ETL 1110-9-10(FR)

5 Jan 91

EXAMPLES OF IMPRESSED CURRENT

CATHODIC PROTECTION DESIGN

2-1. Purpose.

The following examples show the use of design procedures explained

in the previous section:

2-2 Steel fuel oil lines

2-3 Underground storage tanks
2-4 On-grade tank bottoms
2-5 Gas distribution systems
2-6 Elevated water tanks (ice is expected)
2-7 Elevated water tanks (no icing will occur)
2-8 On-grade water storage reservoir (ice is expected)

2-2. Steel Fuel Oil Lines.

Impressed current cathodic protection is desired for the 6-in.

welded fuel oil line shown in figures 2-1A and 2-lB. Since this
pipeline is in existence, current requirement tests have already
been made. There are no other underground structures in the area,
so a surface point groundbed is chosen. Figure 2-2 illustrates a
surface point groundbed anode system using prepackaged ceramic rod
anodes. These prepackaged ceramic rod anodes are further detailed
in figures 2-3 and 2-4.

a. Design data.

1) Soil resistivity in area where groundbed is desired is

2000 ohm-cm.

2) Pipe has 6-in. diameter (outside diameter = 6.625

in.)

3) Pipe length is 6800 ft.

4) Design life for cathodic protection anodes is 15 years

since the structure will no longer be needed after that
time.

5) Design current density is 2-mA per sq ft of bare pipe.

6) The pipe is coated with hot-applied coal-tar enamel.

7) 90 percent coating efficiency based on previous

experience with this type coating.

18
 ETL 1110-9-10(FR)
5 Jan 91

19
ETL 1110-9-10(FR)
5 Jan 91

20
 ETL 1110-9-10(FR)
5 Jan 91

21
ETL 1110-9-10(FR)
5 Jan 91

22
 ETL 1110-9-10(FR)
5 Jan 91

23
ETL 1110-9-10(FR)
5 Jan 91

8) Effective coating resistance at 15 years is estimated

at 2500 ohm-sq ft.

9) The pipeline is isolated from the pumphouse and tank

with insulating joints.

10) For this example, we have decided that the cathodic

protection system circuit resistance should not exceed
2.5 ohms.

11) Electric power is available at 120/240 V single phase

AC from a nearby overhead distribution system.

12) Current requirement testing indicates that 2.8 amp are

needed for adequate cathodic protection.

b. Computations.

1) Calculate the external surface area of the pipe.

Pipe diameter = 6 in.

Pipe length = 6800 ft

Pipe surface
area per lin ft = 1.734 sq ft/lin ft (from
table 3-2)

External pipe
surface area = 6800 lin ft x 1.734 sq
ft/lin ft = 11,791 sq ft

2) Check the current requirement (I) using equation 1-1:

I = (A)(I')(l.0-CE)

Where:
A = 11,791 sq ft - External pipe surface
area from previous calculation.

I' = 2 mA/sq ft - Required current density

from item 5 of paragraph 2-2a.

CE = 0.90- Coating efficiency expressed in

decimal form from item 7 of paragraph
2-2a.

I = 11,791 sq ft x 2 mA/sq ft x (1.0 -

0.90)

24
 ETL 1110-9-10(FR)
5 Jan 91

I = 2358 mA or approximately 2.4 amp

which agrees well with the current requirement test

data provided in item 12 of paragraph 2-2a.

3) Select an anode and calculate the number of anodes

required (N) to meet the design life requirements. Two
sizes are selected for trial calculations using
equation 1-2:

N = I
IA

Where:
I = 2.8 amp (Current requirement from item
12 of paragraph 2-2a)

IA = Current rating per anode, varies de-

pending on anode size from table 3-3.

Several different size anodes could be chosen.

Experience has shown that for this type of groundbed,
60-in. long anode packages are desirable.

For a 3-in. by 60-in. packaged canisters with a 1/8-in.

by 48-in. ceramic anode rod, IA = 1.2 amp/anode (from
table 3-3 for 15-year design life).

N = 2.8 = 2.33; use 3 anodes.

1.2

For a 3-in. by 60-in. packaged canister with a 1/4-in.

by 48-in. ceramic anode rod, IA = 2.4 amp/anode (from
table 3-3 for a 15-year design life).

N = 2.8 = 1.17; use 2 anodes.

2.4

4) Calculate the resistance of a single anode-to-earth (RA)

from equation 1-6:

RA = p K
L

Where:
p = 2000 ohm-cm (Soil resistivity in area
where groundbed is desired from item 1
of paragraph 2-2a)

25
ETL 1110-9-10(FR)
5 Jan 91

K = 0.0213 (Shape function, from table 3-4

[where: L/d = 60 in./3 in. = 20])

L = 5 ft (Effective anode length [canister

length))

d = 3 in. (Anode backfill diameter [canis-

ter diameter])

RA = 2000 x 0.0213
5

RA = 8.53 ohms
5) Calculate the number of anodes required to meet maximum
anode groundbed-to-earth resistance requirements from
equation 1-11:

RA p PF
RN ' %
N Cc

Where:
RN = Groundbed-to-earth resistance.

RA = 8.53 ohms (Resistance of a single

anode-to-earth from the previous
calculation)

N = Assume 5 anodes (discussed below)

p = 2000 ohm-cm (Soil resistivity)

PF = 0.00268 (Paralleling factor from table

3-5 [discussed below])

CC = 20 ft (Center-to-center spacing of
anodes [discussed below])

To determine PF, a figure for N must be assumed. This

paralleling factor compensates for mutual interference
between anodes and is dependent on spacing. From the
law of parallel circuits, it appears that five anodes
might give the desired circuit resistance of 2.0 ohms
maximum, i.e.:

8.53 ohms/anode = 1.706 ohms

5 anodes

26
 ETL 1110-9-10(FR)
5 Jan 91

This is the approximate resistance based on the law for

parallel circuits. (When equal resistance values are
joined together in a parallel circuit, the total resis-
tance value of the circuit is approximately equal to a
single resistance value divided by the number of resis-
tance values.)

To calculate the true anode resistance for five anodes,

we must perform the calculation from equation 1-11.

CC = 20 ft (The spacing must be chosen

based on previous experience to solve
the equation.) The spacing can
typically be from 10 to 50 ft. For
this example, we will try 20 ft:

RN = 8.53 + 2000 x 0.00268

5 20

RN = 1.706 + 0.268

RN = 1.974 ohms

This is within specification, but very close to

exceeding maximum specified circuit resistance. Try
six anodes to allow for variations in soil resistivity
and to allow for wire and pipe-to-earth resistance.
Repeat calculation from equation 1-li,

Where:
N = 6 anodes
PF = 0.00252, paralleling factor from table
3-5

RN - 8.53 + 2000 x 0.00252

6 20

RN = 1.67 ohms

6) Based on the previous selection of six anodes for the

number of anodes to be used, the total circuit
resistance must be determined.

7) Select an area for anode bed placement. Here, the

selected area is 100 ft from the pipeline for improved
current distribution. The anode bed location for this
type design must be far enough away from the structure

27
ETL 1110-9-10(FR)
5 Jan 91

to be protected to assure uniform distribution of the

protective current to all structure components. The
higher the soil or water resistivity, the further away
the ground must be located. For this example, previous
experience has shown that the nearest anode should be
located a minimum of 100 ft from the structure to
assure good current distribution. Since there are no
other underground utilities in the area, the groundbed
may be installed either perpendicular or parallel to
the pipe (figures 2-IA and 2-lB).

8) Determine the total circuit resistance (RT) from

equation 1-3:

RT = RN + RW + RC

Where:
RN = Groundbed resistance-to-earth (ohms)
RW = Header cable and resistance (ohms)
RC = Pipe-to-earth resistance (ohms)

a) Groundbed-to-earth resistance (RN) from step 5.

RN = 1.67 ohms

Specify anodes with individual lead wires of

sufficient length so that each anode wire can be
run directly to the rectifier without splices.
(This is virtually always true for anode bed
designs where the individual lead wire lengths
required do not exceed an average of 400 ft.)

b) Anode lead wire resistance from equation 1-15:

c
LW RMFT
RW '
1000 ft

Where:
LAVG = Total of each actual lead wire
lengths/number of anodes
= (140 ft + 120 ft + 100 ft + 80
ft + 60 ft + 40 ft)/6 anodes
= 90 ft per anode

LW = LAVG/N
= 90/6
= 15 ft

28
 ETL 1110-9-10(FR)
5 Jan 91

= Average anode lead wire length/

number of anodes. This is based
on the circuit resistance for 6
anode lead wires in parallel.

RMFT = 2.58 ohms - Resistance for No.

14 AWG cable which has been
selected from table A-6.

RW = 15 ft x 2.58 ohms
1000 ft

RW = 0.039 ohms
c) Pipe-to-earth resistance (RC) from equation 1-16:

RS
Rc '
A

Where:
RS = 2500 ohm-sq ft - Effective
coating resistance from item 8
of paragraph 2-2a.

A = 11,791 sq ft - External
pipe surface area calculated in
step 1 of paragraph 2-2b.

RC = 2500 ohm-sq ft
11,791 sq ft
RC = 0.212 ohm

d) Calculate the total circuit resistance (RT) from

equation 1-3:

RT = RN + RW + RC

RT = 1.67 + 0.039 + 0.212

RT = 1.921 ohms

e) Since the design requirements call for a maximum

allowable groundbed resistance of 2.0 ohms and RT =
1.921 ohms, the design using six (3-in x 5-ft) ceramic
anode canisters will work.

29
ETL 1110-9-10(FR)
5 Jan 91

9) Calculate the rectifier voltage (VREC) from equation

1-17:

VREC = (I) (RT) (120%)

Where:
I = 2.8 amps (Current requirement
from item 12 of paragraph 2-2a.

RT = 1.92 ohms (Total circuit

resistance from previous
calculation.

120% = Rectifier voltage capacity

design safety factor.

VREC = 2.8 amp x 1.92 ohms x 1.2

VREC = 6.45 V

c. Select rectifier.

Based on the design requirement of 2.8 amperes and 6.45

volts, specify a 10-V, 5-amp rectifier, which is the
nearest standard capacity available from commercial
cathodic protection rectifier manufacturers.

30
 ETL 1110-9-10(FR)
5 Jan 91

2-3. Underground Storage Tanks (USTs).

The service station shown in figure 2-5 has three existing

underground tanks and associated pipe. The quality of the coating
is unknown and it is not feasible to install dielectric insulation
to isolate the UST system. Because of the anticipated large
current requirement, an impressed current protection system is
chosen. To distribute the current evenly around the tanks and
piping, and to minimize interference effects on other structures,
a distributed anode surface bed using vertical anodes is selected.
Vertical anodes can be installed with relative ease in holes cored
through the paving around the UST system. Wiring can be installed
several inches below the paving by cutting and hand excavating
narrow slots/trenchs through the paving.

a. Design data.

1) Soil resistivity is 4500 ohm-cm.

2) Pipe is 2 in., nominal size. Total length of all

buried piping is 750 ft.

3) Tanks are 8000 gal, 96 in. diameter by 21 ft 3 in.

long.

4) Electrical continuity of tanks and piping has been

assured.

5) It is not feasible to install dielectric insulation;

system is therefore not isolated electrically from
other structures.

6) Design cathodic protection anodes for 20-year life.

7) Coating quality is unknown, assume bare.

8) The cathodic protection system circuit resistance

should not exceed 2.5 ohms.

9) Electric power is available at 120 V single phase in

the station building.

10) Current requirement test indicates that 8.2 amperes

are needed for cathodic protection.

b. Computations.

1) Find the external surface area (A) of the storage

tanks and piping.

31
ETL 1110-9-10(FR)
5 Jan 91

Area of each tank = 2 B (tank radius)2 + B (tank

diameter) (tank length)

32
 ETL 1110-9-10(FR)
5 Jan 91

33
ETL 1110-9-10(FR)
5 Jan 91

Area of 3 tanks = 3 [2 x 3.14 x 42 +3.14 x 8 x 21.25]

= 1905 sq ft

Area per lin ft of 2-in. pipe = 0.621 sq ft/ft (from

table A-2)

Total pipe area = 750 ft x 0.621 sq ft/ft = 466 sq ft

Total area = 1905 sq ft + 466 sq ft = 2371 sq ft

2) Check the current requirement (I) using equation 1-1:

I = (A)(I')(1.0-CE)
Where:
A = 2371 sq ft (External tank and piping
surface area from previous
calculation)

I' = 2 mA/sq ft (Required current density

[assumed])

CE = 0.00 (Coating efficiency expressed in

decimal form from item 2 of paragraph
2-3a)

I = 2371 sq ft (2 mA/sq ft) x (1.0 - 0.0)

I = 4742 mA or 4.7 amp.

The 4.7 amp would be reasonable for the facility if it

were insulated. The actual current requirement of 8.2
amp occurs because of current loss to other
underground structures and is also reasonable in
relation to that calculated for an isolated facility.

3) Select an anode and calculate the number of anodes

required (N) to meet the design life requirements.

Calculations can be run on several size anodes, but in

this case 2-in. by 60-in. packaged rod anodes (rod
size = 0.125 in x 4 ft long) are chosen for ease of
construction. Using equation 1-2, the number of
anodes required to meet the cathodic protection system
design life can be calculated:

N = I
IA

34
 ETL 1110-9-10(FR)
5 Jan 91

Where:
I = 8.2 amp (Current requirement from item
10 of paragraph 2-3a)

IA = 1.0 amps/anode (Current rating per

anode from table 3-3)

N = 8.2 = 8.2 anodes; use nine, 2-in.

1.0 by 60-in. packaged rod
anodes

4) Calculate the resistance of a single anode-to-earth

(RA) from equation 1-6:
RA = p K
L

Where:
P = 4500 ohm-cm (Soil resistivity from
item 1 of paragraph 2-3a)

K = 0.0234 (Shape function from table A-4

[where: L/d = 60 in./2 in. = 30])

L = 5 ft (60 in.) (Effective anode

length).

d = 2 in. (Anode/backfill diameter)

RA = 4500 x 0.0234
5

RA = 21.06 ohms
5) Calculate the number of anodes required to meet
maximum anode groundbed resistance requirement. A
distributed anode array does not lend itself to an
exact calculation of equation 1-11 because the anodes
are positioned at various locations and are not
located in a straight line. Equation 1-11 assumes a
straight line configuration. However, to approximate
the total anode-to-earth resistance, equation 1-li may
be used.

35
ETL 1110-9-10(FR)
5 Jan 91

RA p PF
RN ' %
N Cc

Where:
RN = Groundbed-to-earth resistance

RA = 21.06 ohms (Resistance of a single

anode-to-earth from the previous
calculation)
p = 4500 ohm-cm (Soil resistivity from
item 1 of paragraph 2-3a)

CC = 10 ft (Estimated approximate spacing

of anodes)

PF = 0.00212 (Paralleling factor from

table 3-5; assume 9 anodes; reasoning
is the same as in step 5, paragraph
2-2b)

N = 9 anodes (Estimated number of anodes

required; from step 3, paragraph
2-2b)

RN = 21.06 + 4500 x 0.00212

9 10

RN = 3.29 ohms.

Resistance is too high. Additional calculations using

an increasing number of anodes (i.e., 11, 12, 13, 14,
etc.) have to be made; these calculations show that
fourteen anodes will yield a groundbed-to-earth
resistance of 2.26 ohms.

6) Select the number of anodes to be used. The numbers

determined are:

For life = nine anodes maximum required

For resistance = fourteen anodes maximum required

Therefore, the larger number of anodes, fourteen, is

selected.

7) Determine the total circuit resistance (RT) from

equation 1-3:

36
 ETL 1110-9-10(FR)
5 Jan 91

RT = RN + RW + RC

Where:
RN = Groundbed resistance (ohms)
RW = Header cable/wire resistance (ohms)
RC = Structure-to-earth resistance (ohms).

a) Groundbed resistance (RN) from step 5.

RN = 2.26 ohms

b) Header cable/wire resistance (RW) from equation 1-

15:

LW RMFT
RW '
1000 ft

Where:
LW = 150 ft (Effective cable length. The loop
circuit makes calculating effective wire
resistance complex. Since current is
discharged from anodes spaced all along the
cable, one-half the total cable length may
be used to approximate the cable
resistance. Total cable length = 300 ft.
Effective cable length = ½ (300 ft) = 150
ft.)

RMFT = 0.254 ohm (This is the resistance per

1000 lin ft of No. 4 AWG cable, which
has been selected for ease of
handling.)

RW = 150 ft x 0.254 ohm

1000 ft

RW = 0.038 ohm; use 0.04 ohm

c) Structure-to-earth resistance.

Since the tanks and piping are essentially bare and

are not electrically isolated, structure-to-earth
resistance may be considered negligible. Therefore
RC = 0.

37
ETL 1110-9-10(FR)
5 Jan 91

d) Calculate total circuit resistance (RT) from

equation 1-3:

RT = RN + RW + RC

RT = 2.26 + 0.04 + 0 = 2.30 ohms

Since the design requirements call for a maximum

groundbed resistance of 2.5 ohms and RT = 2.30
ohms, the design using fourteen 2-in. by 60-in.
packaged ceramic anodes will work.

8) Calculate the rectifier voltage (VREC) from equation

1-17:

VREC = (I) (RT) (120%)

Where:
I = 8.2 amp (Current requirement from step 2,
paragraph 2-3b)

RT = 2.30 ohms (Total circuit resistance from

previous calculation)

120% = Rectifier voltage capacity design safety

factor.

VREC = 8.2 amp x 2.30 ohms x 1.2

VREC = 22.6 V

c. Select rectifier.

Based on the design requirement of 22.6 V and 8.2 amp, a

rectifier can be chosen. A 12-amp, 24-V unit is selected
because this is the nearest standard commercial size
available.

38
 ETL 1110-9-10(FR)
5 Jan 91

2-4. On-Grade Tank Bottoms.

Four on-grade fuel oil storage tanks are to be constructed with the
configuration shown on figure 2-6. This design may be prohibited
if secondary containment uses a nonconductive membrane beneath the
tanks. The membrane would not allow the cathodic protection
current to flow from the remotely located deep anode through the
nonconductive membrane to the tank bottoms. If this situation
exists, a distributed anode design with the anodes located between
the membrane and the tank bottoms would have to be used. All
piping will be above grade. To minimize the extent of underground
cable, it was decided to use a deep anode groundbed, located just
outside the spill containment dikes. (Note: Some county, state,
or federal agencies such as the EPA may have regulations that
affect the use of deep anode beds because they can provide a
conduit for the mixing of water between aquifer levels. In such
cases, regulations have sometimes required cementing of the annulus
between the deep anode bed casing and the augered hole to prevent
this water migration. The system designer should check with the
applicable agencies before committing to a deep anode design.
Figures 2-7, 2-7A, 2-8, and 2-8A illustrate a typical deep anode
groundbed using ceramic rod anodes. The tank bottoms will be bare.
All piping will be above ground. The tanks will be dielectrically
insulated from the structures. Field tests were made at the site
and the subsurface geology was determined to be suitable for a deep
anode groundbed (reference 25).

a. Design data.

1) Soil resistivity at anode depth is 1500 ohm-cm.

2) Tanks are 75 ft in diameter.

3) Design cathodic protection anodes for a 15-year life.

4) Design current density is 2 A per sq ft of tank bottom.

5) Since the tanks are electrically isolated from each

other, intertank bonds will be required.

6) The cathodic protection system circuit resistance

should not exceed 0.75 ohm.

7) Electric power is available at a switch rack in an

unclassified (nonexplosion proof) area 125 ft from the
desired groundbed location, 230 V AC, single phase.

39
ETL 1110-9-10(FR)
5 Jan 91

8) Since the exterior bottom of these type tanks are

always bare, the coating efficiency will equal 0.00.

40
 ETL 1110-9-10(FR)
5 Jan 91

41
ETL 1110-9-10(FR)
5 Jan 91

42
 ETL 1110-9-10(FR)
5 Jan 91

43
ETL 1110-9-10(FR)
5 Jan 91

44
 ETL 1110-9-10(FR)
5 Jan 91

45
ETL 1110-9-10(FR)
5 Jan 91

b. Computations.
1) Find the surface area to be protected.
Area of each tank bottom = B r2:
A = B x 37.52 = 4418 sq ft
Area of the four bottoms:
A = 4 x 4418 = 17,672 sq ft
2) Determine the current requirement (I) from equation
1-1:
I = (A) (I')(l.0-CE)
Where:
A = 17,672 sq ft (Total surface area from
previous calculation)
I' = 2 mA/sq ft (Current density from item
4 of paragraph 2-4a)
CE = 0.0 (bare) (Coating efficiency from
item 8 of paragraph 2-4a)
I = 17,672 sq ft x 2 mA/sq ft x (1.0 -
0.0)
I = 35 amp

3) Select an anode and calculate the number of anodes (N)

required to meet the design life. The deep anode
groundbed will consist of a series of rods connected to
a continuous header cable. For physical strength, the
1/8-in. or 1/4-in. diameter rods are usually chosen. To
ensure good transmission of current in to the backfill
column, long anodes, typically 6 ft or 8 ft are used.
For this example, 1/4-in. diameter by 72-in. long rods
have been chosen. Using equation 1-2:
N = I
IA
Where:
I = 35 amp (Current requirement from
previous calculation)
IA = 6.6 amp/anode (Current rating per heavy
duty coated anode from table 3-3)
N = 35 = 5.3; use 6 anodes
6.6

46
 ETL 1110-9-10(FR)
5 Jan 91

4) Calculate the required length of the backfill column.

Spacing between anodes depends primarily on the

resistivity of both the backfill column (coke breeze).
If low resistivity calcined fluid petroleum coke is
used, than the spacing between rod anode (1/8-in. and
1/4-in. diameter) should not be greater than twice the
individual rod length. Based on previous design
experience, a spacing between anode rods of 11 ft is
selected.

The minimum length of the backfill column is then

calculated as follows:

6 anodes at 6 ft per anode = 36 ft

Spacing between anodes: 5 at 11 ft = 55 ft
Space above and below anode string* = 20 ft

Total length 111 ft

* Generally, the coke breeze column extends from

10 ft below the bottom anode to 10 ft above the top
anode as shown in figures 2-7 and 2-8.

5) Calculate the backfill column-to-earth resistance

(RA).

This can be done from equation 1-4. Because several

attempts may have to be made to obtain the required
groundbed resistance, the process is facilitated by
using the curves in figures 2-9A through 2-9C. Typical
hole diameters are 6 or 8 in.; a 6-in. diameter hole
has been selected for this groundbed. Figure 2-9C will
be used for this design.

Figure 2-9C shows that, for a 111-ft long coke breeze

backfill column, the resistance to earth per 1000 ohm-
cm is 0.31 ohm. In 1500 ohm-cm soil, the resistance
is 0.31 x 1500/1000 = 0.47 ohm (groundbed resistance in
1000 ohm-cm soil, times actual soil resistivity in ohm-
cm per 1000). This is well below the design
requirement of 0.75 ohm.

6) Determine total circuit resistance (RT) from equation

1-3 :

RT = RA + RW + RC (Because the cathodic

protection system utilizes a single
deep anode groundbed RA = RN)

47
ETL 1110-9-10(FR)
5 Jan 91

48
 ETL 1110-9-10(FR)
5 Jan 91

49
50
 ETL 1110-9-10(FR)
5 Jan 91

Where:
RA = Backfill column-to-earth resistance
(ohms), calculated in step 5 above

RW = Header cable/wire resistance (ohms)

RC = Structure-to-earth resistance (ohms).

a) Backfill column-to-earth resistance (RA) from step

5:

RA = 0.47 ohm

b) Wire resistance

A deep anode groundbed is defined as one where the

top of the backfill column is at least 50 ft below
the surface of the earth. Actual depth will vary,
depending on subsurface geology and the distance
over which the current is expected to spread. In
this example, 65 ft was selected as the depth to
the top of the coke breeze column. The anodes can
be supplied through a single or dual feed. Dual
feed is preferred to reduce both the resistance of
the circuit and the chance of a failure due to a
cable break.

No. 4 AWG cable has been chosen. Cable lengths

have been calculated based on the following
distances, illustrated in the deep groundbed
example shown in figure 2-7.

51
ETL 1110-9-10(FR)
5 Jan 91

From grade to top of backfill column 65 ft

From top of backfill column to

top anode 10 ft

From grade to bottom of backfill

column 176 ft

From bottom anode to bottom of

backfill column 10 ft

From anode hole to rectifier 2

cables at 125 ft 250 ft

From top of anode assembly to

bottom of anode assembly 91 ft

Total cable length from top anode

feed to rectifier 125 ft +
65 ft + 10 ft= 200 ft

Total cable length from bottom

anode feed to rectifier
125 ft + 176 ft - 10 ft = 291 ft

Calculate top cable resistance (RWT) from

equation 1-15:

LWT RMFT
RWT '
1000 ft

Where:
LWT = 200 ft (Cable length from previous
calculation)

RMFT = 0.254 ohm (Resistance per 1000 lin ft

of No. 4 AWG cable which has been
selected for installation. These
resistance values can be found in
table 3-6).

RWT = 200 ft x 0.254 ohm = 0.051 ohm

1000 ft

Calculate bottom cable resistance (RWB) from

equation 1-15:

52
 ETL 1110-9-10(FR)
5 Jan 91

Where:
LWB = 291 ft (Cable length from previous
calculation)
RMFT = 0.254 ohm (Cable resistance per 1000
lin ft [same as above])
RWB = 291 ft x 0.254 ohm = 0.074 ohm
1000 ft
These two cables are in parallel, so that their wire
resistance (RT/B) is calculated from the law of
parallel circuits:
1 = 1 + 1
RT/B RWT RWB
1 = 1 + 1
RT/B 0.051 0.074
1
RT/B = 19.6 + 13.5 = 33.1
RT/B = 0.030 ohm
Since current is dissipating along the portion of the
cable to which the anodes are connected, the
resistance of this cable (RPOS) is taken as one half
its total resistance as was done in example 2-2.
LW R MFT 1 91 ft( x 0.254 ohm/ft 1
RPOS ' x ' x
1000 ft 2 1000 ft 2
*91 ft is the overall anode column length including the
interconnecting wire from the top of the top anode to the bottom
of the bottom anode (see item 4 from paragraph 2-4b.)

RPOS = 0.012 ohm

Negative circuit wire resistance must also be
calculated:

Negative cable from rectifier to closest tank = 125 ft

of No. 4 AWG

Intertank bonds = 170 ft of No. 4 AWG**

**The two intertank bond circuits are in parallel and of about the
same length. From the law of parallel circuits, total resistance
of two parallel circuits of equal resistance is one half the
resistance of each circuit.

53
ETL 1110-9-10(FR)
5 Jan 91

Therefore, one half the cable length is used in this

calculation. The calculation is also conservative since not
all the current flows through the complete intertank bond
circuit.

Total ft of negative circuit wire = 295 ft of No. 4 AWG cable

Negative resistance if calculated from equation

1-15:

LW RMFT
RNEG '
1000 ft

Where:
LW = 295 ft (Negative cable length)

RMFT = 0.254 ohm (Negative cable resistance

per 1000 un ft of No. 4 AWG cable
[table A-6])

RNEG = 295 x 0.254

1000

RNEG = 0.074

Total wire resistance therefore is:

RW = RT/B + RPOS + RNEG = 0.030 + 0.012 + 0.074

RW = 0.116 ohm
Cable insulation is also important. High
molecular weight polyethylene insulation,
commonly used for cathodic protection work, tends to
blister, become brittle, and then crack in deep
groundbed use where chlorine gas generation can occur.
This has been most prevalent in open holes containing
brackish water, but may occur in coke breeze
backfilled holes also. Consequently, to minimize the
chances of cable failure, one of the two following
types of insulation, which show good resistance to
these oxidizing environments should be used:

Polyvinylidene fluoride (Kynar)1

____________________
1
Registered trademark of Penwalt Corp.

54
 ETL 1110-9-10(FR)
5 Jan 91

Copolymer of chlor-tri-fluorethylene and ethylene

(Halar)2

To protect the insulation itself and to

facilitate handling, cables for deep anode
groundbeds also have an outer jacket of high-
molecular weight polyethylene extruded over the
Kynar or Halar insulation.

c) Structure-to-earth resistance (Rc).

Since the tank bottoms are bare, their

resistance-to-earth is considered negligible,
therefore, RC is taken as zero.
d) Calculate total circuit resistance (RT) from
equation 1-3:

RT = RN + RW + RC

RT = 0.470 + 0.116 + 0.0

RT = 0.586 ohm

This is well below the design requirement and,

therefore, this groundbed with 6 - 1/4 in. by 6 ft
ceramic anode rods with total backfill column
length of 111 ft will be used.

7) Calculate rectifier voltage (VREC) from equation 1-17:

VREC = (I) (RT) (120%)

Where:
I = 35 amp (Current requirement from step
2, paragraph 2-4b)

RT = 0.586 ohm (Total circuit resistance

from previous calculation)

120% = Rectifier capacity safety factor

VREC = 35 amp x 0.586 ohm x 120%

VREC = 24.6 V

c. Select rectifier.
____________________
2
Registered trademark of Allied Chemical Corp.

55
ETL 1110-9-10(FR)
5 Jan 91

Based on the design requirement of 24.6 V and 35 amp, a

rectifier can be chosen. A 30 V, 42 ampere unit is
commercially available and is selected. This rectifier can
be pole mounted as illustrated in figure 2-10.

d. Installation.

Figures 2-7 and 2-8 show this deep anode design.

56
 ETL 1110-9-10(FR)
5 Jan 91

57
ETL 1110-9-10(FR)
5 Jan 91

2-5. Gas Distribution System.

It has been decided to install cathodic protection on the gas

distribution piping in a post housing facility. Figure 2-11 shows
a portion of the piping.

The water distribution system has recently been replaced with

nonmetallic pipe. On this basis, it has been decided that the gas
piping can be protected with impressed current from a deep anode
groundbed without causing interference to the water pipe. (Note:
Some county, state, and federal agencies such as the EPA may have
regulations which prevent the use of deep anode beds because they
can provide a conduit for mixing of waters between aquifer layers.
In such cases, regulations have required cementing of the annulus
between the deep anode bed casing and the augered hole to prevent
this water migration. The system designer should check with the
applicable agencies before committing to a deep anode design.)

a. Design data.

1) Experience in the area shows the subsurface

resistivity at a depth of 50 and 200 ft to be 2000 ohm-
cm.

2) Piping consists of:

28,000 ft of 1 1/4-in. diameter pipe

1,200 ft of 4-in. diameter pipe
3,600 ft of 6-in. diameter pipe

3) Design cathodic protection anode for a 20-year life.

4) Experience with similar pipe in the same general soil

type has shown that a design current density of 2 A per
sq ft of bare pipe is conservative.

5) Piping is welded steel, poorly coated; considered to be

bare for protection purposes and, therefore, the
coating efficiency is 0.0 (CE = 0.0).

6) Piping is isolated at each house and at the tie-in to

the main supply line.

7) The cathodic protection circuit resistance should not

exceed 1 ohm.

8) 120/240 V AC, single phase power is available.

58
 ETL 1110-9-10(FR)
5 Jan 91

9) Current requirement tests are not practiced in this

case, so design will be based on calculations. (Note:
Current requirement tests should be conducted whenever
practicable.)

59
ETL 1110-9-10(FR)
5 Jan 91

60
 ETL 1110-9-10(FR)
5 Jan 91

b. Computations.

1) Calculate the external surface area of the pipe (A) to

be protected.

Unit Area*
Pipe diameter Length (sq ft/lin ft) Area (sq ft)

1 1/4 in. 28,000 ft 0.434 12,152

4 in. 1,200 ft 1.178 1,414
6 in. 3,600 ft 1.734 6,242

*from table A-2 Total 19,808

2) Determine current requirement (I) from equation 1-1:

I = (A)(I')(l.0-CE)

Where:
A = 19,808 sq ft (Surface area of pipe to
be protected from previous calculation)

I' = 2 mA/sq ft (Current density, from item

4, paragraph 2-5a)

CE = 0.0 (Coating efficiency [bare pipe])

I = 19,808 sq ft x 2 mA/sq ft x (1.0 - 0.0)

I = 39,616 mA or 39.6 amp; use 40 amp

3) Select an anode and calculate the number of anodes

required (N) to meet the design life. For this
design, tubular anodes have been chosen. The
groundbed will consist of a series of anodes attached
to a continuous header cable. A typical size tubular
ceramic anode used in deep anode beds, 1-in. diameter
by 39.4 in. long, is selected. The number of anodes
are determined using equation 1-2:

N = I
IA

Where:
I = 40 amp (Current requirement from
previous calculation)

IA = 8.0 amp/anode (Current rating per anode

from table 3-3 [in coke breeze])

61
ETL 1110-9-10(FR)
5 Jan 91

N = 40 = 5 anodes
8

To allow a factor of safety, use 6 anodes

4) Calculate the required length of the backfill column.

The maximum allowable spacing between anodes depends

primarily on the resistivity of the backfill column
(coke breeze). For tubular anodes of ½-in. diameter or
greater, maximum spacing between anodes should not
exceed four times the anode tube length. For this
example, we will try the maximum allowable spacing of
13 ft (39.4 in. x 4/12 = 13.1 ft).

The minimum length of the backfill column is

calculated as:

6 anodes at 39.4 in. (3.3 ft) = 19.8 ft

Spacing between anode: 5 at 13 ft = 65.0 ft
Space above and below anode string* 20.0 ft
Total length 104.8 ft
(use 105 ft)

* Generally, the coke breeze column extends from 10 ft below the

bottom anode to 10 ft above the top anode.

5) Calculate the backfill column-to-earth resistance

(RA).

This can be done from equation 1-4. Because several

attempts may have to be made to obtain the required
resistance-to-earth, the process is facilitated by
using the curve in figure 2-9C. Typical hole
diameters are 6 or 8 in.; a 6-in. diameter hole has
been selected for this groundbed.

From figure 2-9C for a 105 ft long coke breeze backfill

column, the resistance to earth per 1000 ohm-cm is
0.325 ohm. In 2000 ohm-cm soil, the resistance is
0.325 x 2 = 0.65 ohm, which is below the design
requirement defined in item 7 of paragraph 2-5a.

6) Determine total circuit resistance (RT) from equation

1-3:

62
 ETL 1110-9-10(FR)
5 Jan 91

RT = RA + RW + RC (Because the cathodic protection

system uses a single deep anode groundbed RA = RN)

Where:
RA = Backfill column-to-earth resistance
(ohms).

RW = Wire resistance (ohms).

RC = Structure-to-earth resistance (ohms).

a) Backfill column-to-earth resistance (RA) from

step 5.

RA = 0.65 ohm

b) Wire resistance (RW) from general equation 1-15:

LW RMFT
RW '
1000 ft

A deep anode groundbed is defined as one where the top

of the backfill column is at least 50 ft below the
surface of the earth. Actual depth will vary,
depending on subsurface geology and the distance over
which the current is expected to spread. In this
example, the depth to the top of the coke breeze
backfill column was determined to be 100 ft. The
anodes can be supplied through a single or dual feed.
Dual feed is preferred to reduce both the resistance
of the circuit and the chance of a failure due to a
cable break.

The assembly is made on a single length of cable,

beginning at the rectifier, running down through the
tubular anodes to the bottom anode and then back up
adjacent to the anodes to the rectifier. Resistance
calculations are made as though there were three
cables as noted below. The conductor provided with
some tubular ceramic anodes is designated EPR/HY5O for
one-in. diameter anodes and EPR/HY16 for 0.63-in.
diameter anodes. These cables have an ethylene-
propylene rubber inner insulation and a
chlorosulphonated polyethylene outer jacket and are
suitable for deep anode use if the insulation is
protected with a chlorine-resistant sheath or shield.

63
ETL 1110-9-10(FR)
5 Jan 91

EPR/HY50 cable has been chosen. The cable

lengths have been calculated based on the
following distances, which are illustrated in the
deep groundbed examples shown in figures 2-12 and
2-13:

From grade to top of backfill column 100 ft

From top of backfill column to top anode 10 ft
From grade to bottom of backfill column 205 ft
From bottom anode to bottom of backfill
column 10 ft
From anode hole to rectifier 2 cables
at 10 ft 20 ft
From top of anode assembly to bottom of
anode assembly 85 ft

Total cable length from top anode feed

to rectifier 10 ft + 100 ft + 10 ft = 120 ft

Total cable length from bottom feed

to rectifier 10 ft + 205 ft - 10 ft = 205 ft

Calculate top cable resistance (RWT) from

equation 1-15:

LWT RMFT
RWT '
1000 ft

Where:
LWT = 120 ft (Cable length from
previous calculation)

RMFT = 0.1183 ohm (Resistance per 1000

lin ft of EPR/HY5O [table 3-6])

RWT = 120 ft x 0.1183 ohm = 0.014 ohm

1000 ft

Calculate bottom cable resistance (RWB) from

equation 1-15:

Where:
LWB = 205 ft (Cable length from
previous calculation)

64
 ETL 1110-9-10(FR)
5 Jan 91

RMFT = 0.1183 ohm (Cable resistance per

1000 lin ft [same as above])

RWB = 205 ft x 0.1183 ohm = 0.024 ohm

1000 ft

These two cables are in parallel, so that total

resistance (RT/B) is calculated from the law of
parallel circuits:

1 = 1 + 1
RT/B RWT RWB

1 = 1 + 1
RT/B 0.014 0.024

1
RT/B = 71.43 + 41.66 = 113.1

RT/B = 0.009 ohm

Since current dissipates along the portion of the

cable to which the anodes are connected, the
resistance of this cable (RPOS) is taken as one half
its total resistance, as was done in example 2-2.

L W RMFT 1 85 x 0.1183 ohm/ft 1

RPOS ' x ' x
1000 ft 2 1000 ft 2

RPOS = 0.005 ohm

Negative cable resistance: The rectifier is

placed 25 ft from the connection to the piping,
using No. 4 AWG HMWPE insulated cable. Negative
resistance is calculated from equation 1-15:

LW RMFT
RNEG '
1000 ft

Where:
LW =
25 ft (Length of cable)

65
ETL 1110-9-10(FR)
5 Jan 91

RMFT = 0.254 ohm (Resistance per 1000

lin ft of No. 4 AWG HMWPE
insulated cable [table A-6])

RNEG = 25 x 0.254
1000

RNEG = 0.006 ohm

Total wire resistance therefore is:

RW =
RT/B + RPOS + RNEG = 0.009 + 0.005 +
0.006
RW =
0.020 ohm

c) Structure-to-earth resistance (RC).

The piping is essentially bare, so structure-to-

earth resistance is negligible (RC = 0.0).

d) Calculate total circuit resistance (RC) from

equation 1-3:

RT = RA + RW + RC (Because the cathodic

protection system uses a single deep
anode groundbed RA = RN)

RT = 0.65 + 0.020 + 0.0

RT = 0.670 ohm

7) Calculate rectifier voltage (VREC) from equation 1-17:

VREC = (I) (RT) (120%)

Where:
I = 40 amp (Current requirement from step
2, paragraph 2-5b)

RT = 0.670 ohm (Total circuit resistance

from previous calculation)

120% = Rectifier voltage capacity design

safety factor

66
 ETL 1110-9-10(FR)
5 Jan 91

VREC = 40 amp x 0.670 ohm x 1.2

VREC = 32.2 V

c. Select rectifier.

Based on the design requirement of 32.2 V and 40 amp, a

rectifier can be chosen. A 36-V, 50-amp unit is
commercially available and is selected.

d. Installation.

Figures 2-12 and 2-13 show how the deep anode groundbed
might look.

67
ETL 1110-9-10(FR)
5 Jan 91

68
 ETL 1110-9-10(FR)
5 Jan 91

69
ETL 1110-9-10(FR)
5 Jan 91

2-6. Elevated Water Tank (Ice Is Expected).

Impressed current cathodic protection is designed for an elevated

water tank (figure 2-14). The tank is already built and current
requirement tests have been done. Anodes must not be suspended
from the tank roof because heavy ice (up to 2 ft thick) covers the
water surface during winter. The anode cables could not tolerate
this weight, so another type of support must be used. An
internally supported hoop shaped wire anode system is selected.

a. Design data.

1) Tank is a pedestal supported spheroid with a 10-in.

riser pipe. Only the bowl will be protected because
the riser pipe is less than 30 inches in diameter. For
riser pipes see section 2-7.

2) Tank dimensions are:

Capacity = 400,000 gal

Diameter of bowl = 51 ft 6 in.
High water depth = 35 ft
Height of bowl above ground = 100 ft

3) Water resistivity is 2000 ohm-cm.

4) Design cathodic protection anodes for a 15-year life.

5) Wire type ceramic anode will be used.

6) Wetted surfaces are uncoated.

7) Area above high water level is kept well coated.

8) Tank is subject to freezing.

9) The cathodic protection circuit resistance must not

exceed 2 ohms.

10) The available electrical power is 120/240 V AC, single

phase.

11) Based on structure current requirement testing

recently performed on this tank, the current required
for adequate cathodic protection is 25 amp. This high
current requirement indicates that the tank internal
coating is severely deteriorated.

b. Computations.

70
 ETL 1110-9-10(FR)
5 Jan 91

1) Calculate the length of wire in ft (LB) needed for the

current required from a modification of equation 1-2:

LB = I
IA

where:
I = 25 amp (Current requirement from
adequate cathodic protection from
item 11 of paragraph 2-6a)

IA = Allowable amp per ft of anode wire

(varies depending on desired anode
life and diameter), found in table
A-3.

Select 0.0625-in. diameter copper cored anode

wire based on the current requirement of 25 amp,
81 ft of anode wire will be required to provide
an anode life of 15 years.

Length of Anode Ring

Wire Diameter (DR)

For 0.0625 in. LB = 25 = 81 ft 25 ft 9 in.

0.31

2) Calculate the desired diameter of the anode wire ring

(DB). Experience shows that the diameter of the anode
wire ring should be between 40 and 70 percent of the
bowl diameter. For this example, use a hoop diameter
equal to 40 percent of the tank bowl diameter:
DR = 51.5 ft x 40% = 20.5 ft

3) Select anode wire:

Prior to calculating the circuit resistance of the

anode wire ring, it must first be checked to determine
if the length is adequate for the desired anode life.
For an anode ring diameter of 20.5 ft, the
circumference is 20.5 x B = 64.4 ft. This length is
inadequate for the 0.0625-in. wire (which requires a
minimum of 81 ft to meet the desired anode life).
Therefore, we will increase the hoop diameter by 10
percent to 50 percent of the tank diameter:

DR = 51.5 x 50% = 25.75 ft

71
ETL 1110-9-10(FR)
5 Jan 91

But this diameter provides an anode length that is

still slightly less than that required for a 15-year
mode life. Therefore, we will use a hoop diameter
that is 55 percent of the bowl diameter:

DE = 51.5 x 55% = 28.3 ft

4) Calculate the anode-to-water resistance (RA) for a

0.0625-in. diameter anode wire using equation 1-14:

0.0016 p 8 DR 2 DR
RA ' (1n % 1n )
DR DA H

Where:
p = 2000 ohm-cm (Water resistivity from
item 3 of paragraph 2-6a)

DR = 28.3 ft (Anode ring diameter from

step 2 of paragraph 2-6b)

DA = 0.00521 ft (0.0625 in)(Diameter of

anode determined in step 3 of
paragraph 2-6b)

H = 21 ft (Anode depth below water

surface.) (Anode depth determined
from the following calculations).

The anode depth below the high water line is

approximately 60 percent of the distance between the
high water line and the bottom of the tank. Water
depth = 35 ft, cf. design data section 2-6a.

Calculate RA:

RA = 0.0016 (2000) [ln 8 x 28.3 + ln 2 x 28.3 ]

28.3 0.00521 21

RA = 0.113 [ln 43,455 + ln 2.70]

RA = 0.113 (10.68 + 0.99)

RA = 1.32 ohms

This is within the design limitation of 2.0 ohms.

72
 ETL 1110-9-10(FR)
5 Jan 91

5) Determine the total circuit resistance (RT), from

equation 1-3:

RT = RN + RW + RC

Where:
RN = Anode-to-water resistance
RW = Wire resistance
RC = Tank-to-water resistance.

a) Anode-to-water resistance (RN) = 1.32 ohms from

step 4 above. (RN = RA since RA is equal to one
continuous wire anode).

b) Header cable/wire resistance (RW) is solved using

equation 1-15:
LW RMFT
RW '
1000 ft

Where:
LW = 115 ft (Effective wire length. The
positive wires from the rectifier
to each end of the anode circle
will be approximately 115 ft long)

RMFT = 0.51 ohm (Effective wire resistance

per 1000 lin ft. Since there are
positive wires from the rectifier
to each end of the anode circle,
each wire will carry about one half
of the current [12.5 amp]. The
wires selected are No. 10 AWG.
Because the two wires are in
parallel, the effective resistance
is one half the single wire
resistance [1.02 ohms per 1000 lin
ft/2 = 0.51 ohm])

RW = 115 ft x 0.51 ohm

1000 ft

RW = 0.06 ohm

c) Tank-to-water resistance (RC) and negative

circuit resistance.

The negative wire is connected to the tank

structure near the rectifier, so its resistance

73
ETL 1110-9-10(FR)
5 Jan 91

is negligible. The tank-to-water resistance is

also negligible because the coating is very
deteriorated.

d) Calculate RT:

RT = 1.32 + 0.06 + 0.00

RT = 1.38 ohms

This is well below the design requirement.

6) Calculate rectifier voltage (VREC) from equation 1-17:

VREC = (I) (RT) (120%)

Where:
I = 25 amp (Current requirement from
step 11, paragraph 2-6a)

RT = 1.38 ohms (Total circuit

resistance from previous
calculation)

120% = Rectifier voltage capacity design

safety factor

VREC = 25 amp x 1.38 ohms x 1.2

VREC = 41.4 V

c. Select rectifier.

Based on the design requirements of 41.4 V and 25 amp, a

commercially available 48-V, 28-amp unit is selected. To
prevent over- or under-protection as the water level
varies, automatic potential control is specified. The
tank-to-water potential is maintained by the controller
through two permanent copper-copper sulfate reference
electrodes suspended beneath the anode wire circle. The
reference electrodes should have a life of at least 5
years. The tank-to-water potential measured by the
controller should be free of IR drop error.

74
 ETL 1110-9-10(FR)
5 Jan 91

d. Installation.

Figure 2-14 shows a typical installation while figure 2-14A

provides a typical detail for a pressure entrance fitting
for underwater power and reference cell wire penetrations.

75
ETL 1110-9-10(FR)
5 Jan 91

76
 ETL 1110-9-10(FR)
5 Jan 91

77
ETL 1110-9-10(FR)
5 Jan 91

2-7. Elevated Water Tank (No Icing Will Occur).

This impressed current design is for a tank (figure 2-15) that has
not been built; thus, it is not possible to measure current
requirements and other factors. Calculated estimates are used.

a. Design data.

1) Tank will be ellipsoidal on both top and bottom.

2) Tank dimensions will be:

Capacity = 500,000 gal

Diameter = 56 ft
Tank height (from ground to bottom of bowl) = 115 ft
Overall tank depth = 39 ft
Vertical shell height = 11 ft
High water level = 35 ft
Riser pipe diameter = 5 ft

3) Water resistivity is 4000 ohm-cm.

4) Design for a 20-year life.

5) The tank water will not be subjected to freezing.

6) Segmented rod anodes will be used; 4-ft long by 0.138-

in. diameter. Note: Segmented rods have an advantage
in that they can be field assembled using factory-made
connections. On the other hand, continuous wire
(.0625-in. diameter) is also available in long lengths
(typically 500 ft). These can be fabricated with
factory-made wire connections but their overall length
must be specified. Continuous wire will almost always
be less expensive.

7) All wetted inner surfaces will be uncoated. Area

above water will be coated.

8) Electric power available will be 120/240 V AC, single

phase.

9) Design for a current requirement of 2.5 A per sq ft

for the bowl and 8.0 A per sq ft for the riser. Due
to the velocity of the water in the riser, the riser's
current requirement is typically much higher than the
bowl.

78
 ETL 1110-9-10(FR)
5 Jan 91

b. Computations.

1) Find the area of wetted surface or tank bowl (A) shown

in figure 2-16 from equation 2-1:

79
ETL 1110-9-10(FR)
5 Jan 91

80
 ETL 1110-9-10(FR)
5 Jan 91

81
ETL 1110-9-10(FR)
5 Jan 91

A = AT + AC + AB (eq 2-1)

Where:

AT = Wetted area of the top section

AC = Area of the center section
AB = Area of the bottom section.

a) Find the appropriate wetted area of the top

section (AT) using equation 2-2:

AT = 2 B rh (eq 2-2)

Where:
r = 28 ft (Tank radius)
h = 10 ft (Water height)

AT = 2 x 3.1416 x 28 ft x 10 ft

A = 1759 sq ft (approximate).

b) Find the wetted area of the center section (AC)

using equation 2-2:

AC = 2 B rh (eq 2-2)

r = 28 ft (Tank radius
h = 11 ft (Water height)

AC = 2 x 3.1416 x 28 ft x 11 ft

A = 1935 sq ft

c) Find the wetted area of the bottom section (AB)

from equation 2-3:

AB ' 2 × A × r × h2 % r2 (eq 2-3)

Where:
r = 28 ft (Tank radius)
h = 14 ft (Water height)

AB ' 2 × 3.1416 × 28 × (14)2 % (28)2

AB = 3894 sq ft

82
 ETL 1110-9-10(FR)
5 Jan 91

d) Calculate (A):

A = 1759 sq ft + 1935 sq ft + 3894 sq ft

A = 7588 sq ft

2) Find the riser pipe area (AR) using equation 2-2:

AR = 2 B rR hR (eq 2-2)

Where:
rR = 2.5 ft (Riser radius)
hR = 115 ft (Height of riser)

AR = 2 x 3.1416 x 2.5 ft x 115 ft

AR = 1806 sq ft

3) Find the maximum design current for the tank bowl (IT)
using equation 1-1:

IT = (A) (I’) (1.0 - CE)

Where:
A = 7588 sq ft (Total wetted area of
tankbowl from step 1 of paragraph
2-7b)
I’ = 2/5 mA/sq ft (Required current
density from item 9 of paragraph
2-7a)
CE = 0.0 (Coating efficiency, wetted
inner surfaces will be uncoated,
from item 7 of paragraph 2-7a)
IT = 7588 sq ft x 2.5 mA/sq ft x (1.0 -
0.0).

IT = 18,970 mA; use 19.0 amp

4) Find the maximum design current for the riser

(IR),using equation 1-1:)

IR = (AR) (I’) (1.0 - CE)

Where:
AR = 1806 sq ft (Total surface area of
riser pipe from step 2 of paragraph
2-7b)

83
ETL 1110-9-10(FR)
5 Jan 91

I' = 8.0 mA/sq ft (Required current

density for riser pipe from item 9
of paragraph 2-7a)

CE = 0.0 (Coating efficiency. Inner

surfaces will be uncoated, from item
7 of paragraph 2-7a)

IR = 1806 sq ft x 8.0 mA/sq ft x (1.0 -

0.0).

IR = 14,448 mA; use 14.5 amp.

5) Select the number of anodes required for the bowl, to

meet the anode system's 20-year design life using
equation 1-2:

N = I
IA

Where:
I = 19 amp (Current requirement
determined in step 3)

IA = 1 amp/anode (Current rating per

anode from table 3-3 for 4-ft long
by 0.138-in. diameter ceramic rods)

N = 19
1

N = 19 rod segments (4-ft long segment)

6) Select the number of anodes required for the riser to
meet the anode system's 20 year design life using
equation 1-2:

N = I
IA

Where:
I = 14.5 amp (Current requirement
determined in step 4)

IA = 1 amp/anode (Current rating per

anode from table 3-3 for 4 ft long
by 0.138-in. diameter ceramic rods)

84
 ETL 1110-9-10(FR)
5 Jan 91

N = 14.5
1

N = 14.5; use 15 rod segments (4 ft.

long)

7) Calculate the radius of the main anode circle (AR),

using equation 2-4:
D x N
AR ' (eq 2-4)
2 (A % N)
Where:
D = 56 ft (Tank diameter, from item 2 of
paragraph 2-7a)

N = 10 anode strings (assumed: it is

necessary to assume a number of
anode strings since there are two
unknowns in this equation.

AR = 56 ft x 10
2 (3.1416 + 10)

AR = 560 ft
26.28

AR = 21.3 ft; use 22 ft for the main

anode circle radius

85
ETL 1110-9-10(FR)
5 Jan 91

86
 ETL 1110-9-10(FR)
5 Jan 91

87
ETL 1110-9-10(FR)
5 Jan 91

8) Determine the center-to-center spacing (Cc) for the

main anode strings.

a) To find circumference spacing (CC), use equation

2-5:

2 A AR
CC ' (eq 2-5)
N

Where:
AR = 22 ft (Radius of main anode circle
from previous calculation.

N = 10 anode strings ([Assumed] Used in

previous calculation)

CC = 2 x 3.1416 x 22 ft
10

CC = 13.8 ft; use 14 ft for center-to-

center spacing between anode
strings.

b) The cord spacing is approximately the same as

circumferential spacing; 14 ft will be used
(figure 2-19).

9) Select main anode system

Number of 4-ft long rod segments needed for the

current requirement (from step 5) = 19. Number of
anode strings utilized (from step 7) = 10. Using two
rod segments per string will provide twenty anodes,
which is sufficient for the current requirement.
However, for rod type anode designs, the main anode
rods should extend from a distance of 4 ft above the
tank bottom to within 4 ft of the HWL. Due to the
curvature of the tank bottom, the total water depth at
the location of the main anodes is approximately 30
ft. Therefore, the minimum rod length should be 22 ft
(30 ft - 4 ft - 4 ft = 22 ft). Since these rods come
in 4 ft lengths, we will use six segments per anode
with a total length of 24 ft.

10) Calculate the resistance of the main anodes to water

(RN) using equation 1-13:

88
 ETL 1110-9-10(FR)
5 Jan 91

89
ETL 1110-9-10(FR)
5 Jan 91

90
 ETL 1110-9-10(FR)
5 Jan 91

0.0052 × p × 1n [D/(2 AR x DE)]

RN '
LB

Where:
p = 4000 ohm-cm (Water resistivity from
item 3 of paragraph 2-7a)

D = 56 ft (Tank diameter from item 2 of

paragraph 2-7a)

AR = 22 ft (Radius of main anode circle

from step 7 of paragraph 2-7b)

DE = 0.275 (Equivalent diameter factor

from figure 2-17)

LB = 24 ft (Length of each anode from

step 9 of paragraph 2-7b)

RN = 0.0052 x 4000 x ln(56/(44 x 0.275))

24

RN = 1.33 ohms.

If the anode rod length-to-diameter ratio (L/d) is

less than 100, the anode-to-water resistance needs to
be adjusted by the fringe factor. (See step 12 for a
discussion of fringe factor.)
In this case, L = 24 ft and d = 0.0115 ft. L/d,
therefore, is (24/0.0115) = 2086. No fringe factor
correction is required.

11) Calculate the stub anode requirement (NS):

a) The main anode radius has been calculated to be

22 ft. The main anodes are spaced to provide
approximately the same distance from the sides
and the bottom of the tank. The main anode will
protect a length inward along the tank bottom
equal to approximately the same spacing that the
anode is spaced away from the tank wall.

b) The anode suspension arrangement for the tank

being considered is shown in figure 2-20. It can

91
ETL 1110-9-10(FR)
5 Jan 91

be seen that stub anodes are required for this

design. For a two-ring anode design (main and
one-stub anode ring), which is usually sufficient
for tanks up to 1 million gal storage capacity,
the 4-ft long stub anodes are located on a radius
one-fourth of the bowl radius, or 7 ft (28 ft x
0.25 = 7 ft). Typically, there will be about one
half as many stub anodes (two ring design) as
there are main anodes so we will plan for five 4-
ft long stub anodes on a 7-ft radius. The
outside radius of the area to be protected by the
stub anodes is approximately 13 ft and the inside
radius is 2.5 ft (riser radius). The stub anodes
are thus located on an 7-ft radius to place them
in the center of the area to be protected. (Note:
For smaller diameter tanks, stub anodes may not
be required.)

c) Find the current division between main and stub

anodes.

(1) The area of tank bottom protected by stub

anodes (As) is found by equation 2-6 (see
figure 2-20):

ASB = B (r22 - r12) (eq 2-6)

Where:
r1 = 2.5 ft (Riser radius)
r2 = 13 ft (Radius of protected segment.)
This is based on the fact that the
main anode string is 6 ft from the
tank wall and that the anode will
protect another 9 ft (1.5 x 6 ft in
toward the center on the tank bottom
due to arc shape of the tank
bottom). Outside radius of the area
to be protected by the stub anodes
is, therefore:

28 ft (tank radius) - 6 ft - 9 ft = 13 ft

ASB = 3.1416 [(13 ft)2 - (2.5 ft)2]

ASB = 3.1416 x 162.75

ASB = 511.3 sq ft; use 512 sq ft as the area to

be protected by the stub anodes.

92
 ETL 1110-9-10(FR)
5 Jan 91

(2) The current requirements for stub anodes

is, therefore;

512 sq ft x 2.5 mA/sq ft = 1280 mA or 1.3 amp

(3) The total current requirement for the bowl

is 19.0 amp (from step 3).

(4) The current for the main anodes is,

therefore;

19.0 amp - 1.3 amp = 17.7 amp

d) Select number of stub anodes (NS).

In step 11, five stub anodes were assumed. Check
the number required from equation 1-2:

NS = I
IA

Where:
I = 1.3 amp (Current requirement from
previous calculation)

IA = 1 amp/anode current rating per anode

from table 2-4 for 4-ft long by
0.138-in. diameter ceramic rods.

N5 = 1.3
1

NS = 1.3; use 2 - 4 ft anode rods

The five anodes selected to provide proper
coverage over the bottom are more than sufficient
for the desired anode life.

12) Calculate the stub anodes-to-water resistance (RN).

Find the stub anode resistance from equation 1-13:

0.0052 × p × 1n [D/(2 A R × DE)]
RN '
LB

93
ETL 1110-9-10(FR)
5 Jan 91

Where:
p = 4000 ohm-cm (Water resistivity from
item 3 of paragraph 2-7a)

D = 56 ft (Tank diameter from item 2 of

paragraph 2-7a)

AR = 7 ft (Radius of stub anode circle

from step lib of paragraph 2-7b)

DE = 0.07 (Equivalent diameter factor

from figure 2-17)

LB = 4 ft (Length of each stub anode)

RN = 0.0052 x 4000 x ln [56/(14 x 0.07)]
4

RN = 21.03 ohms.

Because the stub anodes are short, their

anode-to-water resistance may have to be adjusted
by the fringe factor. The fringe factor depends on
the ratio of length-to-diameter (L/d). If L/d is
less than 100, obtain the fringe factor from figure
2-18. Multiply the calculated stub anode-to-water
resistance by the fringe factor (F) to obtain the
adjusted resistance (RADJ).

RADJ = RN x F (eq 2-7)

Where:
RN = Stub anode-to-water resistance from
step 12.

F = Fringe factor from figure 2-18.

In this example, L/d for the stub anodes is:

L = 4 ft

94
 ETL 1110-9-10(FR)
5 Jan 91

d = 0.0115 ft

L/d = 4 = 348
0.0115

In this case L/d is greater than 100, 50 no fringe

factor correction is required.

13) Determine total resistance of main and stub anodes

(RT) from equation 1-3:

RT = RN + RW + RC

Where:
RN = Anode-to-water resistance.
RW = Header cable/wire resistance.
RC = Tank-to-water resistances.

a) Main anode rods:

RN = 1.33 ohms (from step 10)

RW = 0.13 ohm

Header cable/wire resistance is calculated from

equation 1-15:

LW RMFT
RW '
1000 ft

Where:
LW = 200 ft (After reviewing figure 2-20,
it is estimated that 200 ft of wire
will be required to connect the
rectifier to the anode distribution
wiring at the top of the tank)

RMFT = 0.640 ohm (Wire resistance per 1000

lin ft of No. 8 AWG HMWPE insulated
wire)

RW = 200 ft x 0.640 ohm = 0.13 ohm

1000 ft

95
ETL 1110-9-10(FR)
5 Jan 91

RC = 0.0 ohm (Resistance of the tank-to-

water and negative wire is
negligible)

b) Calculate the total resistance of the main anode

rods circuit (RT):

RT = 1.33 +0.13 + 0.0

RT = 1.46 ohms for main anodes.

c) Calculate the total resistance of the stub anode

rods circuit (RT):
Where:
RN = 21.03 ohms (from step 12)
RW = 0.13 ohm (same as main anode header)
RC = 0.0 ohm (negligible)

RT = 21.03 + 0.13 + 0.0

RT = 21.16 ohms for stub anodes.

14) Design riser anode.

a) Current requirement = 14.5 amp (from step 4)

b) Number of anode rods required from step 6 = 15

rod segments (4-ft long each)

c) Select riser anode system.

For proper current distribution in the riser

pipe, the anode units should not be placed too
far apart. It is generally considered that each
anode unit protects a length along the riser pipe
equal to 1 ½ times the spacing of the anode from
the riser pipe wall plus the length of the anode.
The length of riser protected by one 4-ft long
anode located 2.5 ft from the riser wall is
therefore:

(2.5 x 1.5) + 4 = 7.75 ft

Number of anode required for a 115-ft riser:

N = 115 = 14.8 or 15 anodes

7.75

96
 ETL 1110-9-10(FR)
5 Jan 91

The number of anodes required for current

distribution equals the number needed for the
current requirement. To allow for a factor of
safety, use twenty anodes.

d) Determine anode spacing.

Total riser length = 115 ft

Distance from bottom of riser to bottom of bottom
anode = 1.5 ft
Space consumed by anodes = 20 anodes x 4 ft each
= 80 ft
Total space consumed = 80 + 1.5 = 81.5 ft
Space remaining = 115 - 81.5 = 33.5 ft

For twenty anodes, there are nineteen spaces

Spacing = 33.5 = 1.76 ft or 1 ft 9 in.

19

Such an assembly is possible since anode rod

segments can be connected together with wire.
Since the anodes are spaced so close together, it
is better to use one long anode. Such an anode
has less flexibility than the disjointed cable
connected string, so there is less chance of its
vibrating or being damaged by water turbulence.

For one long anode made of 4-ft segments screwed

together, the number of anodes required is:

115 ft - 1.5 ft (distance from bottom) = 113.5 ft

113.5 = 28.4 anodes
4

Use 28 anode segments to keep the top segment

within the riser.

Total anode length = 28 anodes x 4 ft/anode = 112

ft.

Weight of the anode string will be:

2.4 oz/anode x 28 anodes = 67.2 oz = 4.2 lb

97
ETL 1110-9-10(FR)
5 Jan 91

Weight is not a factor in supporting the string.

15) Calculate the anode-to-water resistance of a single

anode rod (RA), using equation 2-8:

0.0052 p 1n(D/DA)
RA ' (eq 2-8)
LB

Where:
p = 4000 ohm-cm (Water resistivity from
item 3 of paragraph 2-7a)

D = 5 ft (Riser diameter from item 2 of

paragraph 2-7a)

DA = 0.0115 ft (0.138 in) (Diameter of

anode rod from item 6 of paragraph
2-7a)

LB = 112 ft (Length of anode rod from

previous discussion)

RA = 0.0052 x 4000 x 1n (5./0.0115)

112

RA = 1.13 ohms

16) Determine the total circuit resistance (RT) of the

riser anode, from equation 1-12:

RT = RA + RW + RC
Where:
RA = Anode-to-water resistance of a
single anode rod.

RW = Wire resistance.

RC = Tank-to-water resistance.

a) Anode-to-water resistance (RA) = 1.13 ohms from

step 15 of paragraph 2-7b.

b) Header cable/wire resistance (RN) from equation

1-15:

98
 ETL 1110-9-10(FR)
5 Jan 91

LW RMFT
RW '
1000 ft
Where:
LW = 240 ft (After reviewing figure 2-20,
it is estimated that 240 ft of wire
will be required to connect the
rectifier to the riser anode string)

RMFT = 0.640 ohm (Wire resistance per 1000

lin ft of No. 8 AWG HMWPE insulated
wire)

RW = 240 ft x 0.640 ohm = 0.15 ohm

1000 ft

Since this anode string is very long, the metal

of the anode can represent a significant
resistance. Since the current discharges all
along the anode, one half of its length is used
in the resistance calculation.

Manufacturer's data show the longitudinal

resistance of a single 4-ft anode segment to be
0.053 ohm. Effective resistance of the string
is:

0.053 ohm/anode x 28 anodes = 0.74 ohm

2

This resistance is very high compared to the

anode resistance (greater than 10 percent) as a
result, too much current will discharge near the
top of the anode and not enough current will be
discharged near the bottom of the anode.
Therefore, either a double-end feed method will
have to be used or copper-cored rods must be
used. (Note: This is usually only a problem in
fresh water applications when the anode rod
length is greater than 30 ft.) In this case, we
will elect to use copper cored 1/8-in. diameter
rods. Manufacturer's data show the longitudinal
resistance of a single 4-ft long copper-cored rod
of this diameter is 0.0034 ohm. Effective
resistance of this string is therefore:

0.0034 ohm/anode x 28 anodes = 0.048 ohm

2

99
ETL 1110-9-10(FR)
5 Jan 91

Thus, the copper cored anode longitudinal

resistance is less than 10 percent of the
anode-to-water resistance (0.048 ohm/1.13 ohm -
0.043 = 4.3 percent) making this an acceptable
riser anode design.

c) Tank-to-water resistance (RC) and negative

circuit resistance = 0.0 ohm.

d) Calculate total resistance of the riser circuit

(RT):

RT = 1.13 + 0.15 + 0.0

RT = 1.28 ohms for riser anode.

17) Calculate the rectifier voltage (VREC) and current:

a) First, determine the voltage requirement (E) for

each circuit using Ohm's Law:

E = I RT

Where:
I = Current requirement.
RT = Total circuit resistance.

Main Anodes:

I = 17.7 amp (from step 11c).

RT = 1.46 ohms (from step 13b).

E = 17.7 x 1.46 = 25.8 V

Stub Anodes:

I = 1.3 amp (from step 11c).

RT = 21.16 ohms (from step 13c).

E = 1.3 x 21.16 = 27.5 V

Riser Anodes:

I = 14.5 amp (from step 4)

RT = 1.28 ohms (from step 16d)

E = 14.5 x 1.28 = 18.6 V

100
 ETL 1110-9-10(FR)
5 Jan 91

b) Summarize each circuit's resistance, current

requirement and voltage requirement:

Circuit Current Resistance Voltage Required

(amp) (ohm) (V)

Main anodes 17.7 1.46 25.8

Stub anodes 1.3 21.16 27.5
Riser anodes 14.5 1.28 18.6
Total current
requirement 33.5

c) Determine the rectifier voltage (VREC) based on

the largest circuit voltage requirement of 27.5
V, because voltage requirement varies for all
three circuits. With a 120 percent safety factor
as in equation 1-17, the rectifier voltage is
calculated:

27.5 x (120%) = 33 V

Total current required = 33.5 amp.

c. Select rectifier

1) Rectifier capacity.

A commercially available rectifier having a rated

output of 40 V, 42 amp is selected.

Because of the different circuit resistances, separate

control of each circuit is required. This is best
handled by a rectifier having three separate output
circuits.

2) Automatic potential control

To prevent over or under protection as the water level

varies, automatic potential control is specified. The
tank and riser-to-water potentials are maintained by
the controller through permanent copper-copper sulfate
reference electrodes suspended within the bowl and
riser. The reference electrodes should have a life of
at least 15 years.

The automatic controller is located in the rectifier

unit. The controller must be capable of sensing the
potential accurately and free of IR (voltage) drop
error. The control does this by turning off the

101
ETL 1110-9-10(FR)
5 Jan 91

rectifier for a fraction of a second, during which

time the tank-to-water potential is measured. The
measurement is then compared with a preset standard
and the output adjusted accordingly.

d. Installation details.

Figures 2-19, 2-20, and 2-21 show typical details.

e. Guidelines for number of anode rings required.

The number of rings of anodes required varies with tank

diameter. Table 3-7 gives suggestions.

102
 ETL 1110-9-10(FR)
5 Jan 91

103
ETL 1110-9-10(FR)
5 Jan 91

2-8. On-Grade Water Storage Reservoir (Ice Is Expected).

Impressed current cathodic protection is to be designed for the

existing ground level water reservoir shown in figure 2-22.
Coating is in poor condition and expected to deteriorate in the
future. As the tank is not heated, ice forms in the winter.
Current requirement tests have been made.

a. Design data.

1) Tank is cylindrical with a flat bottom.

2) Water resistivity is 2000 ohm-cm.

3) Tank dimensions are:

Capacity = 250,000 gal

Diameter of bowl = 46 ft
High water depth = 20 ft.

4) Design cathodic protection anodes for a 15-year life

since tank will be repainted at that time.

5) Wire type ceramic anode will be used.

6) Design current density is 2.5 A per sq ft of tank area

to be protected.

7) Wetted surfaces are poorly coated. As coating is

expected to deteriorate, design for bare tank.

8) Area above high water level will be kept well coated.

9) Tank is subject to freezing and therefore a hoop type

anode support system will be used.
10) Electrical power available is 120 V AC, single phase.

11) Current requirement at present for adequate cathodic

protection is 9.0 amp.

b. Computations.

1) Find the area of the tank to be protected (A).

A = 2 B r h + B r2

104
 ETL 1110-9-10(FR)
5 Jan 91

105
ETL 1110-9-10(FR)
5 Jan 91

Where:
r = 23 ft (Tank radius from item 3 of
paragraph 2-8a)

h = 20 ft (High water depth from item 3 of

paragraph 2-8a)

A = 2 it x 23 x 20 + it x 232

A = 2890 + 1662

A = 4552 sq ft

2) Compute the current requirement (I) using equation

1-11:

I = (A)(I')(l.0 - CE)

Where:
A = 4552 sq ft (Area of tank to be
protected from previous calculation)

I' = 2.5 mA/sq ft (Required current density

from item 6 paragraph 2-8b)

CE = 0.0 (Coating efficiency, assuming tank

will eventually be essentially bare)

Current required:

I = 2.5 IDA/sq ft x 4552 sq ft

I = 11,380 IDA; use 12 amp

Since the computed 12 amp is larger than the tested

requirement of 9 amp, use the 12 amp as the required
current.

3) Calculate the length of anode wire in ft (LB) needed

for the current required, using a modification of
equation 1-2:

LB = I
IA

Where:
I = 12 amp (Current requirement from
previous calculation)

106
 ETL 1110-9-10(FR)
5 Jan 91

IA = Allowable amp per ft of anode wire

(varies depending on desired anode
life and diameter), found in table A-
3.

Based on selecting a wire anode of 0.0625-in.

diameter, the minimum wire length and hoop diameter
can be calculated:

For 0.0625 in. LB = 12 amp

0.31 amp/ft

= 38.7 ft 12 ft 4 in
(Length of (Minimum
Wire for Diameter of
15-Year Life) Wire Circle)

4) Calculate the desired diameter of the anode wire

circle (DR). Experience shows that the diameter of
the anode wire circle should be between 40 and 70
percent of the tank diameter for a cylindrical tank.
In this case, we will try a hoop shape with a diameter
equal to 60 percent of the bowl diameter:

DR = 60% x 46 ft = 27.6 ft; use 27 ft 6 in

5) Calculate the anode anode-to-water resistance (RA)

from equation 1-14:

0.0016 p 8 DR 2 DR
RA ' (1n % 1n
DR DA H

Where:
p = 2000 ohm-cm (Water resistivity from
item 2 of paragraph 2-8a)

DR = 27.5 ft (Anode ring diameter from

previous calculation)

DA = Assume 0.0052 ft (0.0625 in)

(Diameter of anode wire from step 3
of paragraph 2-8b)

107
ETL 1110-9-10(FR)
5 Jan 91

H = 12 ft (Anode depth below water

surface) Anode depth has been
determined from the following
calculations:

The distance from the bottom of the tank to the anode

wire circle should be about 40 percent of the water
depth.

Water depth = 20 ft from item 3 of paragraph

2-8a.

20 ft x 40% = 8 ft

Anode depth below water surface (H):

H = 20 ft - 8 ft = 12 ft

Calculate RA:

RA = 0.0016 x 2000 [in 8 x 27.5 + in 2 x 27.5]

27.5 0.0052 12

RA = 0.1164 [ln 42,307.7 + ln 4.6]

RA = 0.1164 [10.65 + 1.531

RA = 1.42 ohm

At a current requirement of 12 amp, voltage required

for this resistance, from Ohm's Law is:

E = I x RA
E = 12 x 1.42 = 17.2 V

This is a reasonable voltage, so the resistance of

1.42 ohms is acceptable.

6) Determine the total circuit resistance (RT), from

equation 1-3:

RT = RN + RW + RC

Where:
RN = RA = Anode-to-water resistance.
RW = Header cable/wire resistance.
RC = Tank-to-water resistance.

108
 ETL 1110-9-10(FR)
5 Jan 91

a) Anode-to-water resistance = 1.42 ohms from step

5.

b) Header cable/wire resistance (RW) from equation

1-15:

LW RMFT
RW '
1000 ft

Where:
LW = The positive wire from the rectifier
to the first splice is 15 ft long.
The power feed then continues on
around the hoop to the opposite
side. The length of this run is
about 43.2 ft but since only half
the current is passing through this
portion, its effective length is
43.2/2 = 21.6 ft.

RMFT = 1.02 ohms (From table 3-6, based on

selecting No. 10 AWG cables)

RW = (15 ft + 21.6 ft) x 1.02 ohms

1000 ft

RW = 0.037 ohm

c) Negative circuit and tank-to-water resistance

(RC).

The negative wire is connected to the tank

structure near the rectifier, so its resistance
is negligible. Tank-to-water resistance is also
negligible.

d) Calculate RT:

RT = 1.42 + 0.037 + 0.00

RT = 1.457 ohms; use 1.5 ohms

This is well below the design requirement.

7) Calculate the rectifier voltage (VREC) from equation 1-

17:

109
ETL 1110-9-10(FR)
5 Jan 91

VREC = (I) (RT) (120%)

Where:
I = 12 amp (Current requirement from
step 3)
RT = 1.5 ohms (Total circuit resistance
from previous calculation)
120% = Rectifier voltage capacity design
safety factor.

VREC = 12 amp x 1.5 ohms x 1.2

VREC = 21.6 V
c. Select rectifier.

Based on the design requirements of 21.6 V and 12 amp, a

commercially available 24-V 16-amp unit is selected.

d. Automatic potential control.

To prevent over- or under-protection as the water level

varies, automatic potential control is specified. The tank
and riser to water potential is maintained by the
controller through permanent copper-copper sulfate
reference electrodes suspended with the bowl and riser. The
reference electrodes should have a design life of at least
15 years.

The automatic controller is located in the rectifier unit.

The controller must be capable of sensing the potential
accurately and must be free of IR (voltage) drop error.
The controller does this by turning off the rectifier for
a fraction of a second, during which time the tank-to-water
potential is measured. The measurement is then compared
with a present standard and the output adjusted
accordingly.

e. Installation details.

Figures 2-22 and 2-23 show typical details.

f. Loop anode attachment guidelines.

110
 ETL 1110-9-10(FR)
5 Jan 91

The wire circle, or loop anode is supported from the sides

of the tank by polyester rope as shown in figure 2-22. The
number of supports varies with the tank diameter as
recommended in table 3-8.

111
ETL 1110-9-10(FR)
5 Jan 91

112
 ETL 1110-9-10(FR)
5 Jan 91

2-9. Horizontal Anodes. (Underground Applications)

There are times when it is advantageous to install anode

horizontally as shown in figure 2-24. For further information,
see paragraphs 10.91 through 10.93 of TM 5-811-7 (reference
10). This configuration is particularly helpful when using
packaged ceramic anodes (figure 2-24) since earth backfill can
be solidly tamped around them. The anodes can be laid on the
bottom of a trench or excavation with compacted backfill. This
often achieves better compaction than when tamping in vertical
holes. The design is undertaken in the same manner as
described in Section 2-2 and 2-3. The single anode-to-earth
resistance is calculated by using equation 2-11:

(eq 2-11)

Where:
RA = Anode-to-electrolyte resistance in ohms.
p = Electrolyte resistivity in ohm-cm.
L = Length of anode in ft.
d = Diameter of anode in ft.
h = Depth of anode in ft.

This equation is used to calculate the resistance

of a single anode-to-earth.

For multiple anode installations, equation 1-11 may be used to

approximate total resistance:

RA p PF
RN ' %
N CC

113
ETL 1110-9-10(FR)
5 Jan 91

114
 ETL 1110-9-10(FR)
5 Jan 91

Where:
RN = Resistance-to-electrolyte of "N" number
of anodes

RA = Resistance-to-electrolyte of a single
horizontal anode

N = Number of anodes

p = Electrolyte resistivity in ohm-cm

PF = Paralleling factor (table 3-5)

CC = Spacing between anodes in ft. (The

spacing between anodes is taken as the
center-to-center distance between
horizontal anode.)

As before, when equation 1-11 is applied to horizontal anodes,

it yields approximate results. This is because the equation is
based on vertical anodes. However, the results are
sufficiently accurate for cathodic protection design.

115
ETL 1110-9-10(FR)
5 Jan 91

2-10. Backfilling Packaged Anodes With Coke Breeze.

Although the calculations shown in Sections 2-2 and 2-3 assume

that the packaged ceramic anodes will be buried directly in
the earth, the accepted fail-safe design practice is to bury
the packaged anode canister in a coke breeze backfill.

Backfilling the packaged anodes in coke breeze offers three

advantages. First, it reduces anode-to-ground resistance. A
typical example would be to backfill a 3-in. by 60-in. anode
in a 8-in. diameter by 84-in. long coke breeze column. These
dimensions, d = 0.66 ft and L = 7.0 ft, are then used in
equation 2-8 or 2-10 to calculate resistance-to-earth.

The second advantage of using coke breeze backfill around

packaged anodes is that coke breeze often results in better
compaction then does soil. This also reduces anode-to-ground
resistance and improves anode performance.

The most important reason, however, for backfilling these (as

well as any other) prepackaged anode is that gas-blocking of
the anodes will not occur. Gases (primarily oxygen) are
released at the anode package surface. These can be entrapped
by the soil at the anode package surface which can prevent
further current discharge by the anode. The coke breeze
provides a porous media through which these gases can migrate
and dissipate preventing the possibility of gas blocking.

116