Basic Principles of Corrosion and Cathodic Protection

 Anodic (positive) and Cathodic (negative) areas exist on a metal surface which
is exposed to an electrolyte. The electrolyte may be aqueous, in the case of
water storage tanks, for example, or simply the moisture which is present even
in dry soils in the case of buried structures.

 Corrosion occurs at anodic sites when the metal dissolves into the electrolyte,
the metallic atoms of the metal (typically iron in the case of steel structures)
losing electrons and passing into solution as ions. These ions (typically Fe2+ in
the case of Iron) undergo further reactions to form the corrosion product, which
we commonly identify as rust. Corrosion only occurs at anodic sites.

 Further reactions take place at the cathodic sites, where the electrons released
by the anodic reaction are consumed by combination with ionic species in the
electrolyte.

 The conversion of metal at anodic sites into its corrosion product obviously
results in a loss of metal which may, if left unchecked, result in the eventual
perforation or other failure of the structure at that point.

 The rate of corrosion, or metal loss, is affected by many factors such as the
relative sizes of the anodic and cathodic sites, electrolyte resistivity/conductivity,
temperature, oxygen concentration, etc.

Methods of Corrosion Prevention

Barrier methods

 The surface of the structure is coated to prevent the metal surface from coming
into contact with the surrounding electrolyte. Coatings include paints (many
types), fusion bonded epoxy (FBE) coatings, tapes (hot and cold applied), glass
fibre reinforced epoxies, etc.
 If the barrier is 100% impermeable then no corrosion will occur. However this is
seldom the case in practice; most coating systems are permeable to some
degree, and coating efficiency may be further reduced by factors such as poor
application and/or surface preparation, damage following application, general
deterioration of the coating with age.

Cathodic Protection

 Cathodic protection (CP) is a secondary method of corrosion prevention, usually

used in conjunction with coating systems. The coating system may be
considered as the primary means of corrosion control, with the CP system
providing a secondary means, by which any areas of the structure which are un-
coated are protected.

 Cathodic protection has been used successfully for many years and applied to
almost all types of buried or immersed structures. Properly designed, installed
and maintained CP systems can provide a cost-effective means of prolonging
the life of valuable assets.

 Cathodic protection works by causing a small direct current (d.c.) to flow from an
auxiliary anode or anodes, through the electrolyte, into the surface of the
structure at locations where the coating (if present) is
permeable/damaged/missing.

 The anodes are connected to the structure by suitable lead wires to complete
the electrical circuit and allow electronic current flow to pass through the metallic
part of the circuit. The electrons released by the anodic reactions at the auxiliary
anode flow through the metallic circuit and collect at the structure. In this way
the whole structure becomes the cathode of an electrochemical corrosion cell.
As had been defined above, corrosion only occurs at anodic sites and hence the
structure is said to be cathodically protected.

 In this way, the corrosion activity is displaced to the surface of the auxiliary
anodes, which are slowly consumed and may be replaced at the end of its
design life.
 There are two generic types of cathodic protection system, galvanic (sacrificial)
systems, and impressed current systems.

Galvanic (sacrificial) Cathodic Protection Systems

 These represent the simplest form of cathodic protection. The auxiliary anodes
are made from strongly electronegative, or ignoble, materials such as
magnesium, zinc and aluminium. When connected via a lead wire to the
structure and buried or immersed in the same electrolyte as the structure, the
more active metal will have a greater tendency to corrode than the steel of the
structure.

Impressed Current Cathodic Protection Systems

 In this case, the anodes are made from more inert materials such as high silicon
cast iron, platinised titanium, MMO, graphite, etc. Again the anodes are placed
in the electrolyte and connected to the structure via a lead wire, but the current
is caused to flow by applying an e.m.f., or voltage, from an external power
source (a transformer rectifier). A source of a.c. power is required to supply the
transformer rectifier. The principle however remains the same, with the corrosion
activity taking place at the anodes, which can be designed to give an operating
life of 20-50 years, depending on the anode material used.

Internal Cathodic Protection of Water Storage Tanks

 The requirement for cathodic protection may be determined by considering a

number of factors:

o The resistivity of the water contained in the tank

o Salt or brackish waters have lower resistivities and are therefore

more corrosive

o De-ionised waters have higher resistivities and are less corrosive.

o The criticality of the structure and its intended operating life (although
it should be noted than many industrial structures which were
 originally intended to have design lives of say 20 years have
frequently had their operating lives extended significantly).

o The condition of the coating system.

 Overall condition

 Permeability

 Age

 Damaged areas etc.

o The corrosion history of the tank

 Have any leaks occurred?

 Has inspection shown areas of corrosion and loss of wall

thickness?

 Cathodic protection may be applied by either galvanic or impressed current

systems. In each case anodes may be suspended from the tank roof or mounted
internally. The required number and locations of the anodes is determined by
design, which is normally carried out following a site visit and survey of the
tank(s).

 Installation is usually straightforward and in the case of suspended anode

systems may be carried out without the need to drain the tank contents.

 The specialist cathodic protection contractor will set to work and commission the
system(s) and provide a detailed installation, commissioning and operation
document, which will include recommendations for ongoing maintenance.
Maintenance requirements of both galvanic and impressed current systems are
minimal, although the transformer rectifier(s) of impressed current systems need
regular (typically monthly) inspection to ensure they are switched on.
Summary

 Cathodic Protection is a tried and proven method which is effective in controlling

corrosion on many types of structures worldwide. With proper design, installation
and maintenance the CP system can provide many years of trouble-free service
and prolong the life of the structure.