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Understanding Cathodic Protection and Its Applications

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Understanding Cathodic Protection and Its Applications Jeff Schramuk NACE CP Specialist 5/25/2017 #7695 IEEE‐IAS/IES Dinner Presentation: 5/24/2017 Understanding Cathodic Protection and Its Applications Jeff Schramuk NACE CP Specialist #7695 630‐235‐1559 www.cpsolutionsinc.net 1 Topics to be Covered 1. Corrosion Problems Facing Water Utilities 2. Asset Management 3. Corrosion Chemistry with Specific Examples 4. Pipe Materials and Coatings 5. Basic Cathodic Protection 6. CP for Existing WMs using an Anode Retrofit Program 7. Cathodic Protection for New Water Mains 8. Cathodic Protection Performance Verification 9. Stray DC Current Interference 2 www.cpsolutionsinc.net 1 Jeff Schramuk NACE CP Specialist 5/25/2017 #7695 Section 1 Corrosion Problems Facing Water Utilities 3 What’s the Rest of the (Unexcavated) Pipe Look Like? 4 www.cpsolutionsinc.net 2 Jeff Schramuk NACE CP Specialist 5/25/2017 #7695 State of the Water Industry Report – Year 2016 The Top 3 Issues Facing the Water Industry by All Respondents 1. Renewal & replacement of aging water and wastewater infrastructure. 2. Financing for capital improvements. 3. Public understanding of the value of water systems and services. Source: “2016 State of the Water Industry: The Cornerstone Needs Support”, Journal AWWA, 108:7, Jul-2016, pp. 63-73. 5 What is the leading cause of many water main breaks? Corrosion! 6 www.cpsolutionsinc.net 3 Jeff Schramuk NACE CP Specialist 5/25/2017 #7695 What Are the Consequences of Pipeline Failures? Energy Pipeline “Incidents” Water Main Breaks 7 Section 2 Asset Management 8 www.cpsolutionsinc.net 4 Jeff Schramuk NACE CP Specialist 5/25/2017 #7695 Asset Management: A Real‐World Definition “A water utility’s asset management plan is an optimization process that attempts to meet the competing objectives of cost minimization and reliability maximization.” Source: Rubin, S.J., A Call for Reliability Standards, Journal AWWA, (Jan-2011) 9 Evaluating Failure Risk: Probability vs. Consequences Risk = (Likelihood of Failure) x (Consequence of Failure) 10 www.cpsolutionsinc.net 5 Jeff Schramuk NACE CP Specialist 5/25/2017 #7695 Section 3 Corrosion Chemistry with Specific Examples 11 Corrosion: Practical and Scientific Definitions Practical The Tendency of a Metal to Revert to its Definition Native State Electrochemical Scientific Degradation of Metal as Definition a Result of a Reaction with its Environment 12 www.cpsolutionsinc.net 6 Jeff Schramuk NACE CP Specialist 5/25/2017 #7695 Four Components of a Basic Corrosion Cell Anode – A metal electrode in contact with the electrolyte which corrodes. Cathode ‐ A metal electrode in contact with the electrolyte which is protected against corrosion. Electrolyte – A solution or conducting medium such as soil, water or concrete which contains oxygen and dissolved chemicals. Metal Path – An external circuit that connects the anode and the cathode. 13 Anodes & Cathodes on a Buried Metallic Pipe Cathodic Area (Protected) DC Current Anodic Area (Metal Loss) 14 www.cpsolutionsinc.net 7 Jeff Schramuk NACE CP Specialist 5/25/2017 #7695 Components of a Familiar Corrosion Cell Why is the open‐circuit voltage of a common flashlight battery 1.5 volts? CARBON ROD (Cathode) ZINC CASE I (Anode) I ‐ I NH4 and Cl Paste (Electrolyte) I I WIRE e- (Metallic Path) 15 Practical Galvanic Series Material Potential* Pure Magnesium ‐1.75 Magnesium Alloy ‐1.60 Zinc ‐1.10 More Aluminum Alloy ‐1.00 Mild Steel (New) ‐0.70 Mild Steel (Old) ‐0.50 Active Cast / Ductile Iron ‐0.50 Stainless Steel ‐0.50 to + 0.10 Less Copper, Brass, Bronze ‐0.20 Gold 0.20 Carbon, Graphite, Coke 0.40 *Measured in Volts versus a Cu‐CuSO4 Reference Electrode 16 www.cpsolutionsinc.net 8 Jeff Schramuk NACE CP Specialist 5/25/2017 #7695 17 Galvanic Corrosion at Bi‐Metallic Pipe Connection Photo Credit: Drinking Water Services, City of Ottawa, Canada 18 www.cpsolutionsinc.net 9 Jeff Schramuk NACE CP Specialist 5/25/2017 #7695 Old‐New Pipe Connection Corrosion Cell New Pipe (anode) Old Pipe (cathode) 19 Corrosion Caused by Dissimilar Surface Conditions Scratches (anode) Threaded Coupling (anode) 20 www.cpsolutionsinc.net 10 Jeff Schramuk NACE CP Specialist 5/25/2017 #7695 Galvanic Cell – Same Metals in a Non‐Uniform Electrolyte Similar Phenomenon: Guy Anchor Rod Corrosion for a Communications Tower Steel in Soil (more active anode) Concrete Encased Steel (less active cathode) 21 Galvanic Cell – Same Metals in a Non‐Uniform Electrolyte 22 www.cpsolutionsinc.net 11 Jeff Schramuk NACE CP Specialist 5/25/2017 #7695 Specific Types of Corrosion – Differential Oxygen At the cathode: ‐ ‐ O2 + 2H2O + 4e 4OH O2 Trench Backfill Undisturbed Undisturbed Native Soil Native Soil DC Current Trench Backfill Pipe bottom is usually most corrosive zone! At the anode: 2 Fe 2Fe+2 + 4e‐ 23 Differential Oxygen Corrosion: A Specific Example Cathodic Zone Anodic Zone Photos courtesy of CP Solutions, Inc. 24 www.cpsolutionsinc.net 12 Jeff Schramuk NACE CP Specialist 5/25/2017 #7695 Specific Types of Corrosion ‐ Pitting 25 Pitting Corrosion: Ductile Iron Photo Credit: CP Solutions, Inc. 26 www.cpsolutionsinc.net 13 Jeff Schramuk NACE CP Specialist 5/25/2017 #7695 Pitting Corrosion: Carbon Steel Photos courtesy of CP Solutions, Inc. 27 Selective Metal Corrosion ‐ Cast Iron Graphitization Photos courtesy of CP Solutions, Inc. 28 www.cpsolutionsinc.net 14 Jeff Schramuk NACE CP Specialist 5/25/2017 #7695 Section 4 Pipe Materials and Coatings 29 Basic Electrochemistry – Combined Reactions Note: The electrons just facilitate the reaction! At the anode: 2Fe 2Fe+2 + 4e‐ (iron oxidation‐corrosion) ‐ ‐ At the cathode: O2 + 2H2O + 4e 4OH (reduction of oxygen) Combined Reaction (electrochemical dissolution of iron) +2 ‐ 2Fe + O2 + 2H2O 2Fe + 4OH Convert Ferrous Iron to Ferric Iron (Rust is the Result) 2Fe+2 + 3OH‐ Fe (OH) 2 3 If water and oxygen cannot reach the metal surface, will corrosion be stopped? 30 www.cpsolutionsinc.net 15 Jeff Schramuk NACE CP Specialist 5/25/2017 #7695 Eliminating the Corrosion Cell Steel at -600 mV Copper at -200 mV 31 Prestressed Concrete Cylinder Pipe – Cylinder Forming Photo Credits: Forterra, Inc. 32 www.cpsolutionsinc.net 16 Jeff Schramuk NACE CP Specialist 5/25/2017 #7695 Prestressed Concrete Cylinder Pipe ‐ Wire Wrapping Photo Credits: Forterra, Inc. 33 Prestressed Concrete Cylinder Pipe – Concrete Jacket Photo Credits: Forterra, Inc. 34 www.cpsolutionsinc.net 17 Jeff Schramuk NACE CP Specialist 5/25/2017 #7695 Mortar Integrity on Reinforced Concrete Pipe New installation looks good… Photo Credits: CP Solutions, Inc. …but is there latent damage? 35 Prestressed Concrete Cylinder Pipe – Corrosion Failures Photo Credits: CP Solutions, Inc. 36 www.cpsolutionsinc.net 18 Jeff Schramuk NACE CP Specialist 5/25/2017 #7695 Coated Steel Pipe ‐ Factory‐Applied Coating Systems AWWA C‐214 Standard Tape Wrap Photo Credits: Northwest Pipe AWWA Standard C‐222 Polyurethane 37 Large Diameter Coated Steel Pipe – Installation Photos Photo Credits: CP Solutions, Inc. 38 www.cpsolutionsinc.net 19 Jeff Schramuk NACE CP Specialist 5/25/2017 #7695 Coating Integrity on Coated Steel Pipe New installation looks good… …but is there latent damage? Photo Credits: CP Solutions, Inc. 39 Consider Long Term Pipe Coating Damage Does it adequately resist soil stress? Photo Credits: CP Solutions, Inc. Will my pipe coating resist damage from third‐party “hits” after burial? 40 www.cpsolutionsinc.net 20 Jeff Schramuk NACE CP Specialist 5/25/2017 #7695 Pipe Coating/Tape Wrapping– Long‐Term Effectiveness Photo Credits: CP Solutions, Inc. 41 Pit‐Cast Iron Water Pipe (Circa 1915) Left Photo Credit: CP Solutions, Inc. Right Photo Credit: Ductile Iron Pipe Research Association 42 www.cpsolutionsinc.net 21 Jeff Schramuk NACE CP Specialist 5/25/2017 #7695 Ductile Iron Water Pipe (Contemporary) 3/8” thick (Pressure Class 150) Photo Credit: CP Solutions, Inc. Photo Credit: Ductile Iron Pipe Research Association 43 Poly‐Wrap Integrity on Ductile Iron Pipe New installation looks good… …but is there latent damage? Photo courtesy of CP Solutions, Inc. 44 www.cpsolutionsinc.net 22 Jeff Schramuk NACE CP Specialist 5/25/2017 #7695 DIP Asphalt Coating – A True Corrosion Barrier? Sticky label pulls off coating Close‐up of abraded 1‐mil asphalt coating Photo Credits: CP Solutions, Inc. Loose Poly Wrapping – An Effective Corrosion Barrier? Soil Contaminants Rip and tears in the poly wrapping leave the pipe exposed Loose Polyethylene Wrapping Oxygen and water can travel beneath the poly wrapping Ductile Iron Pipe Have you ever tried to track down a joint leak within a poly‐wrapped water line? 46 www.cpsolutionsinc.net 23 Jeff Schramuk NACE CP Specialist 5/25/2017 #7695 Section 5 Basic Cathodic Protection 47 How Cathodic Protection Works Basic Corrosion: Corrosion occurs where DC current discharges from the metal to the electrolyte. CP Objective: To allow your structure to receive DC current (be cathodic) from an expendable anode placed in the soil. 48 www.cpsolutionsinc.net 24 Jeff Schramuk NACE CP Specialist 5/25/2017 #7695 Practical Galvanic Series Material Potential* Pure Magnesium ‐1.75 Magnesium Alloy ‐1.60 Zinc ‐1.10 More Aluminum Alloy ‐1.00 Mild Steel (New) ‐0.70 Mild Steel (Old) ‐0.50 Active Cast / Ductile Iron ‐0.50 Stainless Steel ‐0.50 to + 0.10 Less Copper, Brass, Bronze ‐0.20 Gold 0.20 Carbon, Graphite, Coke 0.40 *Measured in Volts versus a Cu‐CuSO4 Reference Electrode 49 Galvanic Corrosion – No Cathodic Protection Benefit 1. Anode 2. Cathode 3. Electrolyte Copper -200mV Copper 4. Metal Path Steel -600mV Magnesium -1.7V Magnesium 50 www.cpsolutionsinc.net 25 Jeff Schramuk NACE CP Specialist 5/25/2017 #7695 Galvanic Corrosion Mitigated w/Cathodic Protection 1. Anode 2. Cathode Anode 3. Electrolyte Cathode Cathode 4. Metal Path 51 Typical Horizontal Sacrificial Anode Installation Grade Sacrificial Anode Connection to Pipe Coating Defect 52 www.cpsolutionsinc.net 26 Jeff Schramuk NACE CP Specialist 5/25/2017 #7695 Rectified Anode Cathodic Protection Schematic 53 Rectified Anode Cathodic Protection on a Pipeline DC current is obtained from more noble (inert) metal anodes powered by a transformer/rectifier Photo Credits: CP Solutions, Inc.
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