CATHODIC PROTECTION

Cathodic protection is a secondary line of defence against corrosion, the primary defence being the
coating. When damage to the coating occurs e.g. through impact on the coating during back filling on a
pipeline, sling damage during the lowering in operation, or flotsam impact on an offshore platform leg,
the underlying steel can then be in contact with electrolyte and corrosion can occur. But if these areas
can become cathodic i.e. receive current, corrosion can be avoided. In order for cathodic protection to
be applied, an electrolyte must be present. For example the external surface of a tank cannot have
cathodic protection, but internal surfaces can if the tank is holding an electrolytic medium, but only up
to the level of medium, not above. Underground and subsea pipelines can be protected, but steelwork
above ground in an AGI needs painting. Cathodic protection can be applied in one of two ways.
a)
b)

Sacrificial Anodes Systems.

Impressed Current Systems.

Sacrificial anode systems

This system sometimes called, Galvanic Anode System, works on the principle of bimetallic corrosion,
the natural potential between metals. Any metal which is more electronegative (less noble) or below
steel on the galvanic list can be used as an anode. The choice of metal used would depend upon the
potential required to protect the prescribed area. Sacrificial systems only protect small areas and the
anodes need changing regularly as they corrode away.

Approximately
50 m maximum

Connecting wire of
copper. Minimum
resistance

+
Figure 11.1 Sacrificial system

Aluminium zinc or
magnesium or
alloys of these

Impressed current system

The impressed current system is used to protect long lengths of pipeline from one installation, a distance
of approximately 10 miles. The current needed to run the system comes from the national grid and is
connected through a transformer rectifier (TR). The national grid is very high voltage and very high
amperage and also AC. Anti-corrosion currents need to be DC. The TR rectifies the current to DC and
transforms it to low voltage and amperage. The positive side of the TR is connected to a ground bed
(anode system) and the negative to the pipe, making the pipe the cathode.
The current is released into the electrolyte at the ground bed, passes through the electrolyte and is
received at areas of coating damage on the pipe.
A typical ground bed will be approximately 50 m in length, at the same depth as, and running parallel to
the pipe. The cables carrying the current are of a substantial diameter and pure copper to produce a
circuit of little or no resistance at the anode. The resistance encountered comes in the soil/clay/rock
bearing the electrolyte and this will govern the driving voltage required, and the number of anodes
required to maintain negative potential on the buried pipe.
The voltage required varies but is usually within the range of 10v to 50v at an amperage of around
0.15 amps. A CP system does not eliminate corrosion, it controls where corrosion occurs.
To national grid
supply
TR.
Transformer
rectifier
Current received at
cathode. Protected.

Ground bed
releases current
into electrolyte
Figure 11.2 Impressed current system

Interference
When a buried steel structure is near to, or in the case of another pipeline, passes over or below a
pipeline which is cathodically protected, problems can occur. This is interference but the term can be
misleading. The offending structure does not adversely affect the CP system, but instead is affected by
it.
The interference structure picks up current released from the anode bed and conducts the current
through a circuit of minimal resistance and releases the current again into the electrolyte near to the
protected line. The interference therefore becomes a secondary anode and can suffer severe corrosion.
If there is a possibility of a structure becoming interference then precautions need to be taken to avoid
this eventuality. With the permission of the owner of the offending structure, three main methods can
be employed.
1

Attach isolation joints one pipe length either side of the nearest point of the offending line to the
protected line. Join the two pipe lengths to the protected line with insulated wire and doubler
plates, thus making them the same potential.

Attach isolation joints to both lines, one pipe length either side of the nearest point. Join the two
isolated sections together and install a sacrificial anode to protect both sections.

Double wrap and contra-wrap the protected line giving four tape thicknesses with Cold Applied
Laminate Tape for one pipe length either side of the nearest point.

The method chosen would be at the discretion of the engineer.

Monitoring CP
It is considered that 850 mv will maintain a pipeline in a passive state but most CP engineers will
require a more negative value, -1 to 2v being typical. To ensure that the required potential is being
maintained, checks need to be carried out at regular intervals. One method of monitoring is known as
half-cell reference electrode. The most commonly used half-cell electrode is the copper/copper sulphate
half-cell electrode. It is used for measuring the pipe to earth potential, i.e. cathode to earth, the other
half of the circuit being anode to earth.
Periodically along the line, CP monitoring posts are installed, with a direct wire connection to the pipe,
accessed from a stud on the CP post panel. A voltmeter is connected to the stud and to the
copper/copper sulphate half-cell, which is then pushed into the earth directly above the pipe. This
provides a circuit for electrons from the pipe, into the electrolyte, back to the anode bed.

Voltmeter

Half cell reference

electrode filled with
copper sulphate
solution

CP post

Ground level
Porous plug

Pipe
Figure 11.3 Monitoring CP
Cathodic disbondment
Part of the electrical circuit of the corrosion reaction is the evolvement of Hydrogen gas from the
cathode. Hydrogen is a very powerful gas and can cause cracking in steel, (HICC). If Hydrogen gas
can penetrate underneath a coating it can easily disbond it. This is known as Cathodic or Hydrogen
Disbondment. Over protection of damaged areas on a pipe, results in over production of Hydrogen and
subsequent disbondment of more of the coating, resulting in a bigger area to protect, needing more
current.
All material used on a pipeline have to undergo tests to determine their resistance to cathodic
disbondment. The test is done in the following manner.
A 6 mm diameter hole is drilled into a plate coated with the material to be tested, through the coating
and into but not through the underlying steel. A short length, approximately 50 mm of plastic tube
approximately 50 mm diameter is fixed in position, using typically araldite epoxy or elastomeric sealant
with the drilled hole central to the tube. This is then part filled with 3% solution of common salt,
sodium chloride, and a lid fitted. The lid can be machined from a block of polyethylene with a suitable
diameter hole drilled through. The plate is connected to the negative pole of a battery, an anode is
connected to the positive pole and inserted through the hole in the lid into the salt solution.
When the circuit is switched on the plate is the cathode and Hydrogen (and Chlorine) will be evolved
from the steel, and also at the interface of steel/coating. This enables Hydrogen to penetrate under the
coating, simulating areas of coating damage.
The circuit is stopped after 28 days stripped down, dried off, and using a craft knife, two cuts are made
at an inclusive angle of approximately 30o radiating from the centre of the hole, through the coating to
the substrate. Where disbondment has occurred the coating will chip of as the cuts are being made. The
distance from the edge of the hole to the extent of the disbondment is measured and should not exceed
the stated requirements. For example FBE maximum 5mm after 28 days.
Lid

Plastic ring

Elastomeric
sealant
Battery
Coating

Plate

6 mm diameter
hole

Salt solution