system

cathodic defining the number, the
mass, dimensions, and distribution
The anode must be made to ensure the
compliance with the selected potential criterion in
at any point during the calculation lifespan
The design is done in a general way.
using a simplified method
easily implemented
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Sizing of cathodic protection

The protective current to be provided can be determined:

- by an on-site trial
by adopting the following current density values
Protection by siphoning PE or Epoxy coated steel piping:
0.1 mA/m²
Steel piping with bituminous coating: 0.4
mA/m²
Protection by sacrificial anodes: Steel pipeline coated with PE or Epoxy:
0.05 mA/m²
Steel piping with bituminous coating: 0.1
mA/m²
The difference in density depending on the nature of the sources is explained by the
better distribution of currents with sacrificial anodes.
- by calculation software (PROCOR)
Sizing of cathodic protection

The desired lifespan of the system is to be calculated.

(check if it meets the set objectives):
Draw-off spillway
Its lifespan is calculated based on the data from
material consumption and applying a safety factor (
generally equal to 2), for a period of 15 to 20 years

Sacrificial anodes
It is calculated based on the intensity provided by the anode, combined
with the electrochemical yield.
Knowing the mass of an anode, we deduce the minimum number.
of anodes.

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Sizing of cathodic protection

The geometry of the anode mass - backfill is

to be defined
The resistance of the anode mass will depend on:
- of its shape
of the number and spacing of its different elements
of the resistivity of the medium
His calculation is always more or less empirical. It is based on formulas.
calculation of earth resistance for anode masses of
geometry and given position

•Application of calculation formulas (example: DWIGHT formula)

For a log placed horizontally ρ 4L4L h h²

Rt= (ln+ln−2+ − +...)
4.π.L a 2L16L² h
For n logs
Rt K : facteur de couplage
Ro= K.
n n : number of rails
Sizing of cathodic protection

Example of offshore design:

estimation of the 'initial current requirement' I0 of
each of the surfaces S to be protected from the
initial protective current density j0 and
possibly the initial degradation coefficient
of the coating x0:
I0= j0.S.x0
-same for the conditions of "maintenance" of the
protection after achieving the level of polarization
of balance (effect of calco-magnesian deposit):
Im= [Link]

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 Implementation of protection systems

•Imposed current:
type and characteristics (I, V) of the current source
type of anodes (platinum Ti or Nb)
dimensions, number and distribution of anodes
dimensions of electrical cables
Sacrificial anodes:
type of sacrificial alloy
dimensions, number and distribution of the anodes
Installation
Monitoring
Periodic checks

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 Choice of sacrificial alloys

Magnesium
-very negative potential (fast polarization, strong range)
short lifespan (temporary protection)
the most expensive
Zinc
reliable in all conditions up to 60°C (very safe in
buried, at low initial flow rate, on coated structures
unreliable at high temperature
Aluminum
the least expensive
light
hot-active (but low yield)

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Protection by galvanic anodes

Typical characteristics of galvanic anodes

ambient temperature

Nature of Potential Energy Rate of

the massive alloy mV vs consumption
practice Ag/AgCl/water kg/[Link]
Ah/kg of the sea
The All 2660 -1100 3.3
Zn 760 to 780 -950 to -1030 11.2 to -11.5
Mg 1230 -1500 7.1

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 Comparative cost of anodes (supply)

Aluminum Material Zn Mg
Coût (€/kg) 3 2.3 7.6
Consumption 3.5 11.2 7.7
(Kg / [Link])

Cost price 10.5 25.8 58,5

(€/[Link])

Cost ratio 1 2,55,6

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Sizing of cathodic protection

calculation of the total mass of anodes Mtto install

from the current of "maintenance", of the duration
of calculation D, of consumption
massive practical use of the material of the anodes m
and the utilization factor of these: u : Mt=
D. Im. m /u
• calculation of the number n, of the unit mass M (Mt
= nM) and the dimensions of the anodes (from
initial conditions, generally
determinants), through the notion
of 'anode resistance' and Ohm's law
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Sizing of cathodic protection

This type of calculation considers that the resistance of

the electrolyte between an anode and the structure
protected depends only on the dimensions of
the anode, the cathode being considered at infinity and the
anodic current density being predominant.
Semi-empirical formulas, including the
resistivityρ the average, are used to calculate
the 'anode resistance'; For the anodes
longiformes (length L, equivalent radius r)
used on tubular structures, we use a
Dwight's formulas:
R = ρ /2πL [ln(4L/r)-1]
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Sizing of cathodic protection

We must check that the potential Ecof the work is

always more negative than the protection threshold
accepted, this notably for the conditions
initials :
Ec= EaRi
with i = Im/n et Eapotential 'in charge' of the anode.
The optimization of this design is a concern.
permanent to reduce costs without taking on
risk at the level of service maintenance
It is essentially based on feedback.
Experience and making use of failures

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 Sizing of cathodic protection

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Sizing of cathodic protection

It has nevertheless proven useful to seek to

better to get closer to reality for the cases
the most complex based on the equation
of Laplace which governs the electric field in
the electrolyte:
∇ϕ(x) = ∑[∂2ϕ / ∂x2] (x) = 0
Three-dimensional modeling software
based on finite elements or equations
surface integrals were developed at
early 80s based on this principle

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Sizing of cathodic protection

•PROCOR was developed by CETIM from

his thermal software CASTOR-TH3D, in
collaboration with IFREMER, Elf Aquitaine, DGA
•Use of surface integral equations
with a recognized efficient algorithm
Surface or tubular modeling, taking into account
possible account of the ohmic drop in
longilinear works, heterogeneous electrolyte
Introduction to all types of curves
polarization

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Sizing of cathodic protection

Input of geometric data by pre-

graphics processor (CASTOR PRE3d)
Calculation outputs by color mapping
potentials and current densities
Possible consideration of the evolution of the
polarization curve as a function of time by
application of the Nisancioglu method
(SINTEF)
Algorithm using electrochemical parameters
(reduction of water, from 02dissolved, iron oxidation
and the formation of calco-magnesium deposit
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 Sizing of cathodic protection

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 Sizing of cathodic protection

-500

-550
Vit 0.17
-600 Site
Node at -56 m Site 210j
-650

-700

-750

-800

-850

-900
0 50 100 150 200 250
Temps (jours)

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Sizing of cathodic protection

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Sizing of cathodic protection

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