Cathodic Protection en - Wikipedia
Cathodic Protection en - Wikipedia
Cathodic protection
From Wikipedia, the free encyclopedia
Contents
◾ 1 History
◾ 2 Types
◾ 2.1 Galvanic Zinc sacrificial anode (rounded
◾ 2.2 Impressed current systems object) screwed to the underside of
◾ 3 Applications the hull of a small boat.
◾ 3.1 Pipelines
◾ 3.2 Ships and boats
◾ 3.3 Marine
Pronunciation of the word "Cathodic"
◾ 3.4 Steel in concrete
◾ 3.5 Internal cathodic protection
◾ 3.6 Galvanized steel
◾ 3.7 Automobiles
◾ 4 Testing
◾ 5 Problems
◾ 5.1 Production of hydrogen ions
◾ 5.2 Cathodic disbonding
◾ 5.3 Cathodic shielding
◾ 6 Standards
◾ 7 See also
◾ 8 Notes
◾ 9 References
◾ 10 External links
History
Cathodic protection was first described by Sir Humphry Davy in a series of papers presented to the Royal Society[2] in
London in 1824. The first application was to the HMS Samarang [3] in 1824. Sacrificial anodes made from iron attached
to the copper sheath of the hull below the waterline dramatically reduced the corrosion rate of the copper. However, a
side effect of the cathodic protection was to increase marine growth. Copper, when corroding, releases copper ions which
have an anti-fouling effect. Since excess marine growth affected the performance of the ship, the Royal Navy decided that
it was better to allow the copper to corrode and have the benefit of reduced marine growth, so cathodic protection was not
used further.
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Davy was assisted in his experiments by his pupil Michael Faraday, who continued his research after Davy's death. In
1834, Faraday discovered the quantitative connection between corrosion weight loss and electric current and thus laid the
foundation for the future application of cathodic protection.[4]
Thomas Edison experimented with impressed current cathodic protection on ships in 1890, but was unsuccessful due to
the lack of a suitable current source and anode materials. It would be 100 years after Davy's experiment before cathodic
protection was used widely on oil pipelines in the United States[5] — cathodic protection was applied to steel gas
pipelines beginning in 1928[6] and more widely in the 1930s.[7]
Types
Galvanic
Galvanic or sacrificial anodes are made in various shapes and sizes using alloys of zinc, magnesium and aluminium.
ASTM International publishes standards on the composition and manufacturing of galvanic anodes.[9][10]
In order for galvanic cathodic protection to work, the anode must possess a lower (that is, more negative) electrochemical
potential than that of the cathode (the target structure to be protected). The table below shows a simplified galvanic series
which is used to select the anode metal.[11] The anode must be chosen from a material that is lower on the list than the
material to be protected.
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Anodes for ICCP systems are available in a variety of shapes and sizes. Common
anodes are tubular and solid rod shapes or continuous ribbons of various
materials. These include high silicon cast iron, graphite, mixed metal oxide,
platinum and niobium coated wire and other materials. Simple impressed current cathodic
protection system. A source of DC
For pipelines, anodes are arranged in groundbeds either distributed or in a deep electric current is used to help drive
vertical holes depending on several design and field condition factors including the protective electrochemical
current distribution requirements. reaction.
The output of the ICCP system should be optimised to provide enough current to provide protection to the target
structure. Some cathodic protection transformer-rectifier units are designed with taps on the transformer windings and
jumper terminals to select the voltage output of the ICCP system. Cathodic protection transformer-rectifier units for water
tanks and used in other applications are made with solid state circuits to automatically adjust the operating voltage to
maintain the optimum current output or structure-to-electrolyte potential.[15] Analog or digital meters are often installed to
show the operating voltage (DC and sometime AC) and current output. For shore structures and other large complex
target structures, ICCP system are often designed with multiple independent zones of anodes with separate cathodic
protection transformer-rectifier circuits.
Applications
Pipelines
The output of the DC source is then adjusted to the optimum level after conducting various tests including measurements
of electrochemical potential.
It is sometimes more economically viable to protect a pipeline using galvanic anodes. This is often the case on smaller
diameter pipelines of limited length.[18]
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Water pipelines of various pipe materials are also provided with cathodic protection where owners determine the cost is
reasonable for the expected pipeline service life extension attributed to the application of cathodic protection.
Galvanic anodes are generally shaped to reduced drag in the water and fitted flush
to the hull to also try to minimize drag.[20]
Smaller vessels, with non-metallic hulls, such as yachts, are equipped with
galvanic anodes to protect areas such as lower unit. As with all galvanic cathodic
protection, this application relies on a solid electrical connection between the The white patches visible on the
anode and the item to be protected. ship's hull are zinc block sacrificial
anodes.
For ICCP on ships, a DC power supply is provided within the ship and the anodes
mounted on the outside of the hull. The anode cables are introduced into the ship via a compression seal fitting and routed
to the DC power source. The negative cable from the power supply is simply attached to the hull to complete the circuit.
Ship ICCP anodes are flush-mounted, minimizing the effects of drag on the ship, and located a minimum 5 ft below the
light load line[21] in an area to avoid mechanical damage. The current density required for protection is a function of
velocity and considered when selecting the current capacity and location of anode placement on the hull.
Some ships may require specialist treatment, for example aluminium hulls with steel fixtures will create an
electrochemical cell where the aluminium hull can act as a galvanic anode and corrosion is enhanced. In cases like this,
aluminium or zinc galvanic anodes can be used to offset the potential difference between the aluminium hull and the steel
fixture.[22] If the steel fixtures are large, several galvanic anodes may be required, or even a small ICCP system.
Marine
Marine cathodic protection covers many areas, jetties, harbors, offshore structures. The variety of different types of
structure leads to a variety of systems to provide protection. Galvanic anodes are favored,[23] but ICCP can also often be
used.
Steel in concrete
The application to concrete reinforcement is slightly different in that the anodes and reference electrodes are usually
embedded in the concrete at the time of construction when the concrete is being poured. The usual technique for concrete
buildings, bridges and similar structures is to use ICCP,[24] but there are systems available that use the principle of
galvanic cathodic protection as well,[25][26][27] although in the UK at least, the use of galvanic anodes for atmospherically
exposed reinforced concrete structures is considered experimental.[28]
For ICCP, the principle is the same as any other ICCP system. However, in a typical atmospherically exposed concrete
structure such as a bridge, there will be many more anodes distributed through the structure as opposed to an array of
anodes as used on a pipeline. This makes for a more complicated system and usually an automatically controlled DC
power source is used, possibly with an option for remote monitoring and operation.[29] For buried or submerged
structures, the treatment is similar to that of any other buried or submerged structure.
Galvanic systems offer the advantage of being easier to retrofit and do not need any control systems as ICCP does.
For pipelines constructed from pre-stressed concrete cylinder pipe (PCCP), the techniques used for cathodic protection
are generally as for steel pipelines except that the applied potential must be limited to prevent damage to the prestressing
wire.[30]
The steel wire in a PCCP pipeline is stressed to the point that any corrosion of the wire can result in failure. An additional
problem is that any excessive hydrogen ions as a result of an excessively negative potential can cause hydrogen
embrittlement of the wire, also resulting in failure. The failure of too many wires will result in catastrophic failure of the
PCCP.[31] To implement ICCP therefore requires very careful control to ensure satisfactory protection. A simpler option
is to use galvanic anodes, which are self-limiting and need no control.[32]
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Vessels, pipelines and tanks which are used to store or transport liquids can also be protected from corrosion on their
internal surfaces by the use of cathodic protection.[33] ICCP and galvanic systems can be used.The most common
application of internal cathodic protection is water storage tanks.
Galvanized steel
Galvanizing generally refers to hot-dip galvanizing which is a way of coating steel with a layer of metallic zinc.
Galvanized coatings are quite durable in most environments because they combine the barrier properties of a coating with
some of the benefits of cathodic protection. If the zinc coating is scratched or otherwise locally damaged and steel is
exposed, the surrounding areas of zinc coating form a galvanic cell with the exposed steel and protect it from corrosion.
This is a form of localized cathodic protection - the zinc acts as a sacrificial anode.
Galvanizing, while using the electrochemical principle of cathodic protection, is not actually cathodic protection.
Cathodic protection requires the anode to be separate from the metal surface to be protected, with an ionic connection
through the electrolyte and an electron connection through a connecting cable, bolt or similar. This means that any area of
the protected structure within the electrolyte can be protected, whereas in the case of galvanizing, only areas very close to
the zinc are protected. Hence, a larger area of bare steel would only be protected around the edges.
Automobiles
Several companies market electronic corrosion control devices for automobiles and trucks. The systems are not effective
[34]
and in 1996, the FTC in the USA fined David McCready and ordered him to pay $200,000 in consumer redress and
stop marketing and selling his “Rust Evader" electronic corrosion control for cars.[35] Systems marketed since that time
are no more effective.[36][37]
Testing
Electrochemical potential is measured with reference electrodes. Copper-copper sulphate electrodes are used for
structures in contact with soil or fresh water. Silver/sliver chloride/seawater electrodes or pure zinc electrodes are used for
seawater applications. The methods are described in EN 13509:2003 and NACE TM0497 along with the sources of error
[38]
in the voltage that appears on the display of the meter. Interpretation of electrochemical corrosion potential
measurements to determine the potential at the interface between the anode of the corrosion cell and the electrolyte
requires training[39] and cannot be expected to match the accuracy of measurements done in laboratory work.
Problems
Production of hydrogen ions
A side effect of improperly applied cathodic protection is the production of atomic hydrogen[citation needed], leading to its
absorption in the protected metal and subsequent hydrogen embrittlement of welds and materials with high hardness.
Under normal conditions, the atomic hydrogen will combine at the metal surface to create hydrogen gas, which cannot
penetrate the metal. Hydrogen atoms, however, are small enough to pass through the crystalline steel structure, and lead
in some cases to hydrogen embrittlement.
Cathodic disbonding
This is a process of disbondment of protective coatings from the protected structure (cathode) due to the formation of
hydrogen ions over the surface of the protected material (cathode).[40] Disbonding can be exacerbated by an increase in
alkali ions and an increase in cathodic polarization.[41] The degree of disbonding is also reliant on the type of coating,
with some coatings affected more than others.[42] Cathodic protection systems should be operated so that the structure
does not become excessively polarized,[43] since this also promotes disbonding due to excessively negative potentials.
Cathodic disbonding occurs rapidly in pipelines that contain hot fluids because the process is accelerated by heat flow
[citation needed]
.
Cathodic shielding
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Effectiveness of cathodic protection (CP) systems on steel pipelines can be impaired by the use of solid film backed
dielectric coatings such as polyethylene tapes, shrinkable pipeline sleeves, and factory applied single or multiple solid
film coatings. This phenomenon occurs because of the high electrical resistivity of these film backings.[44] Protective
electric current from the cathodic protection system is blocked or shielded from reaching the underlying metal by the
highly resistive film backing. Cathodic shielding was first defined in the 1980s as being a problem, and technical papers
on the subject have been regularly published since then.
A 1999 report[45] concerning a 20,600 bbl (3,280 m3) spill from a Saskatchewan crude oil line contains an excellent
definition of the cathodic shielding problem:
"The triple situation of disbondment of the (corrosion) coating, the dielectric nature of the coating and the unique
electrochemical environment established under the exterior coating, which acts as a shield to the electrical CP
current, is referred to as CP shielding. The combination of tenting and disbondment permits a corrosive
environment around the outside of the pipe to enter into the void between the exterior coating and the pipe surface.
With the development of this CP shielding phenomenon, impressed current from the CP system cannot access
exposed metal under the exterior coating to protect the pipe surface from the consequences of an aggressive
corrosive environment. The CP shielding phenomenon induces changes in the potential gradient of the CP system
across the exterior coating, which are further pronounced in areas of insufficient or sub-standard CP current
emanating from the pipeline's CP system. This produces an area on the pipeline of insufficient CP defense against
metal loss aggravated by an exterior corrosive environment."
Cathodic shielding is referenced in a number of the standards listed below. Newly issued USDOT regulation Title 49
CFR 192.112 (http://www.gpo.gov/fdsys/pkg/CFR-2009-title49-vol3/pdf/CFR-2009-title49-vol3-sec192-112.pdf), in the
section for Additional design requirements for steel pipe using alternative maximum allowable operating pressure
requires that "The pipe must be protected against external corrosion by a non-shielding coating" (see coatings section on
standard). Also, the NACE SP0169:2007 standard defines shielding in section 2, cautions against the use of materials that
create electrical shielding in section 4.2.3, cautions against use of external coatings that create electrical shielding in
section 5.1.2.3, and instructs readers to take 'appropriate action' when the effects of electrical shielding of cathodic
protection current are detected on an operating pipeline in section 10.9.
Standards
◾ 49 CFR 192.112 - Requirements for Corrosion Control - Transportation of natural and other gas by pipeline:
minimum federal safety standards
◾ AS 2832.4 - Australian Standard for Cathodic Protection
◾ ASME B31Q 0001-0191
◾ ASTM G 8, G 42 - Evaluating Cathodic Disbondment resistance of coatings
◾ DNV-RP-B401 - Cathodic Protection Design - Det Norske Veritas
◾ EN 12068:1999 - Cathodic protection. External organic coatings for the corrosion protection of buried or immersed
steel pipelines used in conjunction with cathodic protection. Tapes and shrinkable materials
◾ EN 12473:2000 - General principles of cathodic protection in sea water
◾ EN 12474:2001 - Cathodic protection for submarine pipelines
◾ EN 12495:2000 - Cathodic protection for fixed steel offshore structures
◾ EN 12499:2003 - Internal cathodic protection of metallic structures
◾ EN 12696:2012 - Cathodic protection of steel in concrete
◾ EN 12954:2001 - Cathodic protection of buried or immersed metallic structures. General principles and application
for pipelines
◾ EN 13173:2001 - Cathodic protection for steel offshore floating structures
◾ EN 13174:2001 - Cathodic protection for harbour installations
◾ EN 13509:2003 - Cathodic protection measurement techniques
◾ EN 13636:2004 - Cathodic protection of buried metallic tanks and related piping
◾ EN 14505:2005 - Cathodic protection of complex structures
◾ EN 15112:2006 - External cathodic protection of well casing
◾ EN 15280-2013 - Evaluation of a.c. corrosion likelihood of buried pipelines
◾ EN 50162:2004 - Protection against corrosion by stray current from direct current systems
◾ BS 7361-1:1991 - Cathodic Protection
◾ NACE SP0169:2007 - Control of External Corrosion on Underground or Submerged Metallic Piping Systems
◾ NACE TM 0497 - Measurement Techniques Related to Criteria for Cathodic Protection on Underground or
Submerged Metallic Piping Systems
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See also
◾ Anodic protection
◾ Sacrificial metal
◾ Wetting voltage
Notes
1. ^ Peabody p.6 23. ^ Roberge p.876
2. ^ Davy, cited in Ashworth 1994 24. ^ Ashworth et al 10:82
3. ^ Ashworth, 10:3 25. ^ Covino et al/
4. ^ Baeckmann, Schwenck & Prinz, p.12 26. ^ Daily
5. ^ Scherer, 38(27), 179 cited in Baeckman 27. ^ Highways Agency Sect. 4.8
6. ^ Robert J. Kuhn, Cathodic Protection of Underground 28. ^ Highways Agency Sect. 2.1
Pipe Lines from Soil Corrosion, API Proceedings, Nov. 29. ^ Highways Agency Sect. 4.5
1933, Vol. 14, p157 30. ^ NACE RP0100-2000 Sect. 5.2.5
7. ^ Natural Resources Canada Retrieved 23 JAN 2012([1] 31. ^ Gummow
(http://www.nrcan.gc.ca/minerals-metals/materials- 32. ^ NACE RP0100-2000 Sect. 5.4
technology/picon/3149)) 33. ^ EN 12499:2003
8. ^ Roberge p.871 34. ^ Robert Baboian - SAE International Paper No. 912270
9. ^ ASTM B843 - 07 35. ^ Federal Trade Commission Press Release
10. ^ ASTM B418 - 09 (http://www.ftc.gov/opa/1996/07/rust3.shtm)
11. ^ Peabody p.304 36. ^ CP Engineer Website
12. ^ Ashworth 10:10 (http://www.cpengineer.com/Corrosion.Technical.html#CP_For_Cars)
13. ^ Roberge p.880 37. ^ NACE International Primer on car electronic protection
14. ^ Peabody p.158 (http://events.nace.org/library/corrosion/Car/car-electronic-
15. ^ Baeckmann, Schwenck & Prinz, p.233 protection.asp)
16. ^ Peabody p.22 38. ^ NACE TM0497 Section 5.8
17. ^ Peabody p.132 39. ^ NACE TM0497 Section 1.2
18. ^ Peabody p.32 40. ^ Roberge Sect. 11.4.1, p.886
19. ^ BS 7361-1:1991 Sect. 6.2 41. ^ Baeckmann, Schwenck & Prinz, p.167
20. ^ BS 7361-1:1991 Sect. 6.2.1.2 42. ^ Baeckmann, Schwenck & Prinz, p.168
21. ^ CP-2 Cathodic Protection Technician-Maritime Student 43. ^ Peabody p.37
Manual NACE International, July 2009, pg 3-11 44. ^ NACE International Paper 09043
22. ^ EN 12473:2000 Sect. 8.3.1 45. ^ Transportation Safety Board of Canada
References
◾ A.W. Peabody, Peabody's Control of Pipeline Corrosion, 2nd Ed., 2001, NACE International. ISBN 1-57590-092-0
◾ Davy, H., Phil. Trans. Roy. Soc., 114,151,242 and 328 (1824)
◾ Ashworth V., Corrosion Vol. 2, 3rd Ed., 1994, ISBN 0-7506-1077-8
◾ Baeckmann, Schwenck & Prinz, Handbook of Cathodic Corrosion Protection, 3rd Edition 1997. ISBN 0-88415-
056-9
◾ Scherer, L. F., Oil and Gas Journal, (1939)
◾ ASTM B843 - 07 Standard Specification for Magnesium Alloy Anodes for Cathodic Protection
◾ ASTM B418 - 09 Standard Specification for Cast and Wrought Galvanic Zinc Anodes
◾ Roberge, Pierre R, Handbook of Corrosion Engineering 1999 ISBN 0-07-076516-2
◾ NACE International Paper 09043 Coatings Used in Conjunction with Cathodic Protection - Shielding vs Non-
shielding Coatings
◾ NACE International TM0497-2002, Measurement Techniques Related to Criteria for Cathodic Protection on
Underground or Submerged Metallic Piping Systems
◾ Transportation Safety Board of Canada, Report Number P99H0021, 1999 [2] (http://www.tsb.gc.ca/eng/rapports-
reports/pipeline/1999/p99h0021/p99h0021.asp)
◾ Covino, Bernard S, et al., Performance of Zinc Anodes for Cathodic Protection of Reinforced Concrete Bridges,
Oregon Dept of Transport & Federal Highway Administration, March 2002
◾ UK Highways Agency BA 83/02; Design Manual for Roads and Bridges, Vol.3, Sect.3, Part 3, Cathodic Protection
For Use In Reinforced Concrete Highway Structures. [3]
(http://www.standardsforhighways.co.uk/dmrb/vol3/section3/ba8302.pdf) (Retrieved 2011-01-04)
◾ Daily, Steven F, Using Cathodic Protection to Control Corrosion of Reinforced Concrete Structures in Marine
Environments (published in Port Technology International)
◾ Gummow, RA, Corrosion Control of Municipal Infrastructure Using Cathodic Protection. NACE Conference Oct
1999, NACE Materials Performance Feb 2000
◾ EN 12473:2000 - General principles of cathodic protection in sea water
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External links
◾ NACE International (http://events.nace.org/library/corrosion/CP/Introduction.asp) (formerly the National
Association of Corrosion Engineers) - Introduction to Cathodic Protection
◾ Institute of Corrosion (http://www.icorr.org/) - A technical society based in the UK
◾ Glossary (http://events.nace.org/library/corrosion/glossaryletters/Introduction.asp) - A comprehensive glossary of
cathodic protection and corrosion terms
◾ Cathodic Protection (http://www.corrosionist.com/corrosion_control_methods_cathodic_protection.htm) - Cathodic
Protection Theory and useful documents on Cathodic Protection
◾ National Physics Laboratory (http://www.npl.co.uk/upload/pdf/cathodic_protection.pdf) - Short introductory paper
on cathodic protection
◾ USDOT CFR 192.112 (http://www.gpo.gov/fdsys/pkg/CFR-2009-title49-vol3/pdf/CFR-2009-title49-vol3-sec192-
112.pdf) - USDOT regulations CFR 192.112 requiring the use on non-shielding corrosion coating systems on steel
pipe using alternative maximum allowable operation pressure.
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