Cathodic Protection Use On Tank Bottoms & Underground Piping In Power Generation Plants
PG&E Office San Francisco January 18, 2007 Craig K. Meier Corrosion Control Incorporated
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Corrosion process for tanks and piping Principles of cathodic protection Effects of coatings Cathodic protection design requirements Selecting the proper system Construction implementation issues Compliance testing Continued monitoring and maintenance
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Energy
Ore
Mill Steel
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Energy Steel Rust Corrosion
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Conventional Current Flow Fe++ Iron ion eCathode Anode Electron flow H2O + 1/2O2 + 2e- 2OHFe Fe++ + 2e-
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Rate of Corrosion
Soil Corrosivity
Resistivity pH Salts
Bi-metallic effect Mixed soils Differences in oxygen
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Excavation Clay Pipe Corrosion Native Soil
Sand
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Corrosion Current
Corrosion
Copper ground -200 mV
Bare steel pipe -500 mV
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Coating flaw Steel pipe Corrosion Copper ground Coating
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Tank floor Corrosion Corrosion Clay lump
Copper ground
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Tank floor Corrosion
Concrete or asphalt
API recommends against the use of asphalt and concrete tank pads.
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Corrosion Losses
Will occur in all plants Rate of loss dependent on soil and materials used Coatings alone do not stop soil corrosion Care during construction can significantly reduce losses
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Corrosion Control
Material selection Bedding Coatings Cathodic Protection
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Coating
Coating flaw
Steel
Reduces amount of exposed metal Coatings are not perfect
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Cathodic Protection
Pipe Ground
Anode H2O + 1/2O2 + 2e- 2OHIEEE PES
Cathodic Protection
Galvanic Impressed Current
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Galvanic Anode
Exothermic weld Pipe -500mV Magnesium anode
-1700mV
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Galvanic Cathodic Protection
Galvanic anodes have a limited current output, 10 to 30 milliamperes per anode. Due to the limited current output, the use of galvanic anodes is limited to coated and electrically isolated underground piping and underground tanks.
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Galvanic Cathodic Protection
Dielectric flange Coating Coating damage
Pipe Magnesium anode
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Bare steel tank bottom Protects only outer floor Galvanic anode
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Impressed Current
AC Power Rectifier
(+)
(-)
Structure
Anode
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Impressed Current
Anode
Unit 1
Unit 2
Unit 3 Rectifier
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Impressed Current
Tank
Rectifier
20
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Impressed Current
Anodes produce high amounts of current, 1000 to 5000 milliamperes per anode. High current output allows protection of bare steel structures. Structures do not necessarily need to be electrically isolated.
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New Power Plant Design
Involve corrosion engineer from the start Obtain site soil resistivitiy data Select piping materials Select coating types and quality control procedures Decide which structures require cathodic protection
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Cathodic Protection Design - Piping
Soil resistivity data Clearly identify piping to receive cathodic protection Yard plan showing piping layout, isometric drawings are difficult to use Location of all risers Type of coating Responsibility of isolation gaskets Desired service life
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Cathodic Protection Design - Tanks
Site soil resistivity data Tank diameters and layout Equipment access Type of foundation Containment Monitoring capability Desired service life
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Design Options
Design documents issued in construction plans Contract responsible for cathodic design
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Design Submittal
Qualifications of person responsible for design, supervision during installation and testing
Can not mail order
Detailed calculations for each tank and pipeline showing current required, number of anodes, circuit resistance and life Material list providing descriptions, models and quantities Product data sheets Detailed installation plans not diagrams
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Implementation
The cathodic design submittals must be approved before construction of structures A site meeting must be held to discuss how the cathodic protection system will be installed, and special concerns during construction Mechanical and electrical foremen should be involved in cathodic discussions
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Avoid Costly Mistakes
Grounding cables must be at least 12 inches from underground pipes Temporary pipe supports must be removed Piping must be inspected for coating quality and separation from grounding before burial
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Grounded Pipeline
Pipe
Ground wire
Anode
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Instrument
Dielectric gasket
Conduit
Anode IEEE PES
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Shunt Ring terminals Tag
Anode
Test station
Pipeline Galvanic anode IEEE PES
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Coating Pipe wall
Weld Coating Pipe wall Standard Weld Clip Post Hydro Weld
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Rectifier
Tank bottom
12 sand
Liner Anode array Anode IEEE PES
Completed Before Testing
All pipe flanges connected and isolated Pipes back filled and cathodic protection is complete AC power to rectifier unit Storage tanks contain product Schedule for testing and training issued
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Compliance Testing - Specialist
Inspect cathodic systems to ensure they are properly installed Test each dielectric flange for isolation Obtain native potentials on pipes and tanks Connect galvanic anodes at test stations and/or energize rectifier(s) Cathodic protection systems on isolated coated structures should operate at least 4 hours before testing Cathodic protection systems on bare steel or grounded structures must operate between 12 hours and 7 days before testing
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-.892
Set to DC volts Pipe
Reference cell Soil IEEE
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Galvanic Anode Current
Set to DC millivolts
Shunt
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Impressed Current Rectifier Unit
Transformer adjustments Meters Breaker Volts Amps Shunt
Output lug IEEE
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Meter
Potential plus gradient
Cell
Potential of steel
Impressed anode
Voltage gradient
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Emeasured = Ptank + I R If the current is momentarily interrupted, I=O, then; Emeasured = Ptank + (O) (R) Instant Off potential
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Cathodic Protection Criteria
Galvanic anodes
-850mV or more negative with anodes connected
Impressed current
-850mV or more negative instant-off -or 100mV polarization shift
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100mV Polarization Criteria
-1104 On Instant off -692 Polarization 167 -525 Native
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Compliance Report
Tabulated Data Narrative analysis of the data Compliance statement Calculated anode life Test procedures and instrumentation As-built drawings O&M Manual
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O&M Manual
Test Procedures Instrument requirements Qualification requirements Frequency Criteria Trouble shooting Spare parts Wiring diagrams
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Conclusions
Cathodic protection is viable and necessary to preserve power plant structures Proper planning and coordination are essential through out the design and construction phases, to ensure cathodic protection systems work properly Properly implemented and monitored cathodic protection will extend the service life of storage tanks and yard piping more than 30 years
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Owner Monitoring & Maintenance
Record rectifier output levels monthly and compare output to target values Repair inoperable rectifiers within 30 days Inspect test stations and dielectric flanges every six (6) months for damage and removal Instruct maintenance staff to replace and test removed dielectric gaskets Annually, obtain potential measurements and ensure effective cathodic protection levels
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