Cathodic control protection

Cathodic control protection Increase in cathodic overpotential nd... 

Cathodic control protection protects the substrate by coating with a less noble metal, for which the slopes of the cathodic polarization curves are steep. The cathodic overpotential of the surface is increased by the coating therefore, the corrosion potential becomes more negative than that of the substrate. Coating materials used for this purpose are zinc, aluminum, manganese, cadmium, and their alloys. The electrode potential of these metals are more negative than those of iron and steel. When exposed to the environment, these coatings act as sacrificial anodes for the iron and steel substrates. 

The electrical conductivity of the electrolyte, the temperature, and the surface condition determines the galvanic action of the sacrificial metal coating. An increase in the cathodic overpotential is responsible for the corrosion resistance of the coating layer. Figure 16.8 shows the principle of cathodic control protection by a sacrificial metal coating. 

Cathodic control protection increase in cathodic overpotential /j, ... 

As an example. Fig. 20-7 shows potential and protection currents of two parallel-connected 750-liter tanks as a function of service life. The protection equipment consists of a potential-controlled protection current rectifier, a 0.4-m long impressed current anode built into the manhole cover, and an Ag-AgCl electrode built into the same manhole [10,11]. A second reference electrode serves to control the tank potential this is attached separately to the opposite wall of the tank. During the whole of the control period, cathodic protection is ensured on the basis of the potential measurement. The sharp decrease in protection current in the first few months is due to the formation of calcareous deposits. 

Figure 20-9 shows the negative effect of uninsulated heating elements on corrosion protection. In a 250-liter tank, an electric tube heating element with a 0.05-m surface area was screwed into the upper third without electrical separation, and in the lower third a tinned copper tube heat exchanger with a 0.61 -m surface area was built in. The Cu heat exchanger was short-circuited for measurements, as required. For cathodic protection, a potential-controlled protection system with impressed current anodes was installed between the two heating elements. The measurements were carried out with two different samples of water with different conductivities. 

A tank with a fixed cover of plain carbon steel for storing 60°C warm, softened boiler feed water that had a tar-pitch epoxy resin coating showed pits up to 2.5 mm deep after 10 years of service without cathodic protection. Two separate protection systems were built into the tank because the water level varied as a result of service conditions. A ring anode attached to plastic supports was installed near the bottom of the tank and was connected to a potential-controlled protection rectifier. The side walls were protected by three vertical anodes with fixed adjustable protection current equipment. 

Many other issues are involved in the application of cathodic protection. For example, consider the case of cathodic protection of underground structures in which the corrosivity of soil is likely to play a major role, as does the degree of aeration and the resistivity. Bacterial effects also can change the corrosion potential. AU these factors influence the corrosion process so that along a pipeline there can be varying cathodic control requirements that have to be estimated from potential measurements, experience, and so forth. 

Organic coatings include phenol formaldehyde, epoxy, polyacryl and polyacryl acid resins, polyamide, polyolefin, bitumen and rubber. The required properties of lining materials in combination with cathodic protection are given in Section 5.2.1. In addition, adequate resistance to water vapor diffusion is required (see Section 5.2.2). These properties are discussed in the basic standard for internal cathodic protection [2], which also reports how these properties can be assured by testing with the aid of Ref. 3. It is convenient to limit the protection potential region to [7 5 = -0.8 V in the presence of resin coatings, which makes potential-controlled protection current equipment necessary. 

The main emphasis in power line corrosion control is to select materials resistant to a specific environmental attack and to galvanize ferrous materijils (carbon steel and cast iron). This approach is used in the design of new lines and is supplemented by selective use of coatings and cathodic (galvanic) protection. The in-service methods are hmited to apphcation of coatings, cathodic protection, juid inhibitors. 

Mixed control protection increase in both anodic and cathodic overpotential, [nj and , ... 

Zinc coatings protect the substrate by means of cathodic control. Cathodic overpotential of the surface is increased by the coating, which makes the corrosion potential more negative than that of the substrate. The coating... 

A typical basic appreciation of cathodic protection by impressed current/cathodic control is as follows ... 

Corrosion. Anticorrosion measures have become standard ia pipeline desiga, coastmctioa, and maintenance ia the oil and gas iadustries the principal measures are appHcation of corrosion-preventive coatings and cathodic protection for exterior protection and chemical additives for iaterior protectioa. Pipe for pipelines may be bought with a variety of coatiags, such as tar, fiber glass, felt and heavy paper, epoxy, polyethylene, etc, either pre-apphed or coated and wrapped on the job with special machines as the pipe is lowered iato the treach. An electric detector is used to determine if a coatiag gap (hoHday) exists bare spots are coated before the pipe is laid (see Corrosion and corrosion control). 

Hard plating is noted for its excellent hardness, wear resistance, and low coefficient of friction. Decorative plating retains its brilliance because air exposure immediately forms a thin, invisible protective oxide film. The chromium is not appHed directiy to the surface of the base metal but rather over a nickel (see Nickel and nickel alloys) plate, which in turn is laid over a copper (qv) plate. Because the chromium plate is not free of cracks, pores, and similar imperfections, the intermediate nickel layer must provide the basic protection. Indeed, optimum performance is obtained when a controlled but high density (40—80 microcrack intersections per linear millimeter) of microcracks is achieved in the chromium lea ding to reduced local galvanic current density at the imperfections and increased cathode polarization. A duplex nickel layer containing small amounts of sulfur is generally used. In addition to... 

Cathodic Protection This electrochemical method of corrosion control has found wide application in the protection of carbon steel underground structures such as pipe lines and tanks from external soil corrosion. It is also widely used in water systems to protect ship hulls, offshore structures, and water-storage tanks. 

Cases I and II are examples of protection by cathodic polarization and III and IV of protection by anodic polarization. In cases I and III, the protection current can be uncontrolled, while in cases II and IV the potential has to be controlled. The development of operationally safe and widely available rectifiers (see Chapter 21)... 

Current control can be more advantageous where rail/soil potentials are predominantly positive. Current control is also preferred in the cathodic protection of steel-water construction if the anode resistance fluctuates due to changes in electrical conductivity. 

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