Protection current densities

The terms protection current and protection current densities refer to any values of total cathodic currents that meet the criterion in Eq. (2-40). However, in the field, and for designing cathodic protection stations, another term is of interest, the protection current requirement. This term is concerned with the lowest value of the protection current that fulfills the criteria in Eqs. (2-39) or (2-40). Since with an extended object having a surface S the polarization varies locally, only the current density for the region with the most positive potential has the value J. In other regions 17. 1 > 7. . For this reason, the protection current requirement 4 is given by ... 

In analyzing the results on a cathodically protected pipeline, the protection current density and coating resistances should be calculated for individual sections of the pipeline in addition to the on and off potentials, the pipe current, and the resistances at insulating points and between the casing and the pipeline. The results should be shown by potential plots to give a good summary [15] (see Fig. 3-20). 

There is a correlation between the average protection current density of the particular measured section... 

Fig. 3-13 Determination of the protection current density and coating resistance of a pipeline (explanation in the text).

The variation in the on and off potentials or the potential difference along the pipeline will usually indicate faults that prevent the attainment of complete cathodic protection. The protection current requirement of the pipeline may be estimated from experience if the age and type of pipeline is known (see Fig. 5-3). Figure 3-20 shows the variation in the on and off potentials of a 9-km pipeline section DN 800 with 10-mm wall thickness. At the end of the pipeline, at 31.84 km, an insulating unit is built in. The cathodic protection station is situated at 22.99 km. Between this and the end of the pipeline there are four pipe current measuring points. The applied protection current densities and coating resistances of individual pipeline sections are calculated from Eqs. (3-40) and (3-41). In the upper diagram the values of... 

A relation can be derived between and the necessary protection current density from Eq. (5-2) together with the pragmatic protection Criterion 2 in Table 3-3 [seeEq. (3-31)] ... 

With the protection current density 7 for the uncoated surface Sq, the protection current density is given by... 

If, however, it is assumed from Eq. (2-40) that the protection current density corresponds to the cathodic partial current density for the oxygen reduction reaction, where oxygen diffusion and polarization current have the same spatial distribution, it follows from Eq. (2-47) with = A0/7 ... 

Protection current density and coating resistance are important for the current distribution and for the range of the electrochemical protection. The coating resistance determines, as does the polarization resistance, the polarization parameter (see Sections 2.2.5 and 24.5). For pipelines the protection current density determines the length of the protection range (see Section 24.4.3). 

In choosing a protection method, the magnitude of the required protection current, which depends on the necessary protection current density, is of considerable importance. From Section 5.2.1.2 a rough estimate of the current demand can be made using Eq. (5-11 ). 

Table 5-1 gives values of electrical resistance for different coating materials. It is advisable to increase these by 100% at the planning stage because of the uncertainty in estimating the protection current density. 

The maximum protected length 2 L is given in Fig. 10-1 and the required protection current in Fig. 10-2. For pipelines with carefully mill-applied PE and excellent field-applied coating of the girth weld area, the protection current densities lie between 1 and 3 jJ.A m With carefully buried pipelines with bitumen (or coal tar) coating, the protection current densities lie between 10 and 30 jUA mr. ... 

In the case of older pipelines and offshore pipelines, protection current densities can amount to several mA m" For older onshore pipelines, the protection current densities are determined by a drainage test according to Section 3.4.3. 

Cathodic protection with magnesium anodes can be just as economical as impressed current anode assemblies for pipelines only a few kilometers in length and with protection current densities below 10 xA m" e.g., in isolated stretches of new pipeline in old networks and steel distribution or service pipes. In this case, several anodes would be connected to the pipeline in a group at test points. The distance from the pipeline is about 1 to 3 m. The measurement of the off potential... 

A check on the cathodic protection of the pipeline should be carried out annually according to Section 10.4, where, of course, only the on potential should be measured. This value should also be compared with the values of the measurements in Section 10.4. If there are no changes in the on potentials and the protection current densities for the individual sections of the pipeline, it can be concluded that the off potential has not changed. The values can easily be compared using computers and represented in plots. If the protection current and potential distribution have changed, or in any case every 3 years, the off potentials as well as the on potentials should be measured. 

For economical and complete cathodic protection against external corrosion without harmful effects on nearby installations, the storage tank to be protected must have good coating and therefore require a low protection current density. In addition, it must have no electrical contacts with other buried installations, such as... 

Based on past experience, it has been found that the protection current density for buried storage tanks coated with bitumen is over 100 /xA m. With coatings in very good condition, it can amount to a few tens of jiA but for coatings in a very poor state, it can rise to a level of mA The protection current demand can... 

For normally buried tanks, tanks with measures against buoyancy and tanks with a secondary containment, no difficulties are to be expected for protection current densities below 200 fJ.A m. On the other hand, the protective action can... 

If the protection current density for underground tank installations is not much... 

In the case of higher protection current densities and protection currents, interference can occur on nearby installations not covered by the protection. The danger of anodic interference must be investigated by making measurements and prevented by taking appropriate measures [7] (see Section 9.2). For the same reasons, anode systems should not be installed near steel-reinforced concrete foundations. 

At the relatively low protection current density of 200 llA m and with the anode positioned on one side, it is to be expected that with this storage tank sufficient reduction in potential would be achieved on the other side of the tank from the anode. The off potential was measured using a measurement point at a depth of about 2 m as f/cu-cuso4 = -0.88 V at the tank. At the other side of the tank as well as above it, off potentials of-0.90 to -0.94 V were found. These potentials were measured with a protection current of 10 mA (anode 1 6 mA, anode 2 4 mA) with an additional resistance of 8 Q in the protection current circuit (see Fig. 11-2). With a direct connection between the tank and the group of magnesium anodes, the initial current was about 16 mA, which after 1 h of polarization decreased to about 14 mA. The reserve current, based on a long-term current of 10 mA, amounted to ca. 40% in the operation of the cathodic protection installation. 

In this case, impressed current protection with several anodes was chosen on the one hand to achieve uniform current distribution with the relatively high protection current density, and on the other hand to avoid large anode voltage cones. A transformer-rectifier with a capacity of 10 V/1 A was chosen. 

Cathodic protection of different materials in installations of dissimilar metals is only possible if the protection potential ranges of the individual materials overlap. Section 2.4 gives information on the protection potential ranges of various systems. If there is no overlapping, then insulating couplings must be installed. This is also appropriate and even necessary if the protection current densities are very different. 

Structures or pits for water lines are mostly of steel-reinforced concrete. At the wall entrance, contact can easily arise between the pipeline and the reinforcement. In the immediate vicinity of the pit, insufficient lowering of the potential occurs despite the cathodic protection of the pipeline. Figure 12-7 shows that voltage cones caused by equalizing currents are present up to a few meters from the shaft. With protection current densities of 5 mA mr for the concrete surfaces, even for a small pit of 150 m surface area, 0.75 A is necessary. A larger distribution pit of 500 m requires 2.5 A. Such large protection currents can only be obtained with additional impressed current anodes which are installed in the immediate vicinity of the pipe entry into the concrete. The local cathodic protection is a necessary completion of the conventional protection of the pipeline, which would otherwise be lacking in the pit. 

Covering the foundations of the tank with bitumen or a mixture of bitumen, sand and gravel ( oiled-sand ) reduces the protection current requirement considerably. Figure 12-8 shows the protection current requirement of the base of some flat-bottomed tanks. The protection current densities of tank bases 1,3 and 4 lie between 0.5 and 2 mA m. The protection current density of tank No. 2 is very much greater. 

After a few years the tank base can no longer be cathodically protected by the initial protection current density of 3 mA m Only after installing additional anodes can the tank base be again cathodically protected with protection current densities of 10 mA m" with a total protection current of 80 A. The reason for the high protection current requirement is unsatisfactory insulation of the tank foundation. 

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