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Design of Galvanic Anode Cathodic Protection

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Design of Galvanic Anode Cathodic Protection Advanced Course Appalachian Underground Corrosion Short Course West Virginia University Morgantown, West Virginia Copyright © 2017 APPALACHIAN UNDERGROUND CORROSION SHORT COURSE ADVANCED COURSE CHAPTER 1 ‐ PIPE‐TO‐SOIL POTENTIAL SURVEYS AND ANALYSIS ............... 1‐1 INTRODUCTION....................................................1‐1 CORROSION MECHANISMS........................................... 1‐1 PIPE‐TO‐SOIL POTENTIAL MEASUREMENT ..............................1‐2 TYPES OF POTENTIAL SURVEYS ....................................... 1‐3 SINGLE ELECTRODE METHOD.........................................1‐4 TWO ELECTRODE METHOD........................................... 1‐5 SIDE‐DRAIN MEASUREMENTS ........................................ 1‐6 ANALYZING PIPE‐TO‐SOIL POTENTIAL DATA............................. 1‐6 PIPE‐TO‐SOIL POTENTIAL SURVEYS AND ANALYSIS OF UNPROTECTED PIPELINES......................................................... 1‐8 INTERPRETATION OF POTENTIALS UNDER NON‐STRAY CURRENT CONDITIONS....................................................... 1‐9 COATED CROSS‐COUNTRY PIPELINE WITHOUT CATHODIC PROTECTION ..................................................... 1‐10 GAS SERVICE LINE ................................................ 1‐11 GROUNDING SYSTEM .............................................. 1‐11 STEEL GAS AND WATER LINES .......................................1‐12 CRITERIA FOR CATHODIC PROTECTION................................1‐13 WHICH CRITERION?................................................1‐14 Structure‐to‐Electrolyte Potential of ‐850 mV or More Negative . ....... 1‐15 Current‐Applied Measurement of ‐850 mV or More Negative ........... 1‐15 100 mV of Cathodic Polarization ................................... 1‐17 Cathodic Protection Coupons.....................................1‐19 Other Criteria..................................................1‐20 USE OF CRITERIA................................................. 1‐25 CHAPTER 2 ‐ EVALUATION OF UNDERGROUND COATINGS USING ABOVEGROUND TECHNIQUES......................................................... 2‐1 INTRODUCTION....................................................2‐1 SURVEY SEQUENCE.................................................2‐1 REFERENCED PROCEDURES .......................................... 2‐2 DEFINITIONS ...................................................... 2‐2 SAFETY CONSIDERATIONS............................................ 2‐4 PIPELINE LOCATING................................................. 2‐5 DIRECT CURRENT VOLTAGE GRADIENT SURVEYS (DCVG) ..................2‐5 ALTERNATING CURRENT VOLTAGE GRADIENT SURVEYS (ACVG) ........... 2‐10 CLOSE‐INTERVAL SURVEYS (CIS).................................... 2‐12 AC CURRENT ATTENUATION SURVEYS (ELECTROMAGNETIC).............. 2‐16 SUMMARY ....................................................... 2‐17 CHAPTER 3 ‐ MATERIALS FOR CATHODIC PROTECTION....................... 3‐1 INTRODUCTION....................................................3‐1 CONSIDERATIONS FOR ALL MATERIALS................................. 3‐1 GALVANIC ANODES.................................................3‐2 Prepared Backfill and Packaging .................................... 3‐3 Wire and Cable Attachment .......................................3‐4 Magnesium Alloys ............................................... 3‐5 Zinc Alloys...................................................... 3‐5 Aluminum Alloys ................................................ 3‐6 IMPRESSED CURRENT CATHODIC PROTECTION SYSTEMS.................. 3‐7 Types of Impressed Current Anodes................................. 3‐8 High Silicon Cast Iron ............................................. 3‐8 Graphite Anodes ............................................... 3‐10 Mixed Metal Oxide Anodes....................................... 3‐11 Platinum Anodes ............................................... 3‐13 Aluminum Anodes .............................................. 3‐14 Lead Silver Anodes..............................................3‐14 Magnetite Anodes.............................................. 3‐15 Polymer Conductive Anodes ...................................... 3‐15 Scrap Steel Anodes..............................................3‐16 Backfill for Impressed Current Anodes .............................. 3‐16 WIRE AND CABLE..................................................3‐17 CABLE TO STRUCTURE CONNECTIONS................................. 3‐17 CABLE SPLICES................................................... 3‐18 SPLICE ENCAPSULATION............................................3‐18 POWER SUPPLIES..................................................3‐19 JUNCTION BOXES..................................................3‐22 PERMANENTLY INSTALLED REFERENCE ELECTRODES .................... 3‐22 TEST STATIONS ...................................................3‐23 FLANGE ISOLATORS AND DIELECTRIC UNIONS..........................3‐25 MONOLITHIC WELD IN ISOLATORS ................................... 3‐26 CASING ISOLATORS AND END SEALS ..................................3‐27 CONCLUSIONS.................................................... 3‐28 CHAPTER 4 ‐ DYNAMIC STRAY CURRENT ANALYSIS.......................... 4‐1 INTRODUCTION....................................................4‐1 STRAY CURRENTS................................................... 4‐1 THE EARTH AS A CONDUCTOR........................................4‐1 POTENTIAL GRADIENTS IN THE EARTH ................................. 4‐2 DETECTION OF DYNAMIC STRAY CURRENTS.............................4‐3 Interpreting Beta Curves.......................................... 4‐5 Determining the Point of Maximum Exposure ........................ 4‐5 METHODS OF MITIGATING THE EFFECTS OF DYNAMIC STRAY CURRENT......4‐5 Controlling Stray Currents at the Source ............................. 4‐6 Mitigation (Drainage) Bonds and Reverse Current Switches ............. 4‐6 Sizing the Mitigation (Drain) Bond .................................. 4‐8 Use of Sacrificial Anodes....................................... 4‐12 Use of Impressed Current Systems................................ 4‐13 STRAY CURRENT FROM ALTERNATING CURRENT (AC) SOURCES ........... 4‐13 CONCLUSIONS.................................................... 4‐14 REFERENCES......................................................4‐15 CHAPTER 5 ‐ DESIGN OF IMPRESSED CURRENT CATHODIC PROTECTION ........ 5‐1 INTRODUCTION....................................................5‐1 REVIEW OF IMPRESSED CURRENT SYSTEM FUNDAMENTALS............... 5‐1 Definition ......................................................5‐1 Theory of Operation.............................................. 5‐1 Application.....................................................5‐2 Advantages and Disadvantages ....................................5‐2 INFORMATION USEFUL FOR DESIGN OF AN IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM ...............................................5‐2 DESIGN OF AN IMPRESSED CURRENT ANODE BED........................5‐4 General........................................................ 5‐4 Selecting an Anode Bed Site ....................................... 5‐4 Selecting Anode Bed Type Based on Site Selection..................... 5‐5 Distributed Anode Bed ...........................................5‐5 Remote Anode Bed .............................................. 5‐6 Deep Anode Bed................................................. 5‐7 Hybrid Anode Bed ............................................... 5‐7 Tests Required for Anode Bed Design ............................... 5‐8 Determining Current Requirements for an Existing Structure ‐ Example #1 . 5‐9 DESIGN CALCULATIONS.............................................5‐10 Existing Structures................................................. 5‐10 Determining Current Requirements for an Existing Structure ‐ Example #2 . 5‐11 Determining Current Requirements for an Proposed Structure ‐Example.... 5‐13 Determining the Number of Anodes................................ 5‐14 Determining the Number of Anodes ‐ Example ......................... 5‐16 Calculating the Anode Resistance‐to‐Earth............................. 5‐17 Calculating the Anode Resistance‐to‐Earth Using a Formula ‐ Example...... 5‐19 Calculating the Anode Resistance‐to‐Earth Using a Chart‐ Example......... 5‐20 Calculating Total Circuit Resistance................................... 5‐20 Calculating Total Circuit Resistance ‐ Example .......................... 5‐21 Sizing the Rectifier or DC Power Supply ................................ 5‐23 DESIGN OF DISTRIBUTED ANODE BED.................................5‐24 DESIGN OF DEEP ANODE BED........................................5‐25 Design of Deep Anode Bed ‐ Example................................. 5‐26 CONCLUSIONS.................................................... 5‐27 CHAPTER 6 ‐ DESIGN OF GALVANIC ANODE CATHODIC PROTECTION........... 6‐1 INTRODUCTION....................................................6‐1 GALVANIC ANODE APPLICATION......................................6‐1 General Uses....................................................6‐1 Specific Uses.................................................... 6‐1 GALVANIC ANODE CATHODIC PROTECTION DESIGN PARAMETERS .......... 6‐2 Galvanic Anode Selection............................................ 6‐2 Anode Current Efficiency ............................................ 6‐3 Current Requirements............................................... 6‐3 Electrolyte Resistivity ............................................... 6‐3 Total Circuit
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