FAUJI FERTILIZER COMPANY LTD.

Engineering Division, Rawalpindi- Pakistan

Muhammed Azeez Sadiq

Date: January 27, 2015

Cathodic Protection
Introduction
Cathodic Protection systems are a vital part of any underground piping. These are deployed
to prevent any corrosion of piping due to the potential differences that exist with the soil.
Proper installation of cathodic protection systems is essential for the pipeline to maintain its
integrity over the years.

Corrosion Phenomenon
Corrosion requires three things to occur.
1. Two dissimilar metals
2. An electrolyte (water with any type of salt or salts dissolved in it)
3. A metal (conducting) path between the dissimilar metals
If the above conditions exist, the following reaction takes place at the more active sites or
anode
2Fe => 2Fe2+ + 4eThe free electrons travel through the metal path to the less active sites, where the following
reaction takes place:
O2 + 4e- + 2H20 => 4 OHRecombination of these ions at the active surface produces the following reaction, which
yields the iron-corrosion product ferrous hydroxide
2Fe + O2 + 2H2O => 2Fe (OH)2

Types of Cathodic Protection

Cathodic protection systems are divided into two categories:
1. Galvanic Cathodic Protection
2. Impressed Current Cathodic Protection

Galvanic Cathodic Protection

Galvanic Cathodic Protection works by introducing a more active metal into the system that
corrodes in preference to the metal in the piping. The activity of the metal refers to its
electronegative potential. A less electronegative metal has a higher activity than a more
electronegative metal. It thus acts as an electron donor and supplies electrons to the other
metal.
Normally, the piping metal acts as anode and corrodes itself. With a more active metal
connected to it electrically, the metal however acts as a cathode with the other more active
metal becoming the anode. Cathodic protection thus prevents corrosion by converting all of
the anodic sites on the metal surface to cathodic sites by supplying electrical current (or free
electrons) from an alternate source.
In the case of aluminum anodes attached to steel, the reaction at the aluminum surface is
4Al => 4AL3+ + 12 eand at the steel surface:
3O2 + 12e- + 6H20 => 12OHAs long as the current arrives at the cathode faster than oxygen is arriving, no corrosion will
occur.

Figure 1. Sacrificial Anode System in Seawater

The anode corrodes over time and must be replaced after a period of time depending on the
corrosive conditions present. Typical metals used as anodes include magnesium, zinc and
aluminum.

Impressed Current System Protection

For larger structures, galvanic anodes cannot
economically deliver enough current to provide
complete protection. Impressed current cathodic
protection (ICCP) systems use anodes
connected to a DC power source. Anodes for
ICCP systems include high silicon cast iron,
graphite, mixed metal oxide, platinum and
niobium coated wire and others.
A typical ICCP system for a pipeline would
include an AC powered rectifier with a maximum
rated DC output of 10-50 A and 50 V. The
positive DC output terminal is connected via
cables to the array of anodes buried in the
ground.
As in sacrificial anode systems, impressed
Figure 2. ICCP System in Seawater
current systems depend on a supply of high energy
electrons to stifle anodic reactions on a metal
surface. In the case of an impressed current system these high energy electrons are
supplied by a rectifier. Low energy electrons that are picked up at a non-reactive anode bed
are given additional energy by the action of a rectifier to be more energetic than the electrons
that would be produced in the corrosion reaction.
The energy for the electron energy pump action of the rectifier is provided by ordinary
alternating current. The effect of these electrons at the structure being protected is the same
as that derived from the sacrificial anode type of cathodic protection system. However, the
anode material serves only as a source of electrons and need not be consumed in providing
protective current.
The materials used for impressed current cathodic protection can pass current into the
environment without being consumed at a high rate. Graphite and high silicon cast iron are
the most commonly used impressed current cathodic protection anode materials.
Anodes in impressed current systems must be inspected and replaced if consumed or
otherwise damaged. As is the case for any electrical equipment, rectifiers used for impressed
current cathodic protection systems require preventative maintenance to insure proper
operation.

Requirements for Cathodic Protection

When a cathodic protection system is installed, it must be checked to ensure that the
potential difference between the metals is acceptable. If a minimum potential difference is not
achieved, then the cathodic protection system will not function effectively. The original NACE
specification for buried utility pipelines proposed the following criteria for determining when a
steel or cast iron structure meets the required standards.

A voltage of -0.85 V relative to a copper/ saturated copper sulfate electrode

A negative (cathodic) voltage shift of at least 300 mV caused by the application of
cathodic protection current
A minimum negative (cathodic) voltage shift of 100 mV determined by interrupting the
current and measuring the voltage decay
A net protective current from the electrolyte into the surface