Professional Documents
Culture Documents
Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi
Aramco and is intended for the exclusive use of Saudi Aramcos
employees. Any material contained in this document which is not
already in the public domain may not be copied, reproduced, sold, given,
or disclosed to third parties, or otherwise used in whole, or in part,
without the written permission of the Vice President, Engineering
Services, Saudi Aramco.
Engineering Encyclopedia
Engineering Encyclopedia
SAUDI ARAMCO
Engineering Encyclopedia
NOTE:
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CONTENTS
PAGES
INFORMATION
Principles and Operation of Cathodic Protection Systems
How Cathodic Protection Works
Measuring Electrical Potential
Operation of Galvanic Anode Systems
1
1
5
7
Galvanic Anodes
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16
17
18
20
Coke Breeze
23
23
24
26
28
Offshore Platforms
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Marine Pipelines
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WORK AID
Work Aid 1: Formula, Criteria, and Guideline for Calculating Cathodic
Protection Requirements for Buried Pipelines
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32
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GLOSSARY
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A Laboratory Corrosion Cell (left) and a Corrosion Cell on a Metal Surface (right)
Figure 1
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positive
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When direct current is applied to a metal surface, its potential becomes more negative. This
shift in electrical potential can be measured and used as a criterion of cathodic protection.
Electrical potentials are always measured with respect to a reference electrode. The coppercopper sulfate (Cu-CuSO4) reference electrode is the most common reference electrode used
for buried structures. The Cu-CuSO4 reference electrode is durable, easy to make, and easy
to maintain. Also, the potential of a Cu-CuSO4 reference electrode changes very little with
temperature.
Figure 7 is a diagram of a Cu-CuSO4 reference electrode. The voltage of a Cu-CuSO4
reference electrode depends on the concentration of copper sulfate in the electrolyte solution.
Saturated solutions are easiest to make and they provide consistent measurements. To make a
saturated solution, copper sulfate crystals are added to water until some of the crystals do not
dissolve. The solution remains stable as long as some copper sulfate crystals are undissolved.
The plug at the bottom of the reference electrode is made of porous material. The porous plug
provides a conductive path between the reference electrode and the electrolyte around a
structure.
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Figure 8 shows how the potential difference between a pipeline and the Cu-CuSO4 reference
electrode is measured. The reference electrode is connected to the positive lead of a high
impedance voltmeter. The common (negative) terminal of the voltmeter is connected to the
pipeline test lead. The voltmeter reading is the sum of the potential between the reference
electrode and the soil and the potential between the pipeline and the soil. The potential
between the reference electrode and the soil is constant. The potential between the pipeline
and the soil can vary. When connected as shown, the potential reading will normally be
positive. By convention, voltage readings are often reported as negative numbers.
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Metal
High potential magnesium alloy
Magnesium alloy (contains Al, Zn, Mn)
Zinc
Aluminum alloy (Contains zinc)
Mild steel
Cast iron
Brass, bronze, or copper
High silicon cast iron
Mill scale on steel
Carbon, coke, graphite
-1.80
More anodic
-1.55
-1.10
-1.05
-0.50 to -0.80
-0.50
-0.20
-0.20
-0.20
+0.30
More cathodic
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Typical Galvanic Anode System in Soil (arrows show the direction of electric current)
Figure 11
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Galvanic Anodes
Galvanic anodes can protect small structures or parts of larger structures. A galvanic anode
supplies a given amount of electric current. Several anodes may be grouped to provide
enough current to shift the potential of a structure. Galvanic anodes are effective when (1)
electric current requirements are low, (2) the structure is well coated, or (3) the electrolyte has
relatively low resistivity. Galvanic anodes are usually made from materials near the top of the
Galvanic Series (e.g., magnesium, zinc, and aluminum).
Magnesium Galvanic Anodes - Magnesium is the most widely used material for buried galvanic
anodes. Saudi Aramco normally uses magnesium anodes on pipelines at road and camel
crossings. A typical 27.3 kg (60 lb) magnesium anode is shown in Figure 14.
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Two types of magnesium anodes are availablestandard alloy and high-potential alloy. Both
have a theoretical energy content of about 2,200 ampere-hours per kg and an efficiency of
50%. Therefore, the actual energy content available is 2,200 ampere-hours per kg x 0.50, or
1,100 ampere-hours per kg. The standard magnesium anode has a solution potential of -1.55
volts versus Cu-CuSO4. High-potential magnesium anodes have a solution potential of -1.80
volts. Saudi Aramco uses high-potential magnesium anodes almost exclusively. NOTE:
Magnesium anodes are susceptible to polarization. For this reason, their solution potential is
reduced by 0.10 volt for design purposes.
Zinc Galvanic Anodes - Zinc anodes are most often used in sea water or in soil resistivities
below 700 ohm-cm. Occasionally they are used in soils up to 2,500 ohm-cm. Pure zinc has a
theoretical energy content of 820 ampere-hours per kg. Zinc anodes typically operate at about
95% efficiency. Therefore, the actual energy content available is 820 ampere-hours per kg x
0.95, or 779 ampere-hours per kg. Zinc anodes have a potential of -1.10 volts versus a CuCuSO4 half-cell.
Zinc galvanic anodes used in soil have long slender shapes to achieve low resistance to earth
(Figure 15). Their shape also provides practical current output despite their low driving
voltages. Zinc anodes are not subject to significant polarization when they are used in
suitable backfill.
CAUTION: Do not use zinc anodes when the temperature will exceed 49 C. This
temperature may cause the polarity of zinc anodes to reverse and result in corrosion of the
structure.
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Aluminum Galvanic Anodes - Aluminum anodes are used in offshore applications. The three
All of these alloys have slightly different theoretical energy contents, but they average
2,700 ampere-hours per kg in sea water service. Aluminum anodes are effective in electrolyte
resistivities less than 700 ohm-cm. The efficiencies of aluminum anodes range from 85% to
95% in sea water. The potentials of aluminum anodes range from -1.05 to -1.15 volt versus
Cu-CuSO4.
Aluminum galvanic anodes are manufactured so they can attach directly to an offshore
structure. Three types of core arrangements are shown in Figure 16.
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Figure 17 shows a typical vertical galvanic anode installed in soil. Galvanic anodes installed
in soil are surrounded with a special chemical backfill material. A typical backfill mixture for
magnesium anodes is 75% hydrated gypsum, 20% bentonite clay, and 5% sodium sulfate.
Clays in the backfill adsorb water from the soil and keep the anode moist for maximum
current output. The backfill materials also prevent passive corrosion films from forming on
the anode. The chemical backfill also lowers the resistance of the anode to the soil. Galvanic
anodes are frequently pre-packaged in backfill material. The entire cloth backfill package may
be buried as shown in Figure 17.
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AA-036385
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scrap steel
platinized niobium
Other types of anodes offer little economic advantage over the above materials. Figure 20
shows a typical center-connected anode. Center connections reduce the consumption of
anode material at the ends of anodes compared to end-type connections.
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High silicon chromium cast iron anodes contain 14% to 15% silicon and about 5% chromium.
High silicon cast chromium iron loses weight at a rate of 1.0 kg /A-year. It forms a stable
amorphous hydrated oxide film that protects the anode surface and conducts electricity. High
silicon chromium cast iron anodes are rated at a maximum current density of 1.0 mA/cm2 in
soils.
Scrap steel is sometimes used as impressed current anode material because it is abundant and
inexpensive. Ordinary steel loses weight at the rate of 9.1 kg/A-year. However, the current
discharge is seldom uniform. The area around the cable connection often corrodes rapidly;
consequently, several cable connections are used. Scrap steel anodes perform erratically, and
the anode bed life is fairly unpredictable. The suggested maximum current density of scrap
steel is 0.5 mA/cm2 in soil.
Mixed Metal Oxide Composite Anodes are used in soil and marine environments. Their major
advantage is their small size and high current output compared to other impressed current
anode materials. The consumption rate of mixed metal oxide composite anodes in soils is low
(7 g/A-year). Their suggested current density is 10 mA/cm2 in soils and 12.5 mA/cm2 in sea
water.
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Platinized niobium anodes protect offshore structures with high current requirements. Niobium
alone is unsuitable as an anode material. Niobium forms very stable oxide films on its
surface. These films have high chemical and electrical resistance. Therefore, niobium is
plated with platinum or platinum alloys, which form conductive oxide films. The niobium
substrate maintains excellent chemical resistance while the platinum layer allows high current
output with low consumption rates (8.63 x 10-6 kg/A-yr). The result is a more efficient anode.
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Coke Breeze
Except for scrap steel, impressed current anodes in soil are usually surrounded with
carbonaceous backfill. The carbonaceous backfill is usually calcined petroleum coke
(sometimes called coke breeze). Coke breeze serves the following purposes:
1. Coke breeze increases the effective size of the anode and lowers the resistance of
the anode to the earth.
2. Coke breeze extends the life of the anode because the coke breeze is consumed
rather than the anode.
Coke breeze consumption depends on good electrical contact between the anode and the
backfill. The backfill must be packed solidly around the anode so that little of the current will
discharge directly from the anode to the soil.
Advantages and Disadvantages of Impressed Current Systems
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0.75 mA/m2 =
750 mA
0.75 amperes
Coatings prevent direct contact between the metal surface and corrosive electrolyte. The
coatings greatly reduce the amount of CP current required to control corrosion. Most of the
CP current is needed at areas where the coating is damaged. For this reason, coatings and
cathodic protection are often used together.
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25
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Guideline
1.
Locate the required current density for the structure in the table above.
2.
If the surface area is not provided, calculate the exposed surface area of the section of
pipeline using the formula provided.
3.
Multiply the required current density by the surface area of the pipeline.
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20.0
0.5
3.0
30.0
Guideline
1.
Locate the required current density for the structure in the table above.
2.
If the surface area is not provided, calculate the exposed surface area of the tank or
vessel using the formula provided.
3.
Multiply the required current density by the exposed surface area of the tank or vessel.
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The design current density requirements for marine structures, shown in the table below, are
listed in Section 4.4 of SAES-X-300.
Environment
Sea water structures
Structures in mud or soil
Marine pipelines
50.0*
20.0
1.
Locate the required current density for the structure in the table above.
2.
If the surface area is not provided, calculate the immersed surface area of the marine
structure.
3.
Multiply the required current density by the total immersed surface area of the marine
structure.
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GLOSSARY
activation polarization
anode
area effect
cathode
cation
close electrode
concentration cell
concentration polarization
contact resistance
corrosion potential
electrochemical reaction
electrolyte
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half-cell
ion
metal path
The contact between the anode and cathode that allows the
flow of electrons and electric current.
oxidation
polarization
reduction
remote electrode
resistance
resistivity
subkha
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