Cathodic protection anode systems

The cathodically protected primary structures may be the hulls of ships, jetties, pipes, etc. immersed in water, or pipes, cables, tanks, etc. buried in the soil. The nearby unprotected secondary structures subjected to interaction may be the hulls of adjacent ships, unbonded parts of a ship s hull such as the propeller blades, or pipes and cables laid close to the primary structure or to the cathodic-protection anode system or groundbed. 

By virtue of the high breakdown potential of the oxide film (approximately 155 V in sea water and 280 V in low conductivity water of pH = 7) tantalum has found use as a substrate for platinum in impressed-current cathodic-protection anodes, which can be used at high impressed voltages (50 V) and high current densities. However, because of its lower cost, niobium is preferred for systems that have to operate at high voltages... 

Corrosion control. Generally corrosion inhibitors, cathodic protection, anodic protection, and coatings are used for this purpose or combination of them. However, cathodic protection is the only method that avoids corrosion completely if the system is not sensitive to hydrogen embrittlement or alkaline medium. Anodic protection is a recent approach when the metal can be passivated in the corrosive solution. In this technique, a current can be applied using a potentiostat, which can set and control the potential at a value greater than the passive potential Ep or below the pitting potential Ep]l for environments containing corrosive species such as chlorides, bromides, etc. 

Anodes have been developed in the form of conductive coatings, metals embedded in concrete overlays, conductive concrete overlays and probes drilled into the concrete. Anodes continue to be developed, applied in new configurations and to new structures. In the next section we will discuss the major components of the cathodic protection system, and particularly the anode systems that are available as these are the most prominent part of the cathodic protection system. Judicious choice of cathodic protection anode can maximize the cost effectiveness of the system. 

Sacrificial anode cathodic protection A system of cathodic protection that u,ses a more easily corroded metal such as zinc, aluminium or magnesium to protect a steel object from corrosion. No power supply is required, but the anode q.v.) is consumed,... 

The system was straightforward. One of the popular impressed current pipeline cathodic protection anodes of that time was made of a corrosion resistant silicon iron, surrounded by a carbon cokebreeze backfill. A well was dug near the pipeline, the anode put in surrounded by the backfill and the system connected to a DC power supply, with the negative terminal connected to the pipeline to make a cathodic protection system. Richard Stratfull look pancake silicon iron anodes, fixed them on a bridge deck and applied a carbon cokebreeze asphalt overlay (Stratfull, 1974). The systems installed in 1973 and 1974 were reviewed in 1989 and were still working (Broomfield and Tinnea, 1992),... 

Cathodic protection is an electrochemical polarization process that is widely and effectively used to limit corrosion. Simply stated, it is an electrical system whose energy operates in opposition to the natural electrochemical decomposition process of corrosion. All cathodic protection systems require the artificial development of an alternative corrosion cell with (-) electrons flowing finm the artificially installed anode to the structure in the metallic path. It also requires the flow of (+) ions (atoms or molecules carrying electrical charge) from the anode to the structure by the electrolyte path and/or (-) ions in the opposite direction. For a constant current, the level of protection depends on the polarization slope of the cathodic reaction on the structure. Current can be supplied by a galvanic or impressed current system. In a galvanic system, the electrons flow because of the difference in half-cell potential between the metal of the structure and the cathodic protection anode metal, given that the anode metal is more reactive than the metal of concern. In an impressed current system, an... 

When an impressed current cathodic protection (ICCP) system is in full operation there is a high possibility for oxygen to be produced at the anode, and in nearly all cells, hydrogen is formed at the cathode. If chloride ions are present, chlorine gas may be formed at the anode. This generation of gas, either oxygen or chlorine, at the anode is not nearly as likely to occur in a natural corroding cell as it is when an ICCP system is used, particularly when inert anodes are used. 

As mentioned above, a positive use of the principle of galvanic corrosion is cathodic protection. In a sacrificial system of cathodic protection, anodes of active metals, like Zn, Mg and Al, are used for protection of steel structures. The sacrificial galvanic anodes provide protection to the less active metals, like steel because they corrode and release electrons. The electrons which are released by the... 

In contrast to cathodic protection, anodic protection is relatively new. Edeleanu first demonstrated the feasibihty of anodic protection in 1954 and tested it on small-scale stainless steel boilers used for sulfimc acid solutions. This was probably the first industrial apphcation, although other experimental work had been carried out elsewhere. This technique was developed using electrode kinetics principles and is somewhat difficult to describe without introducing advanced concepts of electrochemical theory. Simply, anodic protection is based on the formation of a protective film on metals by externally applied anodic currents. Anodic protection possesses unique advantages. For example, the applied current is usually equal to the corrosion rate of the protected system. Thus, anodic protection not only protects but also offers a direct means for monitoring the corrosion rate of a system. As an... 

Impressed current cathodic protection (ICCP) and sacrificial anode cathodic protection (SACP) systems were designed... 

A unique condition encountered on land that has been built up from coral deposits is the presence of blowholes, fissures and caves, which augments the penetration of seawater to areas remote from the actual seashore. Knowing that seawater makes for a very extensive, uniform, low resistivity "ground bed" for cathodic protection anodes, the above condition facilitates the design of unique cathodic protection systems. 

Cathodic Protection Systems. Metal anodes using either platinum [7440-06 ] metal or precious metal oxide coatings on titanium, niobium [7440-03-17, or tantalum [7440-25-7] substrates are extensively used for impressed current cathodic protection systems. A prime appHcation is the use of platinum-coated titanium anodes for protection of the hulls of marine vessels. The controUed feature of these systems has created an attractive alternative... 

The low cost, light weight, and exceUent electrical conductivity of graphite anodes have made this impressed current protection system valuable for cathodic protection of pipelines, storage vessels, process equipment, and also for weU casings both on- and offshore. 

Two areas of passivity are located in Fig. 2-2 where Fe has a very low corrosion rate. In contrast to cathodically protected metals in groups I and II, the corrosion rate of anodically passivated metals in groups III and IV cannot in principle be zero. In most cases the systems belong to group IV where intensified weight loss corrosion or local corrosion occurs when U > U" There are only a few metals belonging to group III e.g., Ti, Zr [44] and A1 in neutral waters free of halides. 

Systems with lifetime-potential curves like type (b) in Fig. 2-17 can be protected anodically as well as cathodically against stress corrosion. The following metals belong to these systems ... 

In the cathodic protection of storage tanks, potentials should be measured in at least three places, i.e., at each end and at the top of the cover [16]. Widely different polarized areas arise due to the small distance which is normally the case between the impressed current anodes and the tank. Since such tanks are often buried under asphalt, it is recommended that permanent reference electrodes or fixed measuring points (plastic tubes under valve boxes) be installed. These should be located in areas not easily accessible to the cathodic protection current, for example between two tanks or between the tank wall and foundations. Since storage tanks usually have several anodes located near the tank, equalizing currents can flow between the differently loaded anodes on switching off the protection system and thus falsify the potential measurement. In such cases the anodes should be separated. 

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. 

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