TATA CONSULTING ENGINEERS SECTION: TITLE

TCE.M6-EL-GL-G- SHEET (i) OF (iii)

816-6311 CATHODIC PROTECTION

DESIGN GUIDE
FOR
CATHODIC PROTECTION

FLOPPY NO : TCE.M6-EL-DWG-004
FILE NAME : [Link]

[Link] RO R1 ISSUE

R1 INITIALS SIGN INITIALS SIGN INITIALS SIGN R1

[Link] RSN Sd/- KP Sd/-

[Link] NRS Sd/- PP Sd/-

[Link] DKB Sd/- UAK Sd/-

DATE 1983-10-24 2000-03-31

FORM NO. 020R2

TATA CONSULTING ENGINEERS SECTION: CONTENTS
TCE.M6-EL-GL-G-
816-6311 CATHODIC PROTECTION SHEET (ii) OF (iii)

PARA NO. TITLE SHEET NO.

1.0 SCOPE 1

2.0 CATHODIC PROTECTION SYSTEM 1

3.0 NEED FOR THE APPLICATION OF

CATHODIC PROTECTION 6

4.0 FIELD SURVEYS 8

5.0 TYPICAL CATHODIC PROTECTION

SCHEME/PRACTICES 10

ANNEXURES

TABLE-1 FACTORS RESPONSIBLE FOR

POTENTIAL DIFFERENCES ON
METAL SURFACE 16

TABLE-2 ELECTROMOTIVE FORCE SERIES 17

TABLE-3 SACRIFICIAL(GALVANIC) ANODES 18

TABLE-4 IMPRESSED CURRENT ANODES 20

TABLE-5 POTENTIALS FOR CATHODIC

PROTECTION 21

TABLE-6 CORROSIVITY OF SOIL 22

TABLE-7 PROTECTIVE CURRENT DENSITY 23

ISSUE
R1

FORM NO. 120 R1

TATA CONSULTING ENGINEERS SECTION: REV. STAT
TCE.M6-EL-GL-G-
816-6311 CATHODIC PROTECTION SHEET (iii) OF (iii)

REVISION STATUS SHEET

[Link]. DATE DESCRIPTION

RO -

R1 2000-03-31 Generally revised and

document typed in MS-
Word

ISSUE
R1

FORM NO. 120 R1

TATA CONSULTING ENGINEERS SECTION: WRITE-UP
TCE.M6-EL-GL-G-
816-6311 CATHODIC PROTECTION SHEET 1 OF 23

1.0 SCOPE

1.1 This design guide gives guidelines for the design of Cathodic
Protection System.

2.0 CATHODIC PROTECTION SYSTEM

2.1 Cathodic Protection is an electrical method of preventing electro-

chemical corrosion of metallic surfaces in contact with electrolyte
such as soil and water. The metallic structures/equipments to
which the cathodic protection system may be applied are:

a) Underground steel pipelines, tanks, grounding conductors etc

and
b) Steel structures, equipments, pipelines etc. in contact with
sea- water.

2.2 In an electrochemical corrosion process current flows from the

anode to cathode metal-area through the electrolyte and
complete the circuit through metallic connection between the
anode and cathode metal areas. In this process, the anodic area
where from the metal enters into the surrounding electrolyte,
corrodes and the cathode metal area where at the corrosion
current enters into the metal from the electrolyte is polarized.
Conditions essential for the operation of corrosion cells are:

1) Presence of areas of different electrochemical potentials on

the metallic surface. This potential difference may be caused
due to electrochemical hetarogenetics (Table-1) or due to
presence of metals of different electrochemical potentials
(Table-2) in the system.

ii) Presence of continuous electrolyte between the anode and

cathode metal areas, and

iii) Presence of continuous metallic connection between the

anode and cathode metal-areas

ISSUE
R1

FORM NO. 120 R1

TATA CONSULTING ENGINEERS SECTION: WRITE-UP
TCE.M6-EL-GL-G-
816-6311 CATHODIC PROTECTION SHEET 2 OF 23

2.2.1 In the absence of any these factors, corrosion cells fail to

operate. It may be noted that anode and cathode areas may
be microscopically close together or miles apart and the same
area may alternately act as cathode and anode.

2.3 Electrochemical corrosion implies existence of anodic and

Cathodic areas. In impressed current cathodic protection, an
external current is superimposed in such a direction that the
metal work to be protected is made to act as a cathode. If the
external direct current (dc) is sufficient, no part of the structure
acts as anode. This entails the use of an auxiliary anode. In a
sacrificial (galvanic) anode type of cathodic protection system,
the protected structure is connected to auxiliary anode (s) of a
material such that the protection current will flow due to the
emf arising from the cell formed.

2.4 Sacrificial Anode Cathodic Protection

2.4.1 Sacrificial anode Cathodic Protection is applied when:

a) Low Protective current is required at low driving voltage.

b) External source of electric power is either not available or
it is uneconomical to use it.
c) It is not possible to install impressed current system due to
practical limitations.

2.4.2 Basic specifications of sacrificial anodes are listed in Table-3

Choice of anodes for a given application is governed by
technoeconomic and practical considerations as follows.

a) Open circuit potential difference between materials of anode

and protected structure should be large enough to drive
required amount of protective current in the circuit,

b) Anode material should not become electrically passive in

surrounding medium,

c) Total weight of anode material required to protect a

metallic structure is given as

ISSUE
R1

FORM NO. 120 R1

TATA CONSULTING ENGINEERS SECTION: WRITE-UP
TCE.M6-EL-GL-G-
816-6311 CATHODIC PROTECTION SHEET 3 OF 23

W = ixsxy
nxcxu

Where, W=Weight of anode, kg

i = Protective current density Amps/m2
s = Protected surface area, m2
n = Current efficiency of anode material, percent
c = Theoretical Amp-years per kg of anode
material
u = Utilization Factor (percent of anode consumed
when it will require replacement)

y = Life of anodes, years

d) Total weight ‘w’ of anode materials is distributed into a

number of anodes such that :

a) Protective current is uniformly distributed,

b) resistance to flow of current is minimum and
c) designed function and operation of the protected
structure are not adversely affected.

2.5 Impressed Current Cathodic Protection

Basic components of Impressed current cathodic protection

system are:

a) Source of direct current (d.c) usually a transformer rectifier

b) Anodes

c) Reference electrodes

d) Scheme for manual /automatic monitoring and control of

protection.

2.5.2 Basic details and ratings of a transformer-rectifier unit are decided

as follows.

a) Direct current (d.c) current rating shall be decided by

considering worst combination of system conditions
DC output current Rating I =ixsxF- (2)

ISSUE
R1

FORM NO. 120 R1

TATA CONSULTING ENGINEERS SECTION: WRITE-UP
TCE.M6-EL-GL-G-
816-6311 CATHODIC PROTECTION SHEET 4 OF 23

Where

i = Protective current density,Amps/m2

s = Protected surface area, m2

F = Factor to account for growth in current

requirements, unequal distribution of
current , etc.

DC output voltage Rating V= I X R

Where R is total circuit resistance including the resistance of

anode and cathode cables, electrolyte and metallic circuit
resistances etc.

2.5.3 Main characteristics of commonly used anodes are listed in Table-

4. Choice of anodes for a given application is governed by several
consideration, most important of which are:

a) Anode should be suitable for application in given

environmental/system conditions.

b) Size, shape and location of anodes should be such that the

protective current is uniformly distributed without affecting
the function and operation of protected structure and
associated equipments, and

c) Anode material required to provide protection should be

minimum possible.

2.5.4 Reference electrodes are permanently installed near the protected

surface to measure structure-to-electrolyte potentials which form
the basis for evaluating corrosion activity (Para 4.2.2) and
effectiveness of Cathodic Protection (Para 2.6 ). Basically, there are
following three (3) types of reference electrodes :

ISSUE
R1

FORM NO. 120 R1

TATA CONSULTING ENGINEERS SECTION: WRITE-UP
TCE.M6-EL-GL-G-
816-6311 CATHODIC PROTECTION SHEET 5 OF 23

a) Copper-Copper sulphate reference electrodes

b) Zinc reference electrodes

c) Silver-Silver Chloride reference electrodes

Zinc reference electrodes can be used both in underground and

underwater system. Silver-Silver Chloride electrodes are suitable for
underwater systems requiring sensitive monitoring of protection.

Copper-Copper Sulphate reference electrodes are extensively used

as a portable reference electrode during various surveys.

2.5.5 Manual/Automatic Monitoring and control schemes

a) All transformer-rectifier units are provided with arrangements

to manually adjust the output from a very low value to 100%
capacity

b) Transformer-rectifier units are provided with arrangements for

the automatic control of the output current to maintain the
structure to electrolyte potential at desired value if protective
current requirements vary continuously with time.
Permanently installed reference electrodes provide
continuous feed-back signal to automatic controller unit of
the transformer-rectifier unit.

c) The transformer rectifier units can also be provided with a

scheme to automatically maintain a fixed value of output
current. Two level (High-Low) automatic current adjustment
scheme is provided wherever either a fixed high or a fixed
low value of current is required for the protection

d) Reference electrodes are installed at selected locations to

give

ISSUE
R1

FORM NO. 120 R1

TATA CONSULTING ENGINEERS SECTION: WRITE-UP
TCE.M6-EL-GL-G-
816-6311 CATHODIC PROTECTION SHEET 6 OF 23

i) Continuous feed-back signal for the operation of automatic

controller of the transformer rectifier unit and

ii) Structure-to-electrolyte potential values on a panel

mounted corrosion voltmeter for the manual control and
adjustment of output current of a transformer rectifier unit.

e) Wherever an anode or a group of anodes require an independent

control and protection, each circuit is provided with:

i) a shunt connected to an ammeter through an anode selector

switch to measure current in each circuit.

ii) a fuse and

iii) Variable resistor to control output current in the circuit

2.6 A structure is considered to be cathodically protected if its

Potential, measured with respect to a standard reference
electrodes is more negative than the value given in Table-5. The
structure is also considered as protected if the original value of
structure to electrolyte potential is swung by –0.35 Volts. However,
this criteria of protection is not universally applicable.

3.0 NEED FOR THE APPLICATION OF CATHODIC PROTECTION

3.1 Commonly used practices for corrosion control are:

a) Use of corrosion resistant materials

b) Use of protective coatings

c) Surface treatment

d) Proper selection of parameters such as velocity of flow,

pressure, and temperature etc. which creates favorable
conditions for the occurrence of corrosion process.

ISSUE
R1

FORM NO. 120 R1

TATA CONSULTING ENGINEERS SECTION: WRITE-UP
TCE.M6-EL-GL-G-
816-6311 CATHODIC PROTECTION SHEET 7 OF 23

3.2 Factor which should be normally considered while assessing the

need for the application of cathodic protection are listed below.
These considerations and cost benefit analysis shall be the basis for
provision of Cathodic Protection.

a) Galvanic coupling between corrosion resistant metal and

near by less noble metal may cause damage to less noble
metal forming the couple and thus reduce the overall
reliability of the equipment.

b) Severe damage can occur if small anode area is galvanically

coupled to large cathode area.

c) Severe localized pitting/corrosion can occur at the holidays/

pinholes in protective coatings.

d) Magnitude of corrosion current and hence corrosion damage

increases with the decrease in electrical resistivity of
electrolyte. Electrolytes of less than 25 ohm-metres resistivity
are considered extremely corrosive and the electrolyte of
more than 100 ohm-metres resistivity are considered least
corrosive.

e) It is generally accepted that cement-mortar lining, if properly

applied, can effectively protect steel underneath it. However, in
the presence of chloride ions reduction in pH value of cement
lining below 12, may lead to corrosion of cement-enclosed
steel.

f) Cathodic Protection can be effective only when the protected

metal surface is completely immersed/buried in the electrolyte
and protective current flows onto the protected surface
through the electrolyte.

g) Cathodic protection system can prevent only electrochemical

corrosion.

3.3 Cathodic protection is also applied to prevent corrosion, caused

by stray D.C. currents. However protection of structures against
stray currents is not in the scope of this guide.

ISSUE
R1

FORM NO. 120 R1

TATA CONSULTING ENGINEERS SECTION: WRITE-UP
TCE.M6-EL-GL-G-
816-6311 CATHODIC PROTECTION SHEET 8 OF 23

4. FIELD SURVEYS

4.1. Field surveys are carried out for collecting the data for
assessing the need for the application and for the design of
cathodic protection scheme . Main field surveys are:

a) Soil Resistivity Survey

b) Structure-to-electrolyte Pre-Potential Survey

c) Line Current Survey

d) Current Drainage Survey

e) Commissioning Survey

4.1.1 Soil Resistivity Survey

a) Electrical resistivity of the soil where the structure to be

protected is buried, is required for:

1) assessing the level of corrosion experienced in the soil(Table-6)

ii) designing a system having a low resistance to flow of

current from anodes to protected structure.

b) Keeping in view the above objectives, electrical resistivity of

soil is measured at several locations as per Wenner’s four
electrode method. In case of underground pipelines the
electrical resistivity is measured along the route of the pipe
line at intervals varying from 100M to 1000M to include
entire range of variation in soil resistivity values.

4.2.2 Structure-to-Electrolyte Pre-Potential Survey

a) Structure-to-electrolyte pre potential survey can be carried out

on existing structures to assess corrosion activities. Structure-
to-electrolyte potentials, measured with reference to copper-
copper sulphate reference electrodes, may vary from –0.2
Volts for old bars steel to 0.8 volts for new well-coated steel.

ISSUE
R1

FORM NO. 120 R1

TATA CONSULTING ENGINEERS SECTION: WRITE-UP
TCE.M6-EL-GL-G-
816-6311 CATHODIC PROTECTION SHEET 9 OF 23

Relatively electronegative metal area acts as the anode

during the operation of corrosion cells in such cases.

b) For measuring structure-to-electrolyte potentials, positive

terminal of the corrosion voltmeter is connected to the
reference electrode and the negative terminal is connected
to the structure. The reference electrode is placed on the
ground surface either just above the underground
structure/pipeline or at a remote location (out side the zone of
influence of corrosion currents) Close measurements give an
idea about the local hot spots and remote measurements
give average potential values indicating the corrosion
activities on overall basis.

c) Structure-to-electrolyte potentials are measured at several

locations In case of underground pipelines, the potentials are
measured at regular spacing of 50-500m and at locations
such as insulating joints, neighbourhood of foreign
structures, waterway, road crossings, terminal stations etc.

e) Permanent Test points are installed along the route of the

pipe-line to facilitate the measurement of structure to
electrolyte potentials for assessing the effectiveness of
cathodic protection system.

4.2.3 Line Current Survey

If corrosion is taking place, there will be current flow to the line at

some points and flow from the line at others. For small local cells,
this pipeline path may be very short but for large cells, often
termed “ long lines”, the current may follow the pipe for hundreds of
meters. It is these long line currents that can be detected in a line
current survey. Test point installations with wires bridging a known
span length of about 30M are provided for this survey. At each
point of measurement, the voltage drop observed and recorded the
direction of current flow (plus or minus).Knowing the span
resistance of the pipe being surveyed, the voltage drops are
converted to equivalent current flow. The value of current flow
together with direction current of flow is then plotted versus line
length.

ISSUE
R1

FORM NO. 120 R1

TATA CONSULTING ENGINEERS SECTION: WRITE-UP
TCE.M6-EL-GL-G-
816-6311 CATHODIC PROTECTION SHEET 10OF 23

4.2.4 Current Drainage Survey

a) Current drainage survey is carried out on existing systems to

assess the requirement of current required for effective
cathodic protection.

b) For current drainage survey an alloy of temporary anodes

usually, MS pipes or scrap steel is installed at a typical
location. Positive terminal of the temporary source of direct
current (d.c) is connected to anodes and the negative
terminal is connected to the structure to be protected. The
structure-to-electrolyte potentials at various locations on the
structure are measured for each value of impressed current.
This data is used for deciding the magnitude of current
required for effective cathodic protection.

4.2.5 Commissioning Survey

Commissioning Survey includes commissioning tests for various

equipments, structure-to- electrolyte potentials measurements at
various test points, measurement of anode bed resistance and
test to assess the effectiveness of insulating joints, bending
connections etc.

5.0 TYPICAL CATHODIC PROTECTION SCHEME/PRACTICES

5.1 General

a) Cement-mortar lined steel and cast iron pipelines are

generally not provided with cathodic protection.

b) In case the structure is provided with some insulating

coating, the protective current is required only at the
pinholes/holidays in the coatings. Therefore, depending on
quality of coating, surrounding environment, periodicity of
coating repair etc,40-100% of total surface is considered as
bars for determining the protective current requirements.

c) Total current required for protection is calculated by

Equation (2).Average protective current density is either based

ISSUE
R1

FORM NO. 120 R1

TATA CONSULTING ENGINEERS SECTION: WRITE-UP
TCE.M6-EL-GL-G-
816-6311 CATHODIC PROTECTION SHEET 11OF 23

on experience or is determined by carryingout current

drainage survey. The surface area ‘S’ calculated by taking
into account the effectiveness of protective coating as
discussed in preceding para. Factor ‘F’ is experience based
and varies from 1.2 to 1.5 depending on system conditions.
Typical average current density values are listed in Table-7
for general guidance.

d) Complete electrical continuity of structure is essential to

ensure low resistance to flow of protective current in its
return circuit. Bonding connections are provided between
flanged joints and other such locations to ensure electrical
continuity.

e) Insulating joints are required between the protected and

unprotected sections of a continuous metallic structure such
that protective current is confined to the protected structure.
However, these joints should be provided only if it is possible
to effectively isolate the concerned metal works.

5.2 Underground Systems

a) Steel pipeline, storage tanks, grounding conductors in plant

area are some of the underground metal works which are
cathodically protected.

b) Minimum spacings between sacrificial anodes and

protected Structure are generally as follows:

Single anode - Minimum 2M for Magnesium and no

minimum for Zinc

Multiple anodes - Minimum 5M for Magnesium and 2M

for Zinc

Anode below the - 1M for Magnesium and no minimum

protected structure for Zinc

c) Ground beds should be located in low resistivity soil area and

anodes should be surrounded by carbon backfill.

ISSUE
R1

FORM NO. 120 R1

TATA CONSULTING ENGINEERS SECTION: WRITE-UP
TCE.M6-EL-GL-G-
816-6311 CATHODIC PROTECTION SHEET 12OF 23

d) Anode beds of impressed current system are generally

installed at locations remote (distance upto 100M) from the
protected structure so that protective current is uniformly
distributed to various parts of the protected structure. Close
anode beds are provided if space for the installation of remote
anode bed is not available or the protection is to be limited to
a specific pipeline/structure section in a congested area.

e) DC output rating of transformer rectifier units is limited to 25 to

50 volts. The resistance of anode bed, anode and cathode
cables etc, is limited such that the output voltage is adequate
to drive rated current through the circuit under worst
conditions.

f) In case of plant of rounding systems, cathodic protection is

provided to:

Protect steel pipelines, cable armours and other metal works

which may corrode due to galvanic coupling with copper
groundings conductors in low resistivity soils, or

to protect steel grounding conductors which may suffer

corrosion in low resistivity soils

In such cases it is not possible to isolate or insulate grounding

conductors from the rest of the underground metal works in the
area. Therefore,cathodic protection is provided by considering the
surface area of all underground metallic structures in the area.
Usually impressed current cathodic protection is provided in
such cases. The anode beds are located at a distance of about
100M from the underground metal works and grounding
conductors. Close anode beds are provided for the protection
of those metal works which may not receive protection from
remote anode beds due to screening effect.

g) Test points are provided at selected locations (para.4.2.2) for the

measurement of structure –to-soil potentials.

h) High silicon ferro alloy or graphite anodes are generally used in

impressed current systems and Zinc or Magenism anodes are
used in sacrifical anode cathodic protection system. Choice of
anode material depends on total cost and availability of anodes

ISSUE
R1

FORM NO. 120 R1

TATA CONSULTING ENGINEERS SECTION: WRITE-UP
TCE.M6-EL-GL-G-
816-6311 CATHODIC PROTECTION SHEET 13OF 23

for system requirements and type of soil. Cast Iron and scrap
steel anodes are also used in some cases.

5.3 Circulating Sea-water cooling system for Power Plants

5.3.1 Sea water is used as coolant in condensers, heat-exchangers etc. in

some power generating stations. Sea-water is very corrosive
electrolyte. Therefore, various metallic structures of a cooling water
system which come in contact with sea-water need protection
against corrosion. Components of sea-water cooling system which
may require cathodic protection are as follows:

1) Intake water channel, if made of sheet steel

ii) Trash rack , travelling water screens

iii) Underwater suction pipes of pumps

iv) Internal surface of suction and discharge pipes of the pumps

v) Internal surface of steel pipes between pumphouse and TG

building

vi) Internal surface of inlet/outlet pipes between main CW inlet/outlet

conduit/tunnel and equipments such as condenser, heat
exchanger, coolers etc.

vii) Steel/ Cast Iron water boxes, tube sheet, tube ends of
condenser heat exchanger, cooler etc in contact with sea water.

5.3.2 Basic features of cathodic protection scheme for various

components of sea water cooling system are as follows:

a) Geometry and size of intake water channel, screens, pipes

water boxes etc, do not permit the installation of remote
anode beds. Therefore impressed current anodes are
installed at maximum possible distance from the protected
structure and sacrificial anodes are fixed directly on the
protected surface.

b) Arrangement for mounting /fixing of anodes and reference

electrodes is selected with due regards to the geometry of the

ISSUE
R1

FORM NO. 120 R1

TATA CONSULTING ENGINEERS SECTION: WRITE-UP
TCE.M6-EL-GL-G-
816-6311 CATHODIC PROTECTION SHEET 14OF 23

protected structures and space available for mounting / fixing

of anodes and reference electrodes.

i) Anodes and reference electrodes for protection of sheet steel

piling of intake water channel are either directly fixed on
inside walls or are suspended from the brackets fixed on the
side walls. Similarly anodes and reference electrodes in the
screen chamber are either suspended from the side walls,
roof etc, or fixed at suitable locations. In the suspension type of
arrangement the anode/reference electrode is either enclosed
inside a large diameter perforated tube of insulating material
or is projected outside the tube.

ii) In impressed current cathodic protection system for internal

surface of pipes, water boxes etc., cantilever (probe) type
anodes and reference electrodes are threaded into the
protected equipments through specially mounted (1½To 1 in
BSP) bosses. Higher the projection of anodes inside the
equipment, more uniform is the spread of protective current.
Reference electrodes are mounted within a distance of 50-
100 mm from the protected surface. Bosses for mounting of
anodes/references electrodes are provided by the designer of
cathodic protection system

iii) Sacrificial anodes and impressed current anodes to be fixed

into protected surfaces or on nearby supports, are procured
complete with inserts for fixing them at selected locations.

c) Anodes of aluminium alloy, Zinc or magnesium can be used in

sea water sacrificial cathodic protection system. But owing to
techno-economic consideration aluminium alloy anodes are
preferred in modern systems.

d) Platinized titanium, platinized niobium, lead alloy, high crome

ferro silicon or graphite anodes can be used in sea water
cathodic protection system. But using technoeconomic
considerations, platinized anodes or lead alloy anodes are
commonly used in modern impressed current cathodic
protection systems.

e) It is preferable to provide independent impressed current

cathodic protection system for each functionally independent
equipment/structure system such that protection to one

ISSUE
R1

FORM NO. 120 R1

TATA CONSULTING ENGINEERS SECTION: WRITE-UP
TCE.M6-EL-GL-G-
816-6311 CATHODIC PROTECTION SHEET 15OF 23

equipment/structure system is not affected during the outage of

other equipment/structure system. More than one unit may
be provided to one functionally independent equipment/
structure system but a common unit system should not be
provided for two or more functionally or operationally
independent equipment/structure system. For example more
than one CP Unit may be provided to one screen chamber or
condenser but more than one screen chamber or condenser
should not be normally protected by one common CP unit
system.

f) Automatic output controlled transformer-rectifier units are

provided for the protection of intake water channel and
equipment/structures in the screen chamber where
protective current requirements change continuously with
tidal variations in sea water level. Condenser water boxes
are provided with automatically controlled cathodic
protection system if optimum use of electricity or close
control of structure-to-sea water potentials is prime
consideration in selecting the type of transformer rectifier
unit.

g) DC output voltage rating of transformer-rectifier units is

generally 12 volts or less unless higher output voltages is
required to allow for the large voltage drops in anode and
cathode cables. Platinized titanium anodes should not be
operated at more than 8-10 volts dc. Platinized niobium
anodes can be operated at high voltages

ISSUE
R1

FORM NO. 120 R1

TATA CONSULTING ENGINEERS SECTION: WRITE-UP
TCE.M6-EL-GL-G-
816-6311 CATHODIC PROTECTION SHEET 16OF 23

TABLE-1 FACTORS RESPONSIBLE FOR POTENTIAL DIFFERENCES

ON METAL SURFACE

Factor Effect

1. Heterogenity of sea Formation of anodic areas where relative

water phase concentration of:
a) Natural salts with active ions is high
b) Hydrogen ions (pH) is high
c) Metal ions is low
d) Oxygen and oxidizing agents is low

2. Heterogenity of soil Anodic areas are formed where

phase a) Soil resistivity is relatively low
b) Supply of oxygen is low

3. Heterogenity of metallic Anodic areas are formed where

surface
a) Protective oxide films are
discontinuous
b) Metallic surface is covered with rust
c) Passive films have micropores
d) Internal stresses are relatively high,

4. Heterogenity of physical Metallic surface acts as anode where

condition
a) Temperature is higher than other
places
b) External direct current (dc) leaves the
metal and enters surrounding
electrolytic.

ISSUE
R1

FORM NO. 120 R1

TATA CONSULTING ENGINEERS SECTION: WRITE-UP
TCE.M6-EL-GL-G-
816-6311 CATHODIC PROTECTION SHEET 17OF 23

TABLE-2 ELECTROMOTIVE FORCE SERIES

S NO ELECTRODE MATERIAL POTENTIAL (VOLTS)

1. Magnesium - 2.34

2. Aluminium -1.67
3. Zinc -0.762
4. Chromium -0.710
5. Ferrous -0.440
6. Cadimium -0.402
7. Nickel -0.250
8. Tin -0.136
9. Lead -0.126
10. Hydrogen + 0.000
11. Copper +0.345
12. Silver +0.800
13. Platinum +1.20
14. Gold +1.40

ISSUE
R1

FORM NO. 120 R1

TATA CONSULTING ENGINEERS SECTION: WRITE-UP
TCE.M6-EL-GL-G-
816-6311 CATHODIC PROTECTION SHEET 18OF 23

TABLE-3 SACRIFICIAL (GALVANIC) ANODES

A. ANODES FOR UNDERGROUND APPLICATION

Characteristics Magnesium Zinc

1. Composition % 6 Al,3Zn,0.2Mn Atleast 99.99%

Balance Mg Zinc
2. Specific gravity 1.94 7

3. Approximate 8 12
consumption per
ampere-year

4. Potential with -1.55 to –1.80 -1.1

respect to Cu / volts volts
CuSO4 reference
electrode

ISSUE
R1

FORM NO. 120 R1

TATA CONSULTING ENGINEERS SECTION: WRITE-UP
TCE.M6-EL-GL-G-
816-6311 CATHODIC PROTECTION SHEET 19OF 23

B. ANODES FOR SEA-WATER APPLICATION

Characteristics Magnesiun Zinc Aluminium

1. Composition % 6 Al,3Zn 99.99% 1) %3-7 Zn

0.15Mn, purity balance 99.8
Balance purity Al
Mg 2) % Zn 5,0.08 Tin
balance 99.8
purity Al
3) Al-Zn-Hg

b) Approximate 8 12 i) 4-8
Practical ii) 4-9
consumption rate iii) 3.5
Kg/amp-year

c) Potential with -1.55 to-1.75 -1.1 i) –1.02

respect to Cu / ii) –1.15 to 1.20
CuSO4 reference iii)-1.1
electrode under
typical operating
conditions, volts

ISSUE
R1

FORM NO. 120 R1

TATA CONSULTING ENGINEERS SECTION: WRITE-UP
TCE.M6-EL-GL-G-
816-6311 CATHODIC PROTECTION SHEET 20OF 23

TABLE-4 IMPRESSED CURRENT ANODES

Anode Current Density A/m2 Consumption Rate kg per

Amp- year

1. High silicon Ferro Alloy % 14.5 Si

0.75Mn,0.95 carbon balance Fe 5-20 0.2-0.5

2. High Chromium Ferro Alloy As

above and 4.5% Chromium

3. Graphite impregnated with wax / 2.5-10 0.2-1

Synthetic resin/linated oil

4. Lead Alloy % 93 lead, 6 Antimony 200 0.05-0.1

1 Silver

5. Platinized titanium 0.0025 thick Pt 500-700 0.006 gm

layer over Ti base metal

ISSUE
R1

FORM NO. 120 R1

TATA CONSULTING ENGINEERS SECTION: WRITE-UP
TCE.M6-EL-GL-G-
816-6311 CATHODIC PROTECTION SHEET 21OF 23

TABLE-5 POTENTIALS FOR CATHODIC PROTECTION

Potential, Volts

Type of reference electrode system

[Link] Metal or Alloy Copper/ Silver/silver Zinc in sea

Saturated Chloride water
Copper in saturated
Sulphate in KCI
sea water

1. Iron and steel

a) Aerobic -0.85 -0.80 -0.75 +0.25

b)Anaerobic -0.95 -0.90 -0.85 +0.15

2. Copper based -0.5 to-0.65 -0.45 to-0.6 -0.4 to-0.55 +0.6to+0.45

alloys

3. Lead -0.6 -0.55 -0.5 +0.5

4. Stainless steel -1.8 -1.75 -1.7 -0.7

5. Aluminium

a) Max. positive -0.95 -0.9 -0.85 +0.15

limit
b) Max. negative -1.2 -1.15 -1.10 -1.10
limit

ISSUE
R1

FORM NO. 120 R1

TATA CONSULTING ENGINEERS SECTION: WRITE-UP
TCE.M6-EL-GL-G-
816-6311 CATHODIC PROTECTION SHEET 22OF 23

TABLE-6 CORROSIVITY OF SOIL

Soil Resistivity ohm-meter Corrosivity Class

Less than 25 Severely corrosive

> 25< 50 Moderately corrosive
> 50 < 100 Mildly corrosive
> 100 Very mildly corrosive

ISSUE
R1

FORM NO. 120 R1

TATA CONSULTING ENGINEERS SECTION: WRITE-UP
TCE.M6-EL-GL-G-
816-6311 CATHODIC PROTECTION SHEET 23OF 23

TABLE-7 PROTECTIVE CURRENT DENSITY

A-Bare Steel free from adverse galvanic influences

Electrolyte condition Current density

mA/m2
1. Sterile natural soil 5-15

2. Well acrated natural soil 20-35

3. Dry well acrated soil, Dry Concrete 5-15

4. Wet soil, moderate/severe condition 25-65

5. Highly acidic soil 50-160

6. Soil with active sulphate reducing bacteria 450

7. Heated-in-soil, moist concrete, sea 50-270

8. Fresh water

-Stationary 50

-Moving 50-65

-Highly turbulent 50-160

-Hot water 50-160

9. Sea-water

-Clean 50-270

-Polluted 500-1600

-Moving (slow) 100-400

10. Heat-exchanger, water boxes etc with non- 600-1600

ferrous tube, plate etc

11. Well coated steel in soil 0.01-0.2

ISSUE
R1

FORM NO. 120 R1

TATA CONSULTING ENGINEERS SECTION: WRITE-UP
TCE.M6-EL-GL-G-
816-6311 CATHODIC PROTECTION SHEET 24OF 23

12. Holiday detected well coated steel pipeline 0.01

in oil

ISSUE
R1

FORM NO. 120 R1