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The presentation is to present how a basic Cathodic Protection System functions to protect steel structures. The idea of Cathodic Protection (CP) System is to prevent and mitigate the corrosion activities occur at structures by using materials called anodes. Anodes material will be

discussed at the slide later and some other applications of it.

By the end of the slide, reader should have basic idea of how CP System protect a structure.

In order for a structure to corrode, three conditions must be present. 1. Two dissimilar metals 2. Electrolyte (water, moisture, liquid and such) 3. Conducting path between the dissimilar metals. Chronology for corrosion protection usually are: 1. Coating System : a. Paint coating b. Physical protection eg. SEASHIELD

2. Cathodic Protection:

Cathodic Protection (CP) System is a proven method to reduce or prevent corrosion rate on metal structures. Two types of CP System: Galvanic CP System & Impressed Current

Cathodic Protection (ICCP) System.

Coating is usually the main protection for the offshore structures before SEASHIELD and/or CP System are implemented. The common coating for offshore structure is Coal Tar Epoxy (CTE).

CTE Coating is a polyamide/epoxy coal tar coating formulated to provide excellent resistance to crude oil, fuel oil, chemicals, corrosion and seawater.
CTE is widely used Dam gates, lining for petroleum storage tanks, water tanks, sewage water treatment tank, marine applications, and heavy duty structural pipe coating.

Advantages for CTE:

Excellent protection for submerged and underground structures. Economical the cheapest yet effective protective coating. Excellent chemical resistance excellent resistance to both acidic and alkaline substances. Excellent abrasion resistance. Easy application simple mixing and application procedures.

Fusion Bonded Epoxy (FBE), it is a one-part, heat cured, thermosetting epoxy coating that provides excellent protection for steel piles and could be used for onshore and offshore application.

FBE can be applied as dual layer product which provides tough physical
properties that minimize damage during handling, transportation, installation and operation. FBE has also been designed for good chemical resistance under most soil condition, seawater environment and wastewater applications.
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Advantages for FBE:

Applied in an automated one-part process so that the mixing, surface preparation, and multiple-coat problems associated with liquid paints are eliminated.

Smooth coating, even coating thickness with no runs, sags, or thin spots
common with applying liquid paints. Durable and provide twice the impact strength of liquid epoxies. The surface provides high abrasion resistance for steel piles. Long-term performance in water and sewage environments including seawater, slurries, methane and hydrogen sulfide exposure.
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SEASHIELD is an physical protection for the steel piles and it is designed to withstand rough and turbulent water condition caused by strong tidal flows and wave action. It seals the substrate against oxygen and water, preventing corrosion and deterioration. SEASHIELD 2000 is the common series used in the severe seawater environment.

Advantages:
Minimal surface preparation. Immediate protection from further corrosion. No curing or drying time. Hoop tension generated by tightening the nuts and bolts guarantees the water tight seal of paste and tape against the pile. The jackets are easily installed with adjustable wrenches.
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There are basically four components of SEASHIELD System: 1. Denso S105 Paste

Soft beige paste which may be applied underwater by gloved hand, stiff bristle

brush or roller on badly corroded and pitted steel above and below water prior to the application of the tape. It displaces water and fills pits and depressions.

2. Denso Marine Piling Tape

A petrolatum tape formulated for application underwater or to wet surfaces. When

applied spirally with sufficient tension it will displace water and develop a water resistant bond to metal surfaces. (150mm or 300mm x 10m rolls)

3. Outer-cover Jacket

A tough ultra-violet resistant HDPE jacket that provides protection to the tape

against abrasion, wave action and accidental impact.

4. Fastenings

An ultra-violet and salt water resistant acetal polymer smart banding that tighten

and hold the HDPE jacket .

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1.

Remove from the area to be protected all marine growth, loosely adhering coating, and corrosion products (rust) from all exposed metal surfaces by using high pressure water jetting. (additional of CHLOR*RID chemical to accelerate the removal of marine growth.)

2. Surface pre-treatment with Denso Paste S105. Denso Paste is applied to the areas of deep pitting or weld scars. 3. Tape Wrapping. Denso Marine Piling Tape is used to wrap the pile after Denso Paste S105 is applied. Wrap around the pile following a spiral path until and overlap of 55% is achieved. 4. Install the HDPE Jacket and tighten by polymer smart banding.

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CHLO*RID as an additional chemical used to remove marine growth.

Steel pile surface should be cleaned and free from barnacles or marine growth.

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High pressure water jetting is sometimes used with CHLO*RID solution to accelerate removal of barnacles.

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Next step is to apply Denso Paste S105 as pre-treatment to fill the cavities, voids, pitting and displace water in pitting.

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Followed by wrapping Denso Marine Piling Tape to the entire areas where HDPE Jacket protect. It also acts as the first layer of protection before jacket is installed.

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After Denso Tape had applied, HDPE Jacket is wrapped to the pile. Then is tighten with polymer smart banding system.

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Figures show a complete HDPE Jacket protected pile with smart banding system.
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Galvanic CP System also known as the Sacrificial Anodes CP System. Anodes will be depleted and consumed by the protected structure after periods of time. Metals usually used as sacrificial anodes are: Aluminum Zinc Magnesium Aluminum and Zinc anodes are widely used in seawater environment whereas magnesium anodes can be used for underground or fresh water. Galvanic CP System is commonly used on structures which require small cathodic protection current and where resistance is low.
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Advantages:

Self-powered. No external power source is required. Easy installation. Low maintenance. Less likely to generate stray current interference on other structures. Its more economical than ICCP if the current requirement is small.

Disadvantages:

Low driving voltage. Limited application in low resistivity soils. Not an economical method for large amounts of CP current requirement. Limited capacity to control stray current effects on the protected structure.

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Sacrificial aluminum anodes are installed at the sheet pile for submerged section.

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Figures shown are the Aluminum sacrificial anodes installed to protect the steel piles.

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Figures shown are the Magnesium anodes in a form of Peggy bag.

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ICCP System is usually used to protect large bare and coated structures in high resistivity electrolytes. ICCP System applies DC current for the anodes but in not Galvanic System. Thus, ICCP System has an extra component to supply current to anodes called TRU, Transformer Rectifier Unit. Materials used as the anodes are: High Silicon Cast Iron Anodes MMO Anodes Platinized Titanium Anodes Platinized Niobium/Tantalum Anodes To note that all anodes perform differently in different service environment. Besides, designing of ICCP System must consider the potential in causing coating damage and generating stray currents that affect other structures.
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Advantages:

High flexibility Applicable to a variety of applications. Current output may be controlled. Not constrained by low driving voltage. Effective in high resistivity soils.

Disadvantages:

Higher maintenance. Higher operating cost. May cause interference on other structures.

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-ve

+ve

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Figure shown is the Transformer Rectifier Unit (TRU) which supply power.
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Figure shown is the Sled Anode. It also called High Silicon Cast Iron.

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Anodes

Supporting Rope

Dead Weight

Figures shown are the LIDA TSATM Anodes: Mixed Metal Oxide (MMO) on titanium anode material and designed to provide superior protection of offshore platforms.
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Figure (left) shown are LIDA Tubular Anodes: Titanium tubes with Mixed Metal Oxide coating. MMO is a crystalline and electrically-conductive coating.

Figure (right) shown are LIDA Wire Anodes: Copper Titanium wire with MMO coating. In two diameter, 1.5 mm and 3 mm.
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Figure (left) shown is the LIDA Pack Canister Wire Anode: For shallow vertical and horizontal surface groundbeds, wet, and marshy soil condition.

Figure (right) shown is the LIDA Rod Anodes: Comprised of Titanium substrate with Mixed Metal Oxide Coating.
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Mooring Dolphin Splash Zone Sea Level SEASHIELD 2000 Smart Banding System Denso Paste & Denso Tape Coal Tar Epoxy Coating

Aluminum Anodes

Sea Water

Sea Bed
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