2/13/2013

Modern Cathodic
Protection for Piping
Stanley Worcester, P.E.
NACE International Certified Cathodic Protection Specialist

February 20, 2013

worcesterstan@stanleygroup.com
303 925-8307

Agenda
1.Corrosion Basics
2.Cathodic Protection (CP) Criteria
3.Cathodic Protection Design (galvanic
anodes)
4.Types of Cathodic Protection Systems
5.Protected Structures
6.Structure Isolation
7.Design Considerations
References
Questions

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What is Cathodic Protection (CP)?

Is it a religion? (catholic?)
Is it a security system? (protection?)
Is it magic?
It is an electrochemical reaction that
mitigates corrosion.

How does it work with a natural

voltage less than a AA battery?

Anode, Cathode, Electrolyte,

Metallic Path Cable Connection
(DC)
(Cable)

- (Mg, Zn) +(Pipe)

Corrosion

Protection

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What is CP?
Electrochemical Reaction
Electrical portion electron flow (later)
Chemical portion removal of electrons (oxidation-Anodic)
and consumption of electrons (reduction reaction-Cathodic)

Anodic
Cathodic
Cathodic

CP - Electrical
Electrical conventional current (electron) flow from
a positive voltage to a negative voltage.
Ohms Law: I=V/R, V=IR, E=IR, R=V/I
I is current (Amperes)
R is Resistance (Ohms, )
V or E is Voltage or potential (Volts)
What is current?
What is resistance?
What is IR drop? Voltage drop

Electrons leaving a power supply are

trying to get to Ground (the earth)?
True or False? False

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Electrical
Question - Does current take the path of least
resistance?

1 Ohm 1,000 Ohms

Answer No, current follows all paths.

Cathodic

Anodic

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New Pipe Corrosion

Elements in Carbon Steel Pipe

1. Iron ductile, soft
2. Carbon - Strong, hard
3. Manganese
4. Silicon
5. Copper
Corrosion rate of buried steel is approximately 6
mils/yr. or 0.006/yr. Since 1 mil = 0.001 inches.
Assume pipe will fail when 1/4 of the wall thickness is
gone, a 0.295 pipe wall thickness will fail in 12
years without any cathodic protection.

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Galvanic Corrosion
Metallic Path Dissimilar Metals

Galvanic Corrosion
Metallic Path Dissimilar Soils

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Cathodic Protection (CP)

Cathodic protection is considered to be effective when
active corrosion is transferred from the metal structure
surface to the installed anode. Effectiveness of
transference can be determined by electrical
measurements.

Industry-accepted criteria for effective protection using

these measurements are fully described in various
NACE International publications including the Standard
Practice SP0169-2007 Control of External Corrosion on
Underground or Submerged Metallic Piping Systems."

Does Size Matter?

Is one anode
sufficient?
Does protection reach
this side of the pipe?

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Typical Packaged Galvanic Anode

Backfill Material
50 Ohm-cm

Cathodic Protection (CP)

Anode Shape Difference
L
Same weight Short & o Same weight
Wide n
g
High resistance Low resistance
&
Small current Large current
T
Long life h
Short life
i
n

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Cathodic Protection Criteria

Known as the -0.850 Volt, pipe-to-soil potential
1. This is a measured voltage between the steel structure &
a copper-copper sulfate reference electrode contacting the
electrolyte near the structure. If voltage difference is more
negative than -0.850 Volts, then the structure is considered
protected with consideration of voltage drop. If the value is
more positive than -0.850 Volts, the structure is either
unprotected or only partially protected.
2. A polarized potential with interruption of protection current
(instant off) of -0.850V.
3. 100mV of cathodic polarization. The formation or decay
of polarization is often measured in impressed current
systems.

Underground Permanent
Reference Electrode?

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Typical CP Design Questions - Example

What structure do I want to protect?
External surface of underground coated, carbon
steel 12 water pipe, 4 depth, 100 long.
What is the surface area?
12 or 1 ft. Diam, 100 Ft long.
PI x D X L = A (Surface Area)
PI () = 3.14
D=1 ft.
L=100 ft.

A = 314 square ft.

Typical CP Design Questions - Example

Is the soil corrosive?
Get soil resistivity ()measurement results and
have laboratory chemical analysis performed.
= 2,000 Ohm-cm, Chlorides = 100ppm,
Sulfates = 100ppm, pH = 7.
What else is in the soil?
Know the area, rural, residential, congested, other
structures, rocky, clay, sand, water table, etc..
What type of CP?
Use galvanic anode design?

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Soil Resistivity Measurements

Do I need CP?

Soil
Laboratory
Analysis

Do I need CP?

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Its the Law

Cathodic protection is a mandated
requirement of federal & state regulations
governing underground transmission
pipeline, gas distribution systems,
hazardous liquids & underground
petroleum tanks. These requirements
include installation, monitoring, &
maintenance of cathodic protection
systems*.

*See CFR References

Typical CP Design Questions - Example

How long do I want the anodes to protect
the structure?
Client wants 20 years. (CP System Life)
Which galvanic anode material is best?
Zinc anodes are typically installed in water or soil
with resistivity's less than 2,000 Ohm-cm.
Std Magnesium is typically 1000-5,000 Ohm-cm
Hi-Potential Magnesium is typically 2000 Ohm-cm
and higher.
What is the pipe coating efficiency?
90-98% for field applied coatings
95-99.9% for new factory coatings

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Typical CP Design Questions

Does a pipe coating alone provide
enough protection?

Is there a perfect coating?

How long will it last?

Is polyethylene encasement of ductile iron

water pipe enough?

48# Mag Anode

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Typical CP Design Questions - Example

Where do I install galvanic anodes?
In permanently moist soil (min 5 ft. deep)
Deeper than bottom of pipe
Protected from future construction
10 away from pipe
Vertical or horizontal?
How do I connect anodes to pipe?
Exothermic weld lead wire to pipe directly?
Terminate anode lead wire in test station and bond
to pipe lead wire.

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Support lead wire and provide slack wire

for settlement

48# Mag Anode

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One Galvanic Anode Direct Connection

What if copper cable is exposed?

Test Station Connection Anode Bank

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Cathodic Protection (CP) Design

Guidelines
Assume a minimum of 1 mA per square
foot required to protect bare structure.
Assume a minimum of 2 mA per square
foot of exposed surface area required to
protect a coated structure.
Current requirements (density) increase
with low soil resistivity, high temperature,
moisture, water flow, dissimilar metals, &
chloride content.

Typical CP Design Questions

What current density do I need?

Reference Army
Technical Manual
TM 5-811-7 1985

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CP Design - Example
Current Requirement for coated pipe
95% coated or 5% of 314 sq. ft. of surface area is
bare. Bare surface area is 314 x 0.05 =15.7 sq. ft.
15.7 sq. ft. x 2mA/sq. ft = 31.4 mA.
Driving Potential of anodes
Zinc = -1.10 V 0.85 (pipe)= 0.25V
Std Mg = -1.55 V 0.85 (pipe) = 0.70V
Hi-Pot Mg = 1.75 V 0.85 (pipe) = 0.90V
Maximum anode resistance R=V / I
Zinc = .25/.0314 = 8.0 Ohms
Std Mg = .70/.0314 = 22.3 Ohms
Hi-Pot Mg = .90/.0314 = 28.7 Ohms

CP Design - Example
Find Total Resistance RT of CP system.
Rv = Anode resistance of vertical anode
Rw = Lead wire resistance of 25 of #12AWG
Rp = Pipe resistance 100 of 12 diameter
Rc = Coating resistance Specified by supplier
(negligible on large structures and this example)
RT = Rv + Rw + Rp + Rc
RT = Rv + 0*

RT = Rv

*Since only the anode resistance is significant in this example.

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CP Design - Example
Find lead wire resistance
Lead wire resistance of 25 of #12AWG, HMWPE
Look up cable table in NEC, Rw = 1.93 Ohms / 1000 ft.
or 0.00193 Ohms per ft. or .0483 Ohms for 25
(negligible)
Find pipe resistance
Pipe resistance 100 of 12 diameter
In Peabody Rp = 5.82 microhms / ft. or
0.00000582 Ohms / ft. (negligible)

CP Design - Example
Comparison of 3 anode types
Zinc anode 18 lbs 5x38 Packaged
Std H-1 Mg 17 lbs 6.5x19 Packaged
Hi Potential Mg 17 lbs 6x29 Packaged

Compare these similar weight anodes for

current output and life expectancy.

Do you ever install just one anode?

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CP Design - Example
Zinc anode 18 lbs, 5 x 38 Packaged
Dwights Equation for vertical anode resistance to earth - feet

Ohms
8.0 Ohms max.
Dwights Equation for multiple vertical anodes in parallel

CP Design - Example
Zinc anode 18 lbs, 5 x 38 Packaged
The resistance to earth for one anode is 10.23 Ohms and for two
anodes in parallel is 5.40 Ohms.

One anode maximum current output is I = V / R

I = 0.25V / 10.23 Ohms = .024 Amps or 24 mA, which is less than
the 31.4 mA required.

Two anodes in parallel maximum current output is I = V / R

I = 0.25V / 5.4 Ohms = .046 Amps or 46 mA max or 31.4 / 2 =
15.7 mA each which is acceptable

One zinc anode could not produce enough current to cathodically

protect the coated pipe.

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CP Design - Example
Std Mg anode 17 lbs, 6.5x19 Packaged
Dwights Equation for vertical anode resistance to earth - feet

Ohms
22.3 Ohms max.
Dwights Equation for multiple vertical anodes in parallel

CP Design - Example
Std Mg anode 17 lbs, 6.5x19 Packaged
The resistance to earth for one anode is 14.18 Ohms and for two
anodes in parallel is 7.48 Ohms.

One anode maximum current output is I = V / R

I = 0.70V / 14.18 Ohms = .049 Amps or 49 mA, which is more
than the 31.4 mA required and therefore acceptable.

Two anodes in parallel maximum current output is I = V / R

I = 0.70V / 7.48 Ohms = .095 Amps or 95 mA, which is more than
the 31.4 mA required and therefore acceptable.
One or two Std Mg anodes could produce enough current to
cathodically protect the coated pipe.

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CP Design - Example
Hi-Pot Mg anode 17 lbs, 6 x 29 Packaged
Dwights Equation for vertical anode resistance to earth - feet

Ohms
28.7 Ohms max.
Dwights Equation for multiple vertical anodes in parallel

CP Design - Example
Hi-Pot Mg anode 17 lbs, 6 x 29 Packaged
The resistance to earth for one anode is 11.44 Ohms and for two
anodes in parallel is 6.0 Ohms.

One anode maximum current output is I = V / R

I = 0.90V / 11.44 Ohms = .079 Amps or 79 mA, which is more
than the 31.4 mA required and therefore acceptable.

Two anodes in parallel maximum current output is I = V / R

I = 0.90V / 6.0 Ohms = 0.150 Amps or 150 mA, which is more
than the 31.4 mA required and therefore acceptable.

One or two High Pot Mg anodes could produce enough current to

cathodically protect the coated pipe.

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CP Design - Example
Zinc anode Life expectancy for coated structure

L (1) = 0.0424 x 18 x 0.90 x 0.85 = 24.3 yrs.

.024 (one anode)
L (2) = 0.0424 x 18 x 0.90 x 0.85 = 37.2 yrs.
.0157 (each anode)
One anode is not sufficient for pipe surface area and two anodes
are acceptable at 37.2 yrs. each.

CP Design - Example
Std Mg anode Life expectancy for coated structure

L (min) = 0.116 x 17 x 0.50 x 0.85 = 17.8 yrs.

.047 (max one anode)
L (1) = 0.116 x 17 x 0.50 x 0.85 = 26.7 yrs.
.0314 (1 anode)
L (2) = 0.116 x 17 x 0.50 x 0.85 = 53.4 yrs. 2 anodes
.0157 (each anode)
One anode is sufficient for pipe surface area and capable of
47 mA discharge but only 31mA is required for protection.

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CP Design - Example
Hi-Pot Mg anode Life expectancy for coated structure

L (min) = 0.116 x 17 x 0.50 x 0.85 = 10.6 yrs.

.079 (max one anode)
L (1) = 0.116 x 17 x 0.50 x 0.85 = 26.7 yrs.
.0314 (1 anode)
L (2) = 0.116 x 17 x 0.50 x 0.85 = 53.4 yrs. 2 anodes
.0157 (each anode)
One anode is sufficient for pipe surface area and capable of
79 mA discharge but only 31mA is required for protection.

CP Design - Example
Summary of 3 anode type Comparison

Which Anode is best?

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CP Design Example 20 Yrs. & 31.4 mA

$100

$110

$170

Previous CP Design Example

Assumptions
Only pipe design, only external design
No dissimilar metals, no aggressive soils
Only vertical anode installation not horizontal
Welded (electrically continuous) pipe not gasketed
bell and spigot joint pipe.
No ROW restrictions
No valves, taps or modifications in pipeline
No shielding by structures, no isolation issues
No backfill damage or future construction damage
No line crossings, no stray current
No rectifiers, no casings
No concrete encasement.

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Types of Cathodic
Protection Systems
Galvanic or sacrificial anode system.
(magnesium, zinc, or aluminum anodes)

Impressed current system. (rectifier with

graphite, mixed metal oxide, silicon iron or
several other anode materials)

Galvanic
Advantages: flexibility in application, anodes
can be installed (evenly distributed) in a variety
of applications & configurations. No outside
power is required, minimal maintenance
required for these systems to function.
Disadvantages: limited protection current
available, limited life, rapid corrosion
(consumption), require replacement on a
regular basis, Design life of a pipeline system
anode is ten to twenty years.

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Impressed Current
Advantages: unlimited current opportunities &
longer life, installed where the structure to be
protected is large, requiring higher levels of current.
Easily adjusted to suite needs and changes.
Disadvantages: requirement for an outside power
source & higher maintenance requirements.
Outside power might come from sources such as
commercial AC converted to DC through a rectifier,
thermoelectric generator, or solar panels. A
significantly higher monitoring & maintenance effort
is required by comparison to sacrificial anode
systems. Higher capital cost and maintenance
costs. Stray currents. Shielded structures.

Impressed Current
What if anode What if + and
cable is exposed? - are reversed?

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Impressed Current Rectifier

Impressed Current
External power source that pushes DC current through
long-lasting anodes. Typical source of power is AC
power converted to DC by a rectifier.
Designed for long life at adjustable high current
output. This requires selection of materials with very
low corrosion (consumption) rates, including treated
graphite, high silicon cast iron, mixed metal oxide, & to
a lesser extent, platinum.
Anodes are normally installed in grouped
configurations in the electrolyte. These groupings at
one location (both horizontal & vertical) in
underground application are called groundbeds.

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Deep Groundbed

Deep Groundbed Drilling - Rural

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Deep Groundbed Drilling - City

Deep Groundbed Drilling - City

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High Silicon Cast Iron Anodes

Anode Centralizers

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Impressed Current Deep Groundbeds

Advantages: Located in congested areas, less real
estate on small footprint, lower resistance, better
current distribution, reduced shielding and stray
current, less damage caused by construction, no
seasonal variation, anodes can be replaced in
future.

Disadvantages: A higher installation cost, higher

anode inspection or replacement cost, care to
prevent ground water intermixing or contamination.

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Structure Junction Box Rectifier Negative

Anode Junction Box Rectifier Positive

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Cathodically Protected Structures

Underground Pipelines: Both sacrificial & impressed current
systems are used. Federal & state regulations require
cathodic protection for most petroleum or gas pipeline
systems.
Underground Storage Tanks (USTs): required by EPA to
either have functional cathodic protection systems or to be of
a non-corrosive material.
Aboveground Storage Tank (ASTs): bottoms can be
protected from soil-side corrosion with cathodic protection.
Unique problems involved with tank applications include
difficulty of distributing current uniformly over tank bottom &
monitoring effectiveness of systems.
Any metal connected to protected structure. (This requires
additional current).

Above-Ground Storage Tank

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Structure Isolation

Protected structures need to be isolated

from other structures by separation,
coatings, or insulated materials.

If isolation is not possible, cathodic

protection anodes can be placed in close
proximity to structure to ensure protection
is achieved.

Insulated Flange Kit

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Testing

Design Considerations
Limitations of cathodic protection must be recognized
during the design process. Cathodic protection will be
effective only on metal surfaces in continual contact
with the electrolyte.
Above-ground structures will not be protected.
The distribution of current to desired areas becomes
difficult in congested, shielded or remote areas.
Examples include multiple pipeline right-of-ways,
shorted castings and storage tank bottoms.

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Design Considerations

Design Considerations

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Design Considerations

Design Considerations

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Stray Current Parallel Pipelines

Stray Current - Crossing

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Testing
Soil resistivity measurements.
Current requirement tests.
Test stations every 500-2000 feet.
Insulated flange kit isolation tests.
Permanent reference electrode tests.
Rectifier voltage adjustments, structure
current resistance, anode currents, current
interruption for instant off readings.

Test Equipment

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Portable
Reference
Electrodes

Underground Reference Electrode

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Above Ground Test Station

Below Grade Test Station

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Below Grade Test Stations

Below Grade Test Stations

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Test Station Terminations

Test Station

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Test Station problems

Test Station problems

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Summary

1.Corrosion Basics
2.Cathodic Protection Criteria
3.Cathodic Protection Design (galvanic
anodes)
4.Types of Cathodic Protection Systems
5.Protected Structures
6.Structure Isolation
7.Design Considerations

References

Control of Pipeline Corrosion A.W. Peabody.

NACE Std SP0169-2007 Control of External Corrosion on
Underground or Submerged Metallic Piping Systems.
Code of Federal Regulations CFR 49.192-2012 Transportation
of Natural and other Gas by Pipeline.
Code of Federal Regulations CFR 49.195-2012 Transportation
of Hazardous Liquids by Pipeline.
Galvanic Corrosion Harvey P. Hack.
NACE Corrosion Engineers Reference Book R. S. Treseder.
ASTM G57 Soil resistivity using the Wenner 4-pin method.

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References

ARMY Technical Manual TM 5-811-7, 1995 Electrical Design,

Cathodic Protection.
USACE Engineering Manual EM 1110-2-2704, 2004 Cathodic
Protection systems for Civil Works Structures.
NACE Std RP0193-2001 External Cathodic Protection of On-
Grade Carbon Steel Storage Tank Bottoms.
NACE Std RP0572-2001 Design, Installation, Operation, and
Maintenance of Impressed Current Deep Ground beds.
NFPA 70-2011 National Electric Code (NEC)
IEEE Std 81. IEEE Guide for Measuring Earth Resistivity,
Ground Impedance, and Earth Surface Potentials of a Ground
System.

Questions?

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