PRINCIPLES OF CATHODIC PROTECTION

CORROSION
Corrosion may be defined as the chemical reaction of metal with a non-metal (or nonmetals) in the surrounding environment, with the formation of compounds which are referred to as Corrosion Products. The conversion of metal into a powdery, nonadherent, friable compound will result in the deterioration of the metallic construction or component. In simple terms, it basically involves two electrodes, i.e anode and cathode immersed in an electrolyte solution that conducts electricity. The corrosion process occurs when positive electric current flow from anode to cathode through the solution. Generally, corrosion occurs at the anode. In view of the electrochemical nature of corrosion, cathodic protection system is now widely applied as an electrochemical method to be devised to control or prevent corrosion. Usually, the aim of designers is to control it within acceptable economic limits rather than to prevent it. However, cathodic protection is restricted to environments of suitable conductivity. It is particularly suitable for steels immersed in sea water and estuarine water but is also widely used in other waters and soil of suitable conductivity.

PRINCIPLES OF CATHODIC PROTECTION

SACRIFICIAL METHOD
No external current source is required with this method. Anodes of suitable metals of more negative potential than steel are attached to the structure to provide electrical contact. This produces a cell in which the steel is the cathode, the anode material corrodes, so must be replaced periodically. The essential requirement for the anode material is its ability to polarize the steel to potential where it either does not corrode or corrodes at an acceptable rate. Other requirements are reasonable cost, ability to be manufactured to suitable shapes and sizes even and reasonably uniform corrosion. Zinc, Aluminum and Magnesium are used in marine situations. All are sufficiently negative to act as anodes to protect steel in sea water. However, in practice, the exact compositions of these metals when used for anode manufacture are important. Certain alloying elements markedly influence the performance of the metals as anodes for cathodic protection. The composition must be such as to produce the following properties: (i) A sufficiently negative potential to ensure cathodic protection in a particular environment. (ii) Ability to continue to corrode during use and not to develop a passive or protective film on the surface. (iii) A high anode efficiency. The advantages of the sacrificial anode method are: (i) Can be used where there is no power. (ii) Initial cost cheaper. (iii) Less supervision required. (iv) Installation is comparatively simple and additional anodes can easily be added if the initial proves to be inadequate. (v) The anodes cannot be fitted incorrectly, e.g. so that current is supplied in the wrong direction, causing additional corrosion instead of protection. (vi) Generally, over protection does not occur.

PRINCIPLES OF CATHODIC PROTECTION

IMPRESSED CURRENT METHOD
The basic principle of the method is illustrated in the following figure:
+ +

Current Flow

Anode

Protected Structure

Electrolyte

The DC current for protection is supplied from external source, delivered through anode (or group of anodes) and electrolyte to the structure to be protected. This current will be polarized the structure cathodically, to a lower potential. If the potential reaches protection potential, the corrosion is technically stopped. For steel of potential of - 850 mV or lower against copper/copper sulphate (Cu/CuSO4) electrode is commonly accepted as protection potential. A range of materials can be used as anodes, such as graphite, high silicon iron, magnetite, mixed metals oxides, lead alloys, platinized titanium (tantalum or niobium), and conductive plastics. The advantages of the impressed current method are: High current capacity can be supplied to protect large structures. Fewer anodes are required. The method is capable of better control to provide optimum performance. Mostly lower initial cost required.

ALUMINIUM SHIP HULL ANODE

WELD ON TYPE

ANODE TYPE AAW 15 AAW 26 AAW 40 AAW 54 AAW 86 AAW 101 AAW 126 AAW 140 AAW 165 AAW 213

ANODE WEIGHT (Kg) 1.5 2.6 4.0 5.4 8.6 10.1 12.6 14.0 16.5 21.3

GROSS WEIGHT (Kg) 1.9 3.2 4.4 6.4 9.8 11.6 14.1 15.3 18.0 24.0

ANODE DIMENSION (mm) La 305 270 305 456 550 550 535 585 550 900 Ba 75 150 152 102 127 130 130 149 130 140 Ta 35 30 38 53 50 65 75 67 96 67

PIPE CORE DIMENSION (mm) Lc 425 370 425 626 650 650 635 750 650 1100 Bc 30 40 30 30 40 40 50 38 50 50 Tc 4 4 4 6 6 6 6 6 6 6

Note: Other dimensions of anodes or cores are also available on request

ALUMINIUM SHIP HULL ANODE

BOLT ON TYPE

ANODE TYPES AAB5 AAB14 AAB25 AAB35 AAB40 AAB44 AAB60 AAB80

GROSS WEIGHT (kg) 1.0 2.0 2.9 3.9 4.4 5.0 6.4 8.4

L (mm) 200 305 300 300 300 456 300 300

W (mm) 100 76 150 150 150 102 200 200

T (mm) 20 36 25 30 40 53 40 50

Lc (mm) 110 205 160 160 160 230 160 160

Note: Other dimensions of anodes or cores are also available on request

ZINC SHIP HULL ANODE

WELD ON TYPE

ANODE TYPE ZAW 18 ZAW 42 ZAW 65 ZAW 80 ZAW 100 ZAW 110 ZAW 140 ZAW 200 ZAW 250

ANODE WEIGHT (Kg) 1.8 4.2 6.5 8.0 10.0 11.0 14.0 20.0 25.0

GROSS WEIGHT (Kg) 2.0 4.6 7.0 8.6 10.6 12.0 15.1 21.4 26.4

ANODE DIMENSION (mm) La 170 305 270 305 305 400 456 580 580 Ba 75 75 150 152 152 150 102 142 142 Ta 25 38 32 32 38 32 53 45 53

PIPE CORE DIMENSION (mm) Lc 230 425 350 425 425 530 600 720 720 Bc 30 30 30 30 30 40 40 40 40 Tc 4 4 6 6 6 6 6 6 6

Note: Other dimensions of anodes or cores are also available on request

ZINC SHIP HULL ANODE

BOLT ON TYPE

ANODE TYPES ZAB11 ZAB22 ZAB31 ZAB36 ZAB69 ZAB79 ZAB100 ZAB114 ZAB158 ZAB200

GROSS WEIGHT (Kg) 1.5 2.6 3.5 4.2 7.3 8.3 10.4 12.0 16.3 20.5

L (mm) 150 200 200 305 300 300 300 456 300 300

W (mm) 75 100 100 76 150 150 150 102 200 200

T (mm) 25 20 30 36 25 30 40 53 40 50

Lc (mm) 75 110 110 205 160 160 160 230 160 160

Note: Other dimensions of anodes or cores are also available on request

ALUMINIUM JETTY ANODE

HARBOUR AND JETTY ANODE

ANODE TYPE AJA 42 AJA 65 AJA 80 AJA 95 AJA 110

ANODE WEIGHT (Kg) 42 65 80 95 110

GROSS WEIGHT (Kg) 47 70 85 100 118

ANODE DIMENSION (mm) La 1500 1500 1500 1500 1500 B1 92.5 100 125 145 150 B2 130 143 150 165 180 T 100 140 150 160 170 Lc 2000 2000 2000 2000 2000

PIPE CORE DIMENSION (mm) Dc 20 20 20 20 25 H 140 140 140 140 160

Note: Other dimension of anodes or cores are also available on request

ALUMINIUM PLATFORM ANODE

CORE: STAND OFF BENT PIPE

ANODE TYPE APF-100-SOBP APF-123-SOBP APF-150-SOBP APF-200-S0BP APF-250-SOBP APF-300-S0BP APF-350-SOSP APF-400-SOBP APF-500-SOBP

ANODE WEIGHT (Kg) 100 123 150 201 250 300 350 400 500

ANODE DIMENSION (mm) La 1500 1750 2000 2450 2450 2450 2450 2450 2450 B1 160 170 170 200 220 250 252 280 300 B2 210 220 215 225 280 330 299 330 380 Ta 150 150 160 155 180 200 227 240 260

PIPE CORE DIMENSION (SCH 80) Lc (mm) 1900 2150 2400 2850 2850 3050 3050 3050 3050 Dc (inch) 2.0 2.0 2.0 2.0 3.0 4.0 4.0 4.0 4.0

CORE: STAND OFF STRAIGHT PIPE

ANODE TYPE

ANODE WEIGHT (Kg) 100 123 150 201 250 300 350 400 500

GROSS WEIGHT (Kg) 110 135 164 218 285 352 402 452 552

ANODE DIMENSION (mm) La 1500 1750 2000 2450 2450 2450 2450 2450 2450 B1 160 170 170 200 220 250 252 280 300 B2 210 220 215 225 280 330 299 330 380 Ta 150 150 160 155 180 200 227 240 260

PIPE CORE DIMENSION (SCH 80 ) Lc (mm) 1300 1150 1800 2210 2210 2210 2210 2210 2210 C (mm) 1100 1350 1600 1910 1910 1910 1910 1910 1910 Dc (inch) 2.0 2.0 2.0 2.0 3.0 4.0 4.0 4.0 4.0

APF-100-SOSP APF-123-SOSP APF-150-SOSP APF-200-S0SP APF-250-SOSP APF-300-S0SP APF-350-SOSP APF-400-SOSP APF-500-SOSP

Note: Other dimensions of anodes or cores are also available on request

ALUMINIUM PIPELINE ANODE

BRACELET ANODE

ANODE TYPE PABA 40 PABA 60 PABA 80 PABA 100 PABA 120 PABA 140 PABA 160 PABA 180 PABA 200 PABA 240

I.D (ins) 4.81 6.94 8.75 10.87 12.87 14.37 16.25 18.31 20.50 24.16

O.D (ins) 6.81 8.94 12.75 14.87 16.87 17.37 19.25 21.81 24.50 28.16

THICKNESS (inch) 1 1 2 2 2 1.5 1.5 1.75 2 2

LENGTH L (inch) 17.2 16 15.5 15.5 15.5 15.5 15.5 15.5 14.5 16

GAP G (inch) 1.5 1.5 2 2 2 2 2 3.5 2 2

NETT WEIGHT (lbs) 25 43 66 80 93 103 118 145 160 181

GROSS WEIGHT (lbs) 29 47 71 88 103 118 134 162 174 209

Note: Other dimensions of anodes or cores are also available on request

ENGINEERING INFORMATION
ALUMINIUM ANODE
The PetroCor Aluminium Alloy Anodes are made from the highest purity aluminium ingot to meet the technical requirement as follows:

ELEMENT

CHEMICAL COMPOSITION ( % ) ASALUM I ASALUM II

0.10 max 0.13 max 4 - 10 0.02 0.01 max Balance 90 % 2550 Amp.Hr/Kg 3.45 Kg/Amp.Year

Si Fe Zn In Cu Al Efficiency Electrochemical capacity in seawater at ambient Temperature Consumption rate in seawater at ambient temperature

0.10 max 0.13 max 3-5 0.04 0.01 max Balance 95 % 2700 Amp.Hr/Kg 3.25 Kg/Amp.Year

Note: Other compositions of material are also available on request

ENGINEERING INFORMATION
ZINC ANODE
The Zinc Anodes are made from the special grade ingot of minimum purity 99.995%. Alloying additions of special element is added to increase the anode efficiency and to improve the uniformity of corrosion. The chemical composition is equivalent to US military Specification 18001-H.

ELEMENT
Cu Al Si Fe Pb Cd Zn Efficiency Potential Electrochemical capacity in seawater at ambient temperature Consumption rate in seawater at ambient temperature

CHEMICAL COMPOSITION ( % )
0.005 max 0.10 0.50 0.125 max 0.005 max 0.006 max 0.025 0.15 Balance 95 % -1.05 Volts vs Ag/AgCl 780 Amp.Hr/Kg

11.25 Kg/Amp.Year

Note: Other compositions of material are also available on request

ENGINEERING INFORMATION MIXED METAL OXIDE (MMO) ANODE

Materials Substrate Shape Size Current Density Anode current output

: Mixed Metal Oxide (MMO) coated Titanium : Titanium to ASTM B338 : Tubular : 0.0254 m diameter x 1 m long : 100 A/m in carbonaceous backfill for soil application : 8 ampere

Mixed metal oxide anodes have proven to operate effectively in all types of environments, including areas with extremely low pH levels (under 1), and high chloride concentrations.

Note: Other dimension of material are also available on request

ENGINEERING INFORMATION TRASFORMER RECTIFIER (OIL COOLED)

Input voltage 115 V or 240 V single-phase 380 / 400 / 440 / 460 /480 V three-phase Frequency 50 or 60 Hz Output can be supplied in various currents and voltages ranging from 12 to 100 volts and 10 to 500 Amperes. Voltage 12, 18, 24, 30, 36, 40, 50, 75, 100 Volts Current 10, 20, 30, 40, 50, 60, 75, 100, 150, 200, 300, 400 or 500 Amp Control Manual continuously variable or adjustable in 15, 20, 24 or 63 steps Automatic constant current or constant potential Protection Output fuse and lightning arrestor Output Rating Continuous at full output Main standard - Auto and double wound transformer components - Silicon or selenium bridge rectifier - Output ammeter and voltmeter - Surge arrester - Fuses - Enclosure Standard Tank - Lockable weatherproof control cabinet with viewing window - Fittings - Oil filling cap and drain plug (for oil-cooled units) - Thermometer pocket and level gauge - Silica gel breather and spare cartridge - Earthing terminal - Lifting lugs Oil Cooled Manual Rectifier

Oil Cooled Variac Rectifier