Wind Powered Cathodic

Protection Installation
Wind-Powered
Generator

Storage Batteries in
Suitable Housing

Groundbed

Structure

1
Electrical Isolation for Corrosion
Control
Separate components of corrosion cells

Separate dissimilar metals

Use with Cathodic Protection

(Interference Mitigation)

2
 FLANGE
INSULATION
KIT

INSULATING UNIONS
(DIELECTRIC
UNIONS)

3
Casing Spacers (@ RX-ings)

4
Cathodic Protection Systems – Amran CPSS

CP FOR PIPELINES

5
 Deep Well Groundbed System
Gas Vent
Anode Typ.100-150 m TRU
Junction Box Negative Distribution
(+) (-) Box
Steel Casing Header Cables

Unperforated Vent Pipe

Anode Tail Cable (Acid Protected Structure
Resistant) tied to the (Pipeline)
Nylon Rope

Perforated Vent Pipe

MMO/Ti Tubular Anode

Anode Centralizer

Active
Column
Coke Breeze
(Earth Contact Backfill) Icp

End Weight

Water Table

6
ICCP Anode Installation

7
Equivalent Circuit – CP System with
Remote Groundbed

EQUIVALENT CIRCUIT FOR A PIPELINE CP

SYSTEM

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Cathodic Protection Systems – Amran CPSS

CP FOR TANKS

9
Corrosion on Tanks

10
Anode Layout – Tank Bottom

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Cathodic Protection Systems – Amran CPSS

CP FOR VESSELS

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Schematic Sketch

CP System - Vessels
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Cathodic Protection Systems – Amran CPSS

CP FOR OTHER
STRUCTURES

14
Tubular Piles
GRP Enclosure

Concrete
Foundation
For Test Station

Concrete Platform

GI/PVC Rope from

End Weight
Cable from Reference
Pile Electrode tied to GI/PVC
support rope

Ag-Ag Cl Reference
Water Electrode tied to
GI/PVC support rope
Aluminum
Anode
End Weight

ed
Sea B 15
Supports to be provided by EPC
Installation Activities– Storage of Equipment /
Materials, Handling (Hiab Trucks, Fork Lift etc.)
at site, with 1 No. Electrician + 1 No. Helper
Sample TCP anode installation shall be performed
and shall be further executed on the similar basis
by EPC Civil / electrical installation crew
Welding of pads for electrical connection to the
structure
Civil / electrical works like trenching, casting of
pedestals, laying of cables, earthing of
equipments, Cable terminations, etc.

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Cathodic Protection Systems – Amran CPSS

INTERFERENCE –
PIPELINES CP SYSTEM

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 Foreign Line Crossings / Parallelism
Current Pickup
Location
Current
TR Discharge
Location
U
Istray
+–
Remote Ground bed

I’cp

Icp = I’cp + Istray

For foreign line parallelism, the current pickup will occur close to the
ground bed, and the discharge will occur at a remote location, into
the earth.
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Foreign Line Crossings / Parallelism
(Contd.)

EQUIVALENT CIRCUIT FOR A PIPELINE CP SYSTEM – WITH

FOREIGN LINE INTERFERENCE

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Foreign Line Crossings / Parallelism
(Contd.)

Mitigation Techniques
◦ Source Removal / Relocation
◦ Isolation of Structures
◦ Metallic Shielding
◦ Galvanic Anode Installation
◦ ICCP system installation at Stray Current
Discharge location
◦ Resistive Bonding
◦ Using special coatings

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OHL Interference
Conductive Coupling – Fault currents

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OHL Interference (Contd.)
Capacitive Coupling – only during
construction phase.

 Once the pipeline is installed into the ground, the

current induced due to capacitive coupling is almost nil.

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OHL Interference (Contd.)
EM Inductive Coupling – during
Parallelism.

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OHL Interference (Contd.)
In all the above cases – Conductive,
Capacitive, Inductive couplings, there is
an unintended current induced into the CP
current path. This is a stray current that
can lead to detrimental effects.

Disclaimer: The pictures above (under AC

interference) and to the right are used from
NACE CP3 training manual, for better
information to the audience only.

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Cathodic Protection Systems – Amran CPSS

MEASUREMENT BASICS

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Criteria for Protection
 As per NACE SP 0169, Section 6.2, Clause 6.2.2.1.1.,

A negative (cathodic) potential of at least 850 mV with the CP

applied. This potential is measured with respect to a saturated
copper/copper sulfate reference electrode contacting the electrolyte.

 As per NACE SP 0169, Section 6.2, Clause 6.2.2.1.2. ,

A negative polarized potential of at least 850 mV relative to a

saturated copper/copper sulfate reference electrode.

 As per NACE SP 0169, Section 6.2, Clause 6.2.2.1.3. ,

A minimum of 100 mV of cathodic polarization between the

structure surface and a stable reference electrode contacting the
electrolyte.

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Reference Electrodes
(Half Cells)

27
 Copper-Copper Sulfate
Reference Electrode
Connection
for Test
Removal
Lead
Cap
Copper Rod
Clear
Window Saturated Copper
Sulfate Solution

Porous
Plug Undissolved Copper
Sulfate Crystals

28
Multimeters

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Sign Convention
If a voltmeter is connected such that
the positive terminal is to the more noble
metal and the negative terminal to the
more active metal, the reading is positive.
Pipe-to-Soil Potential Measurement

Voltmeter Meter display is a Voltmeter

.900 v -.900 v Meter display is a
postive reading. negative reading.
_ Record a negative _ Record a negative
+ +
P/S Potential. P/S Potential.
Reference
Cell Reference
Cell

Electrolyte Electrolyte
Pipe Pipe

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Sign of Voltage for Dissimilar Metals
.600 V
Voltage
measurement
+ is positive

Noble Active
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Voltage Measurements

Driving voltage of galvanic anode system

Rectifier voltage output
Structure-to-electrolyte potential
Voltage drop across a pipe span
Voltage across a current shunt

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Cathodic Protection Systems – Amran CPSS

SURVEY TECHNIQUES

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Types of Survey
Routine
◦ Potential Monitoring Survey (On/Off)
◦ TR parameters
Specialized Surveys
◦ CIPS
◦ DCVG
◦ CAT
◦ Pearson’s Survey
◦ Interference Survey – OHL Lines / Foreign
Lines / Road Crossings and other buried metallic
structures

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CIPS Survey

 Close Interval Potential Survey

(CIPS)

◦ Proof of Cathodic protection

system effectiveness
◦ Measurement of polarized potential
at close intervals over pipeline
◦ Synchronized current interruption
using GPS

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DCVG Survey
 Direct Current Voltage Gradient
(DCVG) survey for External
coating Integrity Assessment

◦ Location of pipeline coating defects

◦ Recommendation of corrective
action where necessary
◦ External assessment of coatings
using DCVG, CIPS and other
◦ Techniques and/or appropriate
combination of technique

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37
Corrosion on Tanks

38
CP Activities

 Details of Tanks

 Engineering & Design

 Description of CP System for Tanks

 Installation

 Testing & Commissioning

39
 Details of Tanks

Diameter Height Operating temp

S. No Tank No. Service Qty
(m) (m) in Degree C

1 179-24-T01 Potable Water 1 25.25 13.6 60

2 179-24-T02 Potable Water 1 25.25 13.6 60

3 179-33-T01 Fire Water 1 23.25 12.8 60

4 179-33-T02 Fire Water 1 23.25 12.8 60

40
Engineering & Design

Based on the provided data, the Cathodic Protection (CP) system

for the 4 Tanks was designed by ACPSS.

The submitted project documents are as follows:

 Design Package for CP System

 Method Statement for Installation and Commissioning of CP
System with Construction Drawings
 Material Data Sheets for CP System

The above documents were reviewed and approved by JEC / QP

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Description of CP System for Tanks
CP SYSTEM

Type of CP System Permanent ICCP System

Design Life 25 Years

TR Unit

DC Power Source AC Input : 230 V, 50 Hz, Single Phase

DC Rated Output : 50 V / 15 A

Distributed Anode Ground Bed

Anode Type : MMO coated ribbon / Ti conductor bar

Anode Bed
Anode Bed Rating : 42 mA / 50 years

Depth of Anode Bed : 400 mm from the tank bottom plates

Anode Junction Box

No of Anode
Junction Box : 1 No. per tank
Junction Boxes
No of Circuits : 7 (including 2 no. of spare circuits)

Shunt Rating : 10 A / 100 mV

Test Station (Box

with GI Frame : 1 No per tank

Permanent : Prepackaged Copper – Copper

Monitoring Facilities Reference Sulfate / Installed 200 mm from the tank
Electrode bottom plate

Monitoring Duct : Installed 200 mm from the tank bottom plate

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Installation

The site activities were conducted in accordance with all project

specifications and standards relating to HSE. This includes but
not be limited to the wearing of all appropriate personal
protective equipment and clothing, such as helmets, safety boots
and overalls. The CP activities were carried out as approved
method statement and list of activities are as follows:

 Anode Mesh Installation

 Reference Cell Installation

 Monitoring Duct Installation

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Installation

 Cable connection to tanks (for drain point & monitoring cable

connections.

 Cathodic Protection cable laying

 Installation of CP equipment like Anode Junction Box (AJB),

Monitoring Test Station & Transformer Rectifier Unit (TR).

44
Installation – Anode Mesh

45
Installation –Anode Mesh

46
Installation – Anode Junction Box

47
Installation – Transformer Rectifier
Unit

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Testing & Commissioning
The installed cathodic protection system was tested and
commissioned by ACPSS CP Engineer in presence of JEC / QP
Representatives

Performance Criteria

Commissioning Equipment

Pre-Commissioning Checks

Commissioning

Commissioning Report

Operation & Maintenance Manual

49
Performance Criteria

QP Engineering Standard (ES.2.2.14.0046) Section 6.4.3

Polarized potential (instantaneous OFF) more negative than -900

mV and less negative than -1200 mV relative to Cu-CuSO4 reference
electrode.

Minimum negative (cathodic) polarization voltage shift of 100mV is

considered adequate

International Standard – NACE

As per clause 4.3.1.3 of NACE-RP-0193, a minimum of 100 mV of

cathodic polarization between the structure surface and a stable
reference electrode contacting the electrolyte. The formation or
decay of polarization may be measured to satisfy this criterion.

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Polarization Measurement

51
Commissioning Equipment

The following list of calibrated equipments shall be used for the

testing and commissioning of CP system:

High impedance multimeter

Saturated Cu-CuSO4 reference electrode
Clamp on Ammeter
Test lead with clamp
Test post key
Water (as required) – proper ground contact for
the reference electrode

52
Pre - Commissioning
The intent of pre commissioning checks was to ensure that CP
system and equipment as installed as per the project documents /
drawings will operate correctly and provide the tanks with a
satisfactory level of protection. The activities are:

Visual Inspection of all

CP equipment

Natural / As found potential

measurement

Transformer Rectifier unit testing

53
Commissioning

Commissioning was carried out in presence of JEC / QP

Representatives on completion of pre commissioning checks.

Energization of Transformer Rectifier unit

Measurement of energized potential

Measurement of instant OFF potential

Anode current output measurements

Final documentation

54
Measurement Techniques

TR Unit

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Operation, Monitoring & Maintenance

Reference Document

Operation and Maintenance Manual for ICCP System of

External Bottom Surface of Tanks # 3045-5-22-0015

The interval of inspection should be the choice or policy of

the Owners. The actual schedule for the potential
monitoring shall be in liability with the Client.

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1. System Shutdown & Restarting

57
1. System Shutdown & Restarting

58
2. Operation & Monitoring

Monthly Monitoring

 Current Source

 Output Voltage

 Output Current

 Structure ON Potentials against permanent Cu-CuSO4 reference

electrode at Test Station locations

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2. Measurement Techniques

 O/P Voltage – Built in Voltmeter or Portable Voltmeter (Multimeter)

 O/P Current – Built in Ammeter or Shunts or Clamp on Ammeter

TR Unit

60
Measurement Techniques
Anode Junction Box
Individual Anode Current
Measurement

61
Measurement Techniques

 Anode Inspection & Survey

Utilizing the known rating of the current measuring shunt, a potential

drop (in mV) is measured across the terminals as shown in above
picture.

The following section illustrates the procedure for calculating the current of
each anode

Example 1:

Shunt Rating 100mV / 10 Amps.

10 A / 100mV – multiplying factor =0.1
64.4mV measured across the shunt terminals
Therefore current= 64.4 X 0.1 = 6.44 Amps

62
Measurement Techniques

Potential Measurement at Test Station

-1 2 5 0mV Multimeter

GRP ENCLOSURE
TANK
SIZE:300X200X120MM

BAKELITE SHEET
TANK TEST

CABLE GLANDS

5 NO. SINGLE CORE 10 MM2 XLPE/PVC

BLACK CABLES FROM REFERENCE CELL
2NO. SINGLE CORE 10 MM2 XLPE/PVC
BLACK CABLE FROM TANK

63
2. Operation & Monitoring

Quarterly Monitoring – Protection Level Survey

 Current Source

 Output Voltage

 Output Current

 Structure ON Potentials on monitoring duct installed below the tank

bottom against portable Cu-CuSO4 reference electrode

64
Measurement Techniques

Potential Measurement – Monitoring Duct

65
Measurement Techniques

Potential Measurement – Monitoring Duct

-1 2 5 0mV Multimeter

GRP ENCLOSURE
TANK
SIZE:300X200X120MM

BAKELITE SHEET
TANK TEST
FROM PORTABLE REFERENCE CELL

CABLE GLANDS

5 NO. SINGLE CORE 10 MM2 XLPE/PVC

BLACK CABLES FROM REFERENCE CELL
2NO. SINGLE CORE 10 MM2 XLPE/PVC
BLACK CABLE FROM TANK

66
2. Operation & Monitoring

Annual Monitoring – Protection Level Survey ( against

Protection Criteria)

 Current Source

 Output Voltage

 Output Current

 Structure ON & instant OFF Potentials against permanent / portable

Cu-CuSO4 reference electrode

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3. Maintenance

Anode Junction Box

 Physical Condition

 Clean, if any foreign material, dirt, nest, etc.,

 Check the cable connections for proper termination and tightness

 Check the cable tags. Replace, if missed.

 Compare the anode current output with previous value and

investigate, if drastic change observed

 Replace the internal components, if damaged or mishandled.

68
3. Maintenance

Test Station

 Physical Condition. Clean, if any foreign material, dirt, nest, etc.,

 Check the cable connections for proper termination and tightness

 Check the cable tags. Replace, if missed.

 Check the permanent reference electrode cable for damage (if any)
by measuring the potential of structure with reference against tail
cables from permanent reference electrode

 Compare the anode current output with previous value and

investigate, if drastic change observed

 Replace the internal components, if damaged or mishandled.

69
3. Maintenance

Transformer Rectifier Unit

70
Transformer Rectifier Unit

 Physical Condition. Clean, if any foreign material, dirt, nest, etc.,

 Check the cable connections for proper termination and tightness

 Check the cable tags. Replace, if missed.

 Check all metering and indication

 Check DC output voltage across the output terminals using

multimeter

 Check DC output current by measuring potential drop across the

shunt using multimeter or using clamp on ammeter on the DC output
positive header cable

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Transformer Rectifier Unit

 Check the condition of Silica gel breather

 Ensure the working condition of the ammeter / voltmeter panel

needles by above measurements

 Check the oil level in the level gauge. Open the top envelope of the
TR unit for further inspection after investigations and clarifications, in
case of defective level gauge.

 Check the inbuilt ON/OFF timer as well

72
Transformer Rectifier Unit – Troubleshooting Procedures

73
Transformer Rectifier Unit – Troubleshooting Procedures

74
Transformer Rectifier Unit – Troubleshooting Procedures

75
Transformer Rectifier Unit – Troubleshooting Procedures

76
Transformer Rectifier Unit – Troubleshooting Procedures

77
Transformer Rectifier Unit – Protection against surge /
lightning thunder

Lightning Arrestors – Provided LA1 at AC input, LA2 at DC

output to protect the unit from AC /DC
transients, lightning effects.

Surge Suppressor - Provided SS1 through SS4 across Diodes,

at AC input, SS5 across Interrupter
Contactor Coil & SS6 across Interrupter
Contactor Contact to protect the devices
from voltage spikes

Reference Documents

Manufacturer Manual – TR Unit (Appendix-B) of Document No.

3045-5-22-0015
Drawing No.: 3045-2-61-0011 Sheet 001 & 002

78
Interference Testing

Interference (in Cathodic Protection) refers to electrical

interference as opposed to physical or chemical interference.
Interference can be defined as any detectable electrical
disturbance on a structure caused by a stray current. Stray
current is defined as a current in an unintended path

No interference / potential drop has been observed on the commissioned

Potable and Fire Water Tanks

Tanks are provided with HDPE liner – CP current leakage is not

envisaged.

79
Interference Testing

80
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 protections
systems work properly.

Properly implemented and monitored cathodic protection will

extend the service life of storage tanks more than 25 years

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