CATHODIC PROTECTION

Introduction:
Cathodic Protection is a technique used to prevent corrosion of:
 Underground “buried steel, cast iron, ductile iron and copper” Metallic
piping systems in a tightly spaced footprint.
 Underground Metallic pipeline systems and steel structure
 Buried , On-grade storage tanks bottom Water tanks interiors
 Other Underground applications such as copper grounding system
,reinforcing steel embedded in concrete, conduit, Equipment and
structural pilings

Cathodic protection is an electrical method (technique) for eliminating

Corrosion occurs. It is one of the most important and effective of all approaches to
corrosion control for underground (-submerged) commodities.
Corrosion engineers and technicians are responsible for designing, installing, and
maintaining Cathodic protection systems to ensure that metal structures remain
protected from corrosion.

Cathodic Protection Definitions:

Anode: an electrode of an electrolytic cell at which oxidation occurs in
Corrosion processes, this is the area where corrosion occurs.

Cathode: an electrode of an electrolytic cell at which reduction occurs in

Corrosion processes,” the area that is not attacked.

Eng. Ashraf Waly

Cathodic Protection: a technique used to prevent the corrosion of a metal Surface by making
that surface the cathode of an electrochemical cell.

Corrosion: a destructive deterioration (Attacked Area) of a metal due to the

Reaction with its environment.

Eng. Ashraf Waly

Electrical Isolation: The condition of being electrically separated from
Metallic structures or the environment.

Electrode Potential: The potential of an electrode measured against a Reference electrode.

Current Density: The current per unit area.

Electrolyte: a chemical substance or mixture, usually liquid, containing ions

that migrate in an electric field. Electrolyte refers to the soil or liquid adjacent to and in contact
with a buried or submerged metallic structure, including the moisture and other chemicals

Galvanic Anode: a metal with relative position in the galvanic series provides sacrificial
protection to metal or metals that are nobler in series, when coupled in an electrolyte.

Sacrificial Protection: Reduction or prevention of corrosion of a metal in an

Electrolyte by galvanic coupling it to a more anodic metal.

Impressed Current: Direct current supplied by a power source external to the

electrode system.

Inhibitor: a chemical substance or mixture, Applied to Corrosion

when added to an environment usually in small concentration, effectively
decreases corrosion.

Interference: Adverse corrosion occurs on a metallic structure caused by an

Unintended flow of cathodic protection current picked up by this structure from one area and
return to its source through another area of the same structure.

Ion: an electrically charged atom or group of atoms.

Polarization: the change of potential of a metal surface resulting from the passage of current
directly to or from an electrolyte.

Reference Electrode: a device whose open circuit potential is constant

under similar conditions of measurement.
Sacrificial Protection: Reduction or prevention of corrosion of a metal in an
electrolyte by galvanically coupling it to a more anodic metal.

Stray Current: Current flowing through paths other than the intended circuit.
Note: Definitions according to NACE RP0169-92

Eng. Ashraf Waly

 CATHODIC PROTECTION

Advantages Disadvantages
1-Provide long-term protection for structures/ 1-Initial installation cost can be relatively high for
equipment. Result a significant cost savings. some projects with budget constraints.Decission
Reducing frequent repairs or replacements. return here to stakeholders

2-Particularly useful for buried or submerged 2- Require a power source, which can be an external
structures, such as underground pipelines, where power supply or sacrificial anodes. Dependence on
direct access for maintenance and inspection is power sources may be a limitation, especially in
difficult. remote or off grid locations.

3-Cathodic protection can be a cost-effective solution 3-Cathodic protection systems are generally low
compared to alternatives such as coating systems or maintenance, periodic monitoring and maintenance
frequent maintenance. It helps to avoid the costs are still necessary to ensure their continued
associated with corrosion related failures. effectiveness. This may involve testing the electrical
potential, inspecting anodes, and addressing any
4-Cathodic protection systems are generally passive issues that arise.
and require minimal maintenance. This makes them
suitable for remote or hard to reach locations. 4-The use of sacrificial anodes in some Cathodic
protection systems involves the consumption of
5-Cathodic protection can be used in conjunction with metals like zinc or aluminum, which can have
coating systems to provide dual layer protection, environmental implications. Proper disposal and
enhancing overall corrosion resistance. recycling practices are essential to minimize
environmental impact.
6-Cathodic protection effectiveness in preventing
corrosion of metal structures. By imposing a negative 5 Cathodic protection system design requires a
potential on the metal surface, the corrosion process thorough understanding of the structure, the
is inhibited. surrounding environment, and the corrosive factors
involved. This complexity can lead to challenges in
system design and implementation.

Reference: Cathodic Protection Handbook

Eng. Ashraf Waly

 CATHODIC PROTECTION STANDARDS
ASME STANDARDS

ASME G8 Standard Test Methods for Cathodic Disbanding of Pipeline Coatings

ASME G95 Testing Method for Cathodic Disbanding of Pipeline Coatings (Attached Cell Method)

ASTM STANDARDS

ASTM American Society of Testing and Material

ANSI STANDARDS

ANSI American National Standards Institute

AWWA STANDARDS

 AWWA C-105-Polyethylene Encasement for Ductile-Iron Piping for Water and other Liquids
 AWWA C214 - Tape Coating Systems for the Exterior of Steel Water Pipelines
 AWWA C222 - Polyurethane Coatings for the Interior and Exterior of Steel Water Pipe and Fittings

NACE STANDARDS

 NACE SP0102 - In-Line Inspection of Pipelines

 NACE SP0104 - The Use of Coupons for Cathodic Protection Monitoring Applications
 NACE SP0106 - Control of Internal Corrosion in Steel Pipelines and Piping Systems
 NACE SP0169 - Control of External Corrosion on Underground or Submerged Metallic Piping Systems
 NACE SP0188 - Discontinuity (Holiday) Testing of Protective Coating
 NACE SP0193 - External Cathodic Protection of On-Grade Carbon Steel Storage Tank Bottoms
 NACE SP0216 - Steel-Cased Pipeline Practices
 NACE SP0205 - External Corrosion Control of Underground Storage Tank Systems by Cathodic Protection
 NACE SP0207 - Close-Internal Potential Surveys on Buried or Submerged Metallic Pipelines
 NACE SP0216 - Sacrificial Cathodic Protection of Reinforcing Steel in Atmospherically Exposed Concrete Structures
 NACE SP0290 - Impressed Current Protection of Reinforcing Steel in Atmospherically Exposed Concrete Structures
 NACE SP0502 - Pipeline External Corrosion Direct Assessment Methodology
 NACE SP0607 - Petroleum and Natural Gas Industries-Cathodic Protection of Pipeline
 NACE SP21434 -Cathodic Protection Systems for the Mitigation of External Corrosion of Buried and Submerged Metallic Piping
Systems at Nuclear Power Plants
 NACE Publication 1E100 -Engineering Symbols Related to Cathodic Protection
 NACE TR01105 -Sacrificial Cathodic Protection of Reinforced Concrete Elements
 NACE TR21447 -Consequences of Coating Failures as Related to Interaction with Cathodic Protection
 NACE TR21463 -Criteria for Evaluation of Cathodic Protection Methods for Steel in Existing Concrete Structures
 RP0169-92 -Recommended Practice. “Control of External Corrosion on Underground or Submerged Metallic Piping Systems"
 RPO572-85 -Recommended Practice. “Design, Installation, Operation and Maintenance of Impressed Current Deep Ground beds”
 NACE RP0186 - Application of Cathodic Protection for External Structures of Steel Well Casings

OTHER CODES & STANDARDS

BRITISH STANDARD BS 7361 , API 651 ,J.MORGAN

Eng. Ashraf Waly

There are two cathodic protection techniques as follow:

 Sacrificial (Galvanic):

Use of a more active metal as a source of protection current (anode)

Anode is electrically connected to the structure to protected & chosen to be

higher on the galvanic chart allowing the structure to become a cathode
Easy installation, No external power source and require virtually no monitoring or
maintenance

Common galvanic anode materials:

 Magnesium (High potential for soils)

 Zinc (Lower potential for soils below 1500 ohm-cm) above 1500 ohm-cm)

 Aluminum (Seawater applications)

Important Note : Galvanic anode shape and weight are vary:

Longer anode = more current per given soil

Heavier anode = longer life.

Anode is electrically connected to the structure to protected & chosen to be

higher on the galvanic chart allowing the structure to become a cathode

Eng. Ashraf Waly

Eng. Ashraf Waly
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Eng. Ashraf Waly
 IMPRESSED CURRENT ANODES CATHODIC PROTECTION TYPES

Uses a sacrificial anode connected to an external DC power source. DC flows from

source to anode, to protected material, to source.

Involves the enforcement of protection current by the use of a DC power source

Connected to anodes (positive terminal) and to cathode (negative terminal)

There are three basic approaches to for underground piping and structures
1. Deep Anode

High current capacity anodes are installed from the structure in “a deep hole drilled”
vertically 150+ feet deep. This is analogous to lighting a football field with floodlights.

Eng. Ashraf Waly

 Buried and on-grade storage tanks are in contact with the soil and hence it is externally
cathodically protected
 Tanks cathodic protection could be made through sacrificial anodes (not recommended) or
through impressed current systems
 Impressed systems could be made utilizing either deep well,shallow horizontal groundbeds,
distributed anodes system or anode mesh underneath storage tanks.
Note: Before any cathodic protection is to be made tank shall be electrically isolated from piping
and tank earthling shall also be considered

2. Shallow Anode or Distributed Anode Bed

Another method is to use a shallow ground bed anode design where many
smaller capacity ground bed anodes are spaced near the intended structures –
analogous to street lamps lighting a street.

Eng. Ashraf Waly

3. Linear Anode

The third method is to place a linear anode parallel to and in close proximity to
the piping to be protected discharging current continuously along its length –
similar to fiber optic lighting.

Eng. Ashraf Waly

 CATHODIC PROTECTION TYPES COMPARISON
Sacrificial Anode Impressed current Anode
1-No need for external power source 1-Requires an external power source

2-Easy to design and install 2- Require skills for design and install

3-Used for limited surface areas and 3-Used also for Coated and Uncoated
well coated structures surfaces

4-No determinable effects 4-Caused serious problems if not

handled carefully
5-Uncontrollable
5-Can be controlled
6-Limited to low resistivity
environments 6-Used at any resistivity environments

7-Low maintenance 7- High maintenance

Eng. Ashraf Waly

Cathodic Protection Questions & Answers

1. What is the minimum distance required for an anode that having an individual DC. Source?
Ans. 50 Meters

2. In underground-buried pipelines within how many days to provide, achieve or install galvanic anode for
Temporary C.P. Systems using a 3-pin test station?
Ans. 30 Days

3. What is the minimum Design life of impressed current cathodic protection system for C.P.?
Ans. 20 Years

4. What is the minimum Design life of a galvanic anode system for electrically Isolated short pipeline
section. (GACP)?
Ans. 20 Years

5. What is the minimum design life for temporary C.P. system?

Ans. 2 years

6. What is the minimum current density requirement for uncoated pipeline surface?
Ans. 20.00 (mA/m²)

7. What is the minimum current density requirement for coated pipeline surface?
Ans. 0.10 (mA/m²)

8. What is the minimum Current density requirement for temporary C.P. system for coated pipelines?
Ans. 0.005 (mA/m²)

9. What is the pipeline minimum negative pipe to soil on potential with reference to a copper/copper
sulfate electrode (As Designed)?
Ans. 1.2 VDC

10. What is the pipeline minimum negative pipe to soil on potential with reference to a copper/copper
sulfate electrode for Temporary CP. System?
Ans. 1.0 VDC

11. What is the pipelines maximum negative pipe to soil on potential with reference to A copper/copper
sulfate electrode?
Ans. 3.0 VDC

12. What is the pipeline valves and associated buried piping minimum negative pipe to soil on potential
with reference to a copper/copper sulfate electrode Include pipeline junctions, PS, CS and Others?
Ans. 1.0 VDC

Eng. Ashraf Waly

13. What is the pipeline valve and associated buried piping maximum negative pipe to soil on potential
with reference to a copper/copper sulfate electrode include pipeline junctions, PS, CS and Others?
Ans. 3.0 VDC

14. What is the impressed Current anode design parameters consumption rate for high silicon cast iron
anode materials?
Ans. 0.45(Kg/Ay)

15. What is the maximum current density of an impressed current anode design parameters for high
silicon cast iron anode material?
Ans. 0.7(mA/cm²)

16. What is the galvanic anode design parameter consumption rate for magnesium anode material?
Ans. 7.71(kg/Ay)

17. What is the galvanic Anode design parameter potential for Magnesium anode material?
Ans. -1700(mV)(Cu/CuSO4)

18. How many meters deeper than if we classified the anode installation as Deep Anode Beds?
Ans. 15 Meters

19. What is the minimum anode Bed distance from Buried structure with rectifier Rated output of 35
Amps. Or less?
Ans. 35 Meters

20. What is the minimum anode Bed distance from buried structure with rectifier Rated output of 50
Amps?
Ans. 75 Meters

21. What is the minimum Anode Bed distance from buried structure with a rectifier rated output of 100
Amps?
Ans. 150 Meters

22. What is the minimum Anode bed distance from buried structure with rectifier Rated output of 150
Amps?
Ans. 225 Meters

23. What is the minimum distance of separate adjacent anode beds powered from separate power
sources?
Ans. 50 Meters

24. What type of enclosure requirement for oil Immersed rectifier units?
Ans. Type OA

25. What type of enclosure requirement for dry type or Air cooled unit’s rectifier?
Ans. Type AA

Eng. Ashraf Waly

26. What is the rectifier minimum Distance in of a hydrocarbon plant perimeter fence?
Ans. 30 Meters

27. What is the rectifier minimum distance with in of a coastline?

Ans. 1 Kilometer

28. What is the maximum DC. Voltage Requirements of a CP. Rectifier?

Ans. 100 VDC

29. How many meters intervals in paved areas directly over the pipeline for CP. access test station?
Ans. 20 Meters

30. We have to provide CP. Test station per kilometer?

Ans. 1 KM.

31. What is the minimum mounting requirement of an oil immersed rectifiers above ground?
Ans. 300 mm

32. What is the above grade mounting requirement for NEMA rating enclosures?
Ans. 1.8 Meters

33. What is the enclosure minimum installation requirement with in the rectifier?
Ans. 3 Meters

34. What is the percentage requirement of Circuit breaker rating for the rectifier input current at rectifier
rated load?
Ans. 125%

35. What is the limit-splicing interval of buried main positive cable runs, between rectifier and anode bed
junction box?
Ans. 150 Meters

36. How many pound of Magnesium Anode required to be installed?

Ans. 100 Lbs.

37. Parallel pipeline should be bond in every ______ Kilometers?

Ans. 10 KM

Thank you for reading

Eng. Ashraf Waly