Cathodic Protection - Presentation

UNDERSTANDING CATHODIC
PROTECTION
&
ITS EFFECTIVENESS IN
PREVENTING CORROSION.
The fuel that doesn’t cost the Earth.

Agenda
Mounded Storage Vessels.
How Mounded Storage vessels fall prey for Corrosion.
Corrosion prevention Methods adopted for Mounded Bullets
What is Cathodic Protection.
Difference Between Sacrificial & Impressed C.P.System.
Choutuppal Plant Cathodic Protection System Design.
Conclusion.

Survey Conducted before Cathodic Protection.
 Soil Resistivity.
MOUNDED STORAGE VESSELS.
Soil Resistivity gives the corrosive nature of the soil.
A semi conventional pressure vessel covered by layer of Soil or Sand which
reduces
Mounded
the possibility of Fire Engulfment, Radiation from a fire in close
Bullet to Soil Potential (Voltage).
Proximity & Eliminate the possibility of BLEVE.
The Storage vessel to the Soil Voltage reveals to which extent the bullet is
prone to corrosion.
 Current Survey.
It Estimates the current required to Soilprotect
/ Sand. the Storage vessel
effectively. Once the current required is known then the number of
Transformers Rectifier Units, weights ofLPG Storage
anodes, Vessel
Cable / Bullet
length etc can be
determined.
R.C.C. (Reinforced Cement
Concrete.

How Mounded Storage vessels fall prey for Corrosion.
Mounded LPG bullets by design, to be immersed in soil will corrode because

of electrochemical reaction between the metallic surface of the storage
tank and the surrounding soil due to presence of Moisture and O2/CO2
gasses.
There are over 50 general types of soil that have been characterized for
corrosion properties. Each of the different types of soils has different soil
resistivity values.
The Storage immersed in soil of different resistivity values exhibit
different electrical potentials. The electrical potential in those soils
determines which area become anodic and cathodic.

Why DC Current Flow ?
As discussed in the earlier slide the anode and the cathode are determined
by the different soil resistvity values.
Since both the anode and cathode are electrically continuous and the
electrolyte is in contact with both, current flows, resulting in oxidation and
reduction reactions.
The area of the tank, which is the anode, corrodes.

Dry Soil where Resistivity is more.
Cathodic Area of the Tank.
Anodic Area of the Tank.

Moisture Soil where resistivity is less.
Corrosion prevention Methods adopted for Mounded Bullets
Protecting underground storage tanks from corrosion can be achieved

through the Combination of
1. EXTERNAL COATING. 2. CATHODIC PROTECTION.
An effective external protective coating insulates 99% mounded bullet

surface from the soil environment, thus preventing the flow of corrosion
current from the anode to the cathode.
How ever NO Coating is perfect. Damage from construction or soil stresses

create tiny defects, which may result in accelerated corrosion at the
defect.
Cathodic protection prevents corrosion at those defects by applying DC
Current from external source, forcing the tank to become cathode.

What is Cathodic Protection.
Cathodic Protection is a method of reducing corrosion by minimizing the

(Potential) Voltage difference between Anode and Cathode.
Cathodic protection is achieved by applying a current to the Storage vessel

from outside source. When enough current is applied, the whole mounded
structure will be at one potential, thus, anode and cathode sites will not
exist.
CATHODIC PROTECTION.
Sacrificial Anode Impressed Current.

Sacrificial Anode Cathodic Protection system.
As the name indicates sacrificial, high energy electrons are sacrificed by

the second metal which is inserted in close proximity of the Storage vessel
to be protected.
The sacrificial anode technique uses the natural potential difference that
exists between the Storage vessel and a second metal in the same
environment to provide the driving voltage.
The DC Current flows from the anode to
the storage vessel when they are coupled.
HOW?
The Open circuit voltage of the storage
vessel is -0.50 Volts.
The Open circuit voltage of the Second
metal is -1.55 to -1.80 Volts.
When these two metals are coupled the
difference will be 1 to 1.25 V results in
current flow.
Sacrificial Anode Cathodic Protection systems.
Advantages.
Simple to Install.
Independent of any source of electric power.
Suitable for localized protection.
Less liable to cause interaction on neighbors structure.
Disadvantages.
Moderate in obtaining uniform electrode potential across the storage

vessel.
Constant Driving Voltage.
Constant Driving Current.
More electrical connections.

Impressed Current Cathodic Protection system.
Impressed current systems are fundamentally the same as Sacrificial anode

systems in their operation, expect that in this system a rectifier or other
power source is used to increase the potential of the electrons from anode
to provide the desired protective current.
In this systems the anodes are energized

by an external DC Power Source. These
anodes are inserted in the soil and are
connected to the positive terminal of the
power source, and vessel which is to be
protected at the negative terminal.

Impressed Current Cathodic Protection.
Advantages.
 Adjustable Voltage.
Adjustable Current.
Can be used in almost any resistivity environment.
Can be used in any size of the structure
Less Amount to be spent than compared to Sacrificial systems per sq.ft.
Comparatively few anodes are required.
Disadvantages.
 Significant Operation and Maintenance requirements.

Sacrificial Vs Impressed Current Cathodic Protection.
S.No Sacrificial Anode System. Impressed Current Anode System.

1 No External Power Required. External Power Required.
2 Fixed Driving Voltage Adjustable Driving Voltage.
3 Fixed Current. Adjustable Current.
4 Limited Current (10 to 50 Milli amperes) Unlimited current (10 to 100 amperes).
Can be used in almost any resistivity

5 Usually used in lower resistivity electroloytes. evironment.
usually used with small or very well coated

6 strucutres. can be used on any size of structure.
7 Low Rs/Unit Cost. High Rs / Unit Cost.
8 High Rs / Sq.Ft of Metal Protected. Low Rs / Sq.Ft of Metal Protected.
9 Low Maintenance. High Maintenance.
10 Does not cause stray current corrosion. Stray DC Currents can be generated.

Survey Conducted before Cathodic Protection.
 Soil Resistivity.
Soil Resistivity gives the corrosive nature of the soil.
 Mounded Bullet to Soil Potential (Voltage).

The Storage vessel to the Soil Voltage reveals to which extent the bullet is
prone to corrosion.
 Current Survey.
It Estimates the current required to protect the Storage vessel
effectively. Once the current required is known then the number of
Transformers Rectifier Units, weights of anodes, Cable length etc can be
determined.

Current Demand vs. Soil Resistivity .
Soil Resistivity (Standard).
Environment Milli amperes per

Sq.Ft.
Soil Resistivity <1,000 ohm-cm 6 – 25.0
Soil Resistivity 1,000 to 10,000 ohm-cm 3 – 6.0
Soil Resistivity 10,000 to 30,000 ohm-cm 2.0 to 3.0
Soil Resistivity > 30,000 ohm-cm 1.0 to 2.0
Concrete 0.5 to 1.5

Current Demand vs. Coated Steel.
Coated Steel (Standard).
Environment Milli amperes per

Sq.Ft.
Epoxy or High Performance Coating. 0.001 to 0.005
Reinforced Coal Tar 0.005 to 0.025
Asphalt mastic 1.2” Thick. 0.001 to 0.005
Tank Bottoms. 0.05 to 2.0

Choutuppal Plant Cathodic Protection System.
Design Basis.
Bullet Diameter 3.536 Mtr
Bullet Length 13.5 Mtr
Number of Bullets 2 No's.
Percentage Bare Steel Surface 3%
Cathodic Protection Current Density for Bare

Steel 25 Ma/Sq.Mtr
Soil Resisitvity Min 10,000 Ohm-cm to Max 500 Ohm-cm
CP Criterial (-)850 mV to (-)1150 mV
Design Life 25 Years.

Current Requirement.
Size of the Bullet 13.5 M (L) x 3.536 (M)D 13.5 M (L) x 3.536 (M)D
Surface Area for One Bullet 174 Sq.Mtr 174 Sq.Mtr
Accessories (10%) 17.4 Sq.Mtr 17.4 Sq.Mtr
Total Surface Area for One Bullet 191 Sq.Mtr 191 Sq.Mtr
3% Bare Surface at the End of

Design Life 5.73 Sq.Mtr 5.73 Sq.Mtr
Current Density for Bare Steel 25 m A / Sq.Mtr 25 m A / Sq.Mtr
Total Current Requireement 0.143 Amps. 0.143 Amps.

Impressed Current Anode for Cathodic Protection.
At Choutuppal Filling Plant Copper conductor is used to deliver the required

current over considerable distance without incurring substantial longitudinal
voltage drop. The name given by the manufacturer as ANODE FLEX.
Components Of Impressed Current Anode.
 Copper Conductor.
Conductive Polymer, sealing the copper conductor from Chemical Attack,
yet allowing current to flow through it, from the conductor to the
environment all along its length.
Coke Breeze. Pre-Packaged, High Performance calcined petroleum coke
breeze, serving as the active matrix in which the electro chemical
reactions take place. Designed to produce 40mA for 25 Years.
Fabric Jacket. Holding the coke breeze in place around the anode.
Protective Braid. Tough, Porous, Non-Conductive protective Braid.

Total Length of the Anode Flex Required.
For One Bullet.
Vessel Diameter 3.536 Mtr
Vessel Length 13.5 Mtr

Current Output for 25 Years
Designed. 40mA/meter.
Total Theoretical Length of Anode
Flex 3.6 Mtrs.
Considering the Layout and Geometry of the bullet, the anode flex strings
are to be placed parallel so as to cover the entire surface area of the bullet.
Hence total length is 124 Meters.
So No of Anode Flex Strings for Each Bullet is 4 No’s comprising of 15.5

Meters Length. Which covers 50% of the Bullet Surface area.

Transformer Rectifier Rating calculations.
The Voltage of the Transformer Rectifier unit at maximum current output

can be calculated using the formula.
V = I x Rt + V anode.
I = Current Required (0.143 Amps).

Rt = Total Circuit Resistance = 1.655 Ohms.
(Ground Bed Resistance, Cabel Resistance & Total circuit Resistance.)
Vanode = Back emf of Anode (2 Volt).
V = 0.143 x 1.655 + 2 Volts.

2.23 Volts.

Stationary Reference Electrode.
Reference Electrode STELTH2
Copper / Copper Sulphate half-cells are typically favored for Potential

measurements of Storage vessels in soil.
Storage vessel to soil potential is actually the potential measured between

the Storage vessel and the reference electrode.

Effective Protection of Mounded Bullet.
A.C. Input Voltage 240 V
A.C.Input Current 6A
D.C.Out Put Voltage 0 to 25 v
D.C.Out put Current 0 to 25 A.
Reference Voltage to be
achieved. (-0.85)V to (-)2.5V

Conclusion.
As per the Design calculations of our cathodic protection system it

is obvious that the Voltage measured between Reference electrode
and the Mounded Bullet is -0.85 Volts to -2.5 Volts then the Storage
vessel in at the safer side i.e., no corrosion occurs.
If the Voltage measured is More Negative the Storage vessel is

under protected and leads to corrosion.
If the Voltage measured is beyond -2.5Volts the Bullet is over
protected and leads to embrittlement and leads to fracture.

Thank You.

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UNDERSTANDING CATHODIC

The fuel that doesn’t cost the Earth.

The fuel that doesn’t cost the Earth.

The fuel that doesn’t cost the Earth.

Mounded LPG bullets by design, to be immersed in soil will corrode because

The fuel that doesn’t cost the Earth.

The area of the tank, which is the anode, corrodes.

Cathodic Area of the Tank.

Anodic Area of the Tank.

Protecting underground storage tanks from corrosion can be achieved

An effective external protective coating insulates 99% mounded bullet

How ever NO Coating is perfect. Damage from construction or soil stresses

The fuel that doesn’t cost the Earth.

Cathodic Protection is a method of reducing corrosion by minimizing the

Cathodic protection is achieved by applying a current to the Storage vessel

Sacrificial Anode Impressed Current.

The fuel that doesn’t cost the Earth.

As the name indicates sacrificial, high energy electrons are sacrificed by

Moderate in obtaining uniform electrode potential across the storage

The fuel that doesn’t cost the Earth.

Impressed current systems are fundamentally the same as Sacrificial anode

In this systems the anodes are energized

The fuel that doesn’t cost the Earth.

The fuel that doesn’t cost the Earth.

S.No Sacrificial Anode System. Impressed Current Anode System.

Can be used in almost any resistivity

usually used with small or very well coated

The fuel that doesn’t cost the Earth.

 Mounded Bullet to Soil Potential (Voltage).

The fuel that doesn’t cost the Earth.

Environment Milli amperes per

The fuel that doesn’t cost the Earth.

Environment Milli amperes per

The fuel that doesn’t cost the Earth.

Bullet Length 13.5 Mtr

Number of Bullets 2 No's.

Percentage Bare Steel Surface 3%

Cathodic Protection Current Density for Bare

Soil Resisitvity Min 10,000 Ohm-cm to Max 500 Ohm-cm

CP Criterial (-)850 mV to (-)1150 mV

Design Life 25 Years.

The fuel that doesn’t cost the Earth.

Surface Area for One Bullet 174 Sq.Mtr 174 Sq.Mtr

Accessories (10%) 17.4 Sq.Mtr 17.4 Sq.Mtr

3% Bare Surface at the End of

Current Density for Bare Steel 25 m A / Sq.Mtr 25 m A / Sq.Mtr

Total Current Requireement 0.143 Amps. 0.143 Amps.

The fuel that doesn’t cost the Earth.

At Choutuppal Filling Plant Copper conductor is used to deliver the required

Components Of Impressed Current Anode.

The fuel that doesn’t cost the Earth.

For One Bullet.

Vessel Diameter 3.536 Mtr

Vessel Length 13.5 Mtr

So No of Anode Flex Strings for Each Bullet is 4 No’s comprising of 15.5

The fuel that doesn’t cost the Earth.

The Voltage of the Transformer Rectifier unit at maximum current output

I = Current Required (0.143 Amps).

V = 0.143 x 1.655 + 2 Volts.