Cathodic protection systems are designed to protect metal structures from corrosion by creating a sacrificial anode. However, if the system fails or is not properly maintained, the protective current can find alternative paths that cause unintended corrosion of nearby structures. Three case studies are presented where failed cathodic protection systems resulted in corrosion of underground utilities, electrical shock hazards, and costly pipeline repairs. The document emphasizes the importance of proper installation, maintenance, testing and record-keeping of cathodic protection systems according to industry standards to prevent such issues.
The Ultimate Guide to Choosing WordPress Pros and Cons
Corrosion
1. Corrosion Impact of
Cathodic Protection on
Surrounding Structures
Robert A. Durham, PE
D2 Tech Solutions
Marcus O. Durham, PhD, PE
THEWAY Corp.
2. Introduction
Corrosion not new topic – since history
Loss of material leaving a metal
Flow through a medium
Returns to metal at different point
ANODE CATHODE
3. History
Sir Humphry Davy, 1824
British ships copper clad corrosion
Proposed attaching zinc
Considered impressed current
Batteries not perfected
4. Takes Many Forms
Oxidation, rust, chemical, bacteria
All are result of electrical current
Treatments: chemical, coatings, electrical
Proper impressed current can stop
May not be practical
CATHODE ZINC
ANODE
ELECTROLYTE
5. Mandatory
Cathodic Protection
Underground metal pipe
with hazardous gas or liquids
Underground metal pipe
within 10’ of steel reinforced concrete
Water storage tanks
>250,000 gallons
6. Fundamentals
Components
Anode sacrifices metal, pos battery
Cathode receives metal, neg battery
Electrolyte, non-metallic medium,
with some moisture to support
current flow
+ANODE
CATHODE
CHEMICAL
ANODE
-CATHODE
7. Fundamentals
Circuit
For corrosion to exist:
1. Metal conductor
2. An electrolyte
3. A potential difference
#1 & #2 when pipe in soil or water
#3 caused by environment
or differences in electrochemical
properties
8. Cause & Mitigation
Same elements that cause corrosion
can be used to control
Al electronegativity = 1.61
Fe electronegativity = 1.83
Result = electrochemical attraction
Molecules from Al, thru electrolyte, to Fe
Protect Fe
9. Cause & Mitigation
If force Al to more negative (cathodic)
Fe molecules through electrolyte to Al
Al is protected
Can create problems if CP system fails
Current flow takes unexpected path
Protects and destroys wrong metal
10. Problem
CP is common practice on vessels, wells
and cross-country pipelines
CP is designed to protect pipe or vessel
Current can take unintended path
Can create negative results on other
metals
Three cases examined
11. Case 1
Pipeline systems
2 with rectifiers
1 without, not petro
Rectifier at major lake crossing
Nearby soil some limestone rocks
High soil resistivity
Near residences
12. Case 1
Problems @ residences
Corrosion of underground lines
Ground wires corroded
Electric shock from water exiting faucets
Indications of compromised ground
system
13. Case 1
Routine rectifier readings
Complete path
Not intended
Through residence metal
Investigation, break in rectifier lead
14. Case 1
For corrosion to occur
need electrical circuit
Without direct path thru anode, will find
alternate path thru adjacent metal
RECTIFIER
STRUCTURE
+ -
BREAK
ANODE SOIL
ALTERNATE METAL PATH
CORROSION
POINT
15. Case 1
Corrosion of water & sewer
Costly & inconvenient
More serious
Electrical ground electrode conductor
gone
Propane lines damaged
Routine maintenance may not
catch slow trends
16. Case 2
Pipeline systems
3 with rectifiers
1 without, not petro
Rectifier on hill, ¾ mile from residence
Nearby soil sandy w/ substantial sandstone
High soil resistivity
Very remote
Near 1 residence with barns
Near petroleum production
17. Case 2
Pipeline systems had –1.45 V pipe to soil
8 month period of problems
All copper tubing in concrete floor
replaced
3/4” copper supply replaced twice
Computer monitor & TV failed due to
voltage
Multiple motors burned out
Fluorescent lights not ignite
18. Case 2
Electrical safety
Shock by water from shower
Shock when touch metal of pre-engineered
building
Hole burned in bldg from energized ground wire
Ground conductors
Electrician measure 40 volts on ground wire at
service entrance
Utility measured 90 volts
on ground wire at pump station
19. Case 2
Problems
Rectifier grounding electrode, 178 Ohm
>5 times NEC allowance
Ground rod driven only 5’
remainder sticking up
Utility
Meter ground corroded in two
Ground resistance, 48 Ohms
20. Case 2
Problems pump station
1 pump 277 V 1-phase
w/ no ground whatsoever
Other sites ground electrode resistance
of 750 – 1000 Ω
Without ground stray currents
travel along metal
21. Case 2
CP failure source of corrosion
Plumbing and electrical
Pump station was source of shock
Inadequate grounding
Need proper systems maintenance
Other systems can complicate matters
22. Case 3
Well casing
6500 feet, 5.5” steel
Penetrate variety of soils
High pressure gas
Known corrosion problems
CP system
Rectifier, 5 anodes
8 Amps impressed
23. Case 3
Routine
Rectifier current read normal
Pipe/soil readings not routine
3 years, corrosion of pipe
$350,000 replacement
24. Case 3
Investigation
Tank bottoms like new
Pipeline pristine
Casing eaten up
Hammer union insulating flange shorted
Current took preferential path thru line &
tank
25. Electrical Bonding
NEC requires grounding electrode
NEC requires bonding metal to ground
Problems
Steel, ductile or cast iron sacrifice to
copper
Bond
Pipe, well casings, tanks etc.
Not the grounding electrode
w/o bonding, risk of shock
26. Electrical Bonding
Bonding to ground will short CP to earth
Do not bond to CP system
Precludes using large metal surface as
grounding electrode
CP has inherent personnel protection
Drive potential ~ 1 volt negative
Very low circuit resistance < 2Ω
Adequate path for dissipation of
current in a fault
Use resistance bond for close metal
27. Standards
Cases emphasize importance of proper
C/P maintenance
Beyond monthly current reading
Preserve integrity of system
DOT regulated periodic maintenance
Become more stringent
December 29, 2003
28. Standards
DOT 12/29/03
Protected a) Tests for corrosion once per year
Pipelines b) By Dec. 29, 2003, accomplish objectives of
NACE RP0169-96
c) Inspect removed pipe; if corrosion, inspect
adjacent and correct
Unprotected Pipe Electric corrosion survey every three years
Rectifier Electrically check once every 2 months
Reverse Current Electrically check once per year
Switch
Diodes Electrically check once per year
Critical Electrically check once every 2 months
Interference Bonds
Interference Bonds Electrically check once per year
Breakout Tanks Inspect system per API RP 651
29. Standards
Record keeping
Show location of CP piping, CP facilities, anodes
Neighboring structures bonded
Maintain for life of pipeline
Tests
Tests, survey, or inspection per table
Demonstrate adequacy
Maintain 5 years
Inspection of protected & critical
interference bonds
Life of pipeline
30. Standards
49 CFR Part 192
49 CFR Part 195
40 CFR Part 280
UL 1746
NACE RP0169
NACE RP0177
NACE RP0193
NACE RP0285
NACE RP0286
NACE RP0388
API RP 632
API RP 651
STI R892
STI R972
31.
32. Installation & Maintenance
Initial
Imperative to isolate protected pipe
Visual and testing
Check resistance between protected,
ground, other
If not open circuit -> problem
Electrical w/in 5 feet
Bond per NEC
33. Installation & Maintenance
Periodic current
Show drastic changes
Failed rectifier, broken connection
Trend over time
Decrease I
Increase V
Shows failing anode or connection
8
7
6
5
4
Volts
Amps
3
2
1
0
1 2 3 4 5 6 7 8 9
34. Installation & Maintenance
Annual
11 or 13 month cycle
Over time will see all seasons and
climatological conditions
Complete periodic
Same as initial
Energized, so measure voltage difference
not resistance
Half-cell P-S, and ground bed to soil
Rectifier
35. Conclusions
Corrosion Happens
CP sacrifices one metal to protect other
Requires complete path
Failure may cause unintended path
Resultant corrosion can be costly and
compromise safety
New regulations in effect Dec 29, 2003
With proper installation, maintenance and
inspections CP can be safe and effective