Cathodic Protection

System

Task Name Designation

Prepared By Imran Shafee Tr. Petroleum Engineer

Reviewed By Sheikh Mubin Ashraf Petroleum Engineer

Submitted To Shabir Khan Incharge Sujawal

Mari Petroleum Company Limited

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Agenda
Introduction

Working Principle of CP

CP Components

CP Techniques

CP Design

Anode Configuration

CP System at SGCPF
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Cathodic Protection

Introduction

• The processing of metals into usable materials takes a lot of

energy.
• Corrosion is a reaction where refined metals release that
energy and return to their natural state.
• Corrosion occurs where current leaves the structure
• Cathodic protection stops the energy from leaving the metal
and prevents corrosion by applying current to the surface
• Cathodic Protection (CP) is an electrochemical process
where DC current is applied to a metal to slow or stop
corrosion reaction.
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Example
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Corrosion Cell
Anode
• Location where corrosion occurs
• Positive electrode in an electrolytic cell
• Metal loosing an electron and tends to degrade

Cathode
• Location where protection occurs
• Negative electrode in an electrolytic cell
• Chemical reaction is a reduction reaction
• The metal gaining electrons

Electrolyte

• Any material in contact with both the anode and the cathode which will allow ions to migrate
• Can be any soil or liquid adjacent to and in contact with the anode and cathode

Metallic Path
• Any conductor which allows electrons to flow from the anode to the cathode
• Electron flow must be present for electrochemical corrosion to occur
• In the case of a tank or pipeline, this can be the tank or pipe itself, or it can be a metallic bond to different
metallic structure
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Cathodic Protection
Working Principle
• Principle of cathodic protection is, connecting an external
anode to the metal to be protected and the passing of an
electrical current so that all areas of the metal surface
become cathodic and therefore do not corrode
• Corrosion moves to external anode from structure to stop
further corrosion from occurring
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Cathodic Protection
Corrosion Rate Vs. Current

• Corrosion rate drops as we apply

CP current
• Corrosion rate goes to nearly
zero and the structure is
considered cathodically protected
• For some metals, if you apply too
much current, you can cause
damage to the metal
• Too much current can damage
some metals such as stainless
steel and titanium
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Cathodic Protection
Corrosion Rate Vs. Current
• Corrosion rate drops as we apply CP current
• Corrosion rate goes to nearly zero and the structure is considered
cathodically protected
• For some metals, if you apply too much current, you can cause damage
to the metal
• Too much current can damage some metals such as stainless steel and
titanium
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Cathodic Protection Components

Structure Being Protected

Electrolyte that Current can Flow Through

Ando System Delivering Current

Cabling

• For connecting structures & anode system

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Cathodic Protection Techniques

Galvanic(Sacrificial) Cathodic Protection

• Involves protecting a metal surface of a structure using another metal

that is more reactive
• Latter metal, usually called the galvanic or sacrificial anode, has a less
negative electrochemical potential compared to the metal being
protected
• Sacrificial anode undergoes oxidation
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Galvanic Anodes
 Electro- potential of common metals buried in soil
 Potential in mV relative to Cu/CuSO4 reference electrode

Anodes Electro-Potential

Magnesium -1700

Aluminum -1150

Zinc -1100

Carbon Steel -550

Ductile Iron -525

Ductile Iron -300

Copper -200

Silver +200

Gold +800

Platinum +1000
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Cathodic Protection Techniques

Impressed Current Cathodic Protection (ICCP)

• In larger structures, galvanic current is not enough to prevent corrosion so

impressed current is applied in opposite direction and to convert corroding
metal from anode to cathode
• In ICCP, electrons are supplied to the cathodic structure using an external
DC power source (also called a rectifier).
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ICCP Anode
 The most commonly used materials for impressed current anodes
are graphite and high-silicon cast iron
 The best materials is one which has a low rate of weight loss per
ampere-year

Mixed-Metal Oxide Anodes

 MMO anodes have become the anode of choice for most
applications
 MMO consists of a coating over a titanium substrate
 They have negligible consumption rate (dimensionally stable)
 Available in a wide range of configuration, spheres, ribbon, wire,
rods, tubes, plates & mesh
 They have maximum current density of 9.3 A/ft2
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Comparison of CP Techniques
Anode System Advantages Disadvantages
 Simple & reliable  Low output
Sacrificial Anodes
 No need of external power  Short life
 Often lower cost  No power switch
 Little to no maintenance  Difficult to test
 Limited Use
 Additional anodes to
increase current output

 Long Life  Requires Power

Impressed Current Anodes
 Exceptional reliability
 Need Closer monitoring
 Large current from small anodes
 Wide range of configuration & maintenance
 Negligible consumption rate
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Cathodic Protection Design

Evaluating the Structure
• Structure geometry
• Bare surface area vs. coated surface area
• Quality & type of coating
• Electrical continuity of the structure
• Metallurgy

Evaluating the Environment

• Electrolyte resistivity/conductivity
• Presence of other structure that might affect or be impacted by CP system
• Variations in the environment

Anode Placement and Constraints

• Physical constraints for locating anodes
• Current distribution issues, how far away from the structure can the anode be
placed
• Availability of power
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Anode Configurations
Remote Anode Systems
• Used to project current over a wide area
• Placed a distance away from the structure being protected
• Deep anode beds or remote horizontal ground beds

Discrete Anode Systems

• Located at a short distance from the structure being protected
• 5-10 ft. away from structure
• 5-10 ft. depth
• Can be galvanic or impressed current

Linear Anode
• Installed parallel to the structure being protected
• Used for new construction pipeline & plant applications
• Low power system
• Easy to install
• Very reliable
• Long Life: 50-100 years
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Additional Components in CP System

Anode Backfill
• Increases size of anode to reduce resistance to earth & bears some of the
consumption resulting from current discharge
• Provide a uniform electrolyte, maintain moisture
• Lower the resistance to earth to allow the anode to produce the required
electrical current in an efficient and reliable manner

Rectifier
• Increase the potential of the electrons from the anodes in order to provide
the desired protective current
• Convert alternating current into controlled direct current

Test Station
• Used to measure the current applied to pipeline
• Direct connection with pipe line

Reference Electrode
• Fixed potential electrode of know potential,
• Buried near the test stations and find the potential applied to pipeline
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CP System at SGCPF

Sacrificial CP system

• Condensate Storage Tank 1 & 2

• Slope Vessel
• Glycol Tank
• Fire Water Pipeline

ICCP System

• Sujjal-1 Pipeline
• Condensate Storage Tank 3 & 4
• Fire Water Tank
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CP Design at SGCPF
 Sacrificial CP for Condensate Storage Tanks
Tank diameter (O.D) 5m= 16.41 ft
Surface Area 211 sq. ft
Soil Resistivity 2000 Ohm-cm
CP system Life (Y) 20 years
Estimated Current Density 1.2mA/[Link].
Sacrificial Anode Magnesium
 Soil resistivity measured with resistivity meter using four pin method at
location near condensate tank which was 2000 ohms-cm at 6 ft. depth
 It was proposed to use 7.7 Kg magnesium anodes packed in backfill
constituting 75% gypsum, 20% bentonite & 5% sodium sulphate resistivity
of 5 ohm-cm
 Protection Current Requirement
𝟏𝐦𝐀
Current 𝐑𝐞𝐪𝐮𝐢𝐫𝐞𝐝 = 𝐒𝐮𝐫𝐟𝐚𝐜𝐞 𝐀𝐫𝐞𝐚 (𝐟𝐭 𝟐 ) 𝐗 𝐂𝐮𝐫𝐫𝐞𝐧𝐭 𝐃𝐞𝐧𝐬𝐢𝐭𝐲 ( )
𝐟𝐭 𝟐
= 1.2 X 211
=253 mA =0.253 A
Required Driving Potential =0.75 V
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No. of Anodes
 Based on Magnesium Weight
𝐈𝐦 𝐱 𝐘 𝐱 𝐀𝐧𝐨𝐝𝐞 𝐂𝐨𝐧𝐬𝐮𝐦𝐭𝐢𝐨𝐧 𝐑𝐚𝐭𝐞
Weight (W) =
𝐔𝐥𝐭𝐢𝐥𝐢𝐱𝐚𝐭𝐢𝐨𝐧 𝐅𝐚𝐜𝐭𝐨𝐫
Where,
W= Total weight of Mg anodes in kg required to supply required protection current
Y= Life of CP system=20 Year
Im= Total average current required to protect the structure in Amp
Consumption rate = 7.90 Kg
Utilization factor = 0.85
𝟎.𝟐𝟓𝟑𝐗𝟐𝟎𝐗𝟕.𝟗𝟎
Weight (W) = 𝟎.𝟖𝟓
W= 47.03 kg
No. of 7.7 kg Magnesium Anodes = 47.03/7.7
=6.1

 Based on Anode Resistance

𝟎.𝟎𝟎𝟓𝟐𝑰 𝟖𝑳
Anode Resistance (Rv) = 𝐋𝐧 − 𝟏
𝑳 𝒅
=11.447 ohms
𝐃𝐫𝐢𝐯𝐢𝐧𝐠 𝐏𝐨𝐭𝐞𝐧𝐭𝐢𝐚𝐥
Current per anode = 𝑹𝒗
0.75
Current Per Anode= 11.447
Current Per Anode = 0.066 Ampere
𝟎.𝟐𝟓
Number of Anodes = 𝟎.𝟎𝟔𝟔 = 3.8
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Sacrificial CP System
Tank-1 Tank-2 Fire Water Pipeline Glycol Tank Slope Vessel

No. of Anodes Based on Anode

6 6 9 3 5
Weight

No. of Anodes Base on Anode

4 4 6 2 3
Resistance

Spread One:5
Present Status of Anode 6 6 3 5
Spread Two:4

Required Current 253 mA 253 mA 350 mA 102 mA 202 mA

Applied Current 396 mA 396 mA 479 mA 198 mA 330 mA

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ICCP at SGCPF

 Mixed metal oxides (MMO) anodes are used for

ICCP
 5 MMO anodes installed at Sujjal-1 line
 25 test stations at Sujjal-1 line
 Copper sulphate used as reference Electrode
 Range of voltage is -850 mV to -1200 mV for
proper ICCP
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