addressing defective cathodic protection systems on … 1/eichlin.pdf · cathodic protection...
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Addressing Defective Cathodic Protection Systems On Above Grade Storage Tanks
NISTM-2013 Ralph Eichlin Corrosion Control Incorporated
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Cathodic Protection Systems
Cathodic protection is used to control corrosion on the underside (soil side) of above grade petro-chemical tanks
Effective cathodic protection will increase reliability and reduce costs associated with maintenance and inspection
Several states, the DOT and the DoD require the use of cathodic protection to reduce product release
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Cathodic Protection Types
Galvanic
Impressed Current
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Single Bottom Storage Tanks
(-) (+)
Protective Current
Tank
Anode
Foundation
Rectifier
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Cathodic Protection Arrangement
Many above grade tanks are equipped with under floor containment liners
The type of liner used will determine the anode placement
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Clay Fabric Containment Liner
Tank
(-)
(+)
Anode
Rectifier
Clay Fabric Liner
Soil
• Current passes through liner • Anodes can be placed below liner or around tank • Replacement anodes can be placed around tank
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Non-Conductive Liner
Tank
(-)
(+)
Anode
Rectifier
Plastic Liner Current will not pass through liner
Sand
Tank Floor
• Containment liner blocks current from reaching tank bottom • Cathodic protection readings around tank give indication of
effective corrosion control • Tank bottom subject to corrosion above liner
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Cathodic Protection – Plastic Liner
• Anodes are placed in sand between liner and tank bottom • Anodes can not come in contact with tank bottom • Distance between anode and floor determines current distribution
Anode
Shell
Bottom
Foundation Sand
Liner
Tank
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Galvanic Ribbon Systems
Spacing between ribbons must adequate to provide current distribution
Sand fill can not be corrosive, and must remain relatively dry
When moisture enters the sand, most galvanic systems continue to protect the tank bottom but a shorter anode service life may result.
Some early galvanic ribbon systems were actually used to detect leaks
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Zinc Anode Ribbons
36 to 60 inches
Cable Connections
Tank Shell
Zinc ribbon
Test Box
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Magnesium Anode Ribbons
Magnesium Ribbons
Permanent reference cell centered between ribbons
#10 RHW-USE
Tank Shell
Splice Test Box
24” Centers
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Galvanic Anode Splice
To Next Anode
Mastic Patch
Exposed Steel Core
Solid Copper Crimp To Next Anode
#10 RHW-USE
Magnesium Ribbon
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Galvanic Test Box
Live Shell
Sand
New Floor
Reference Cells
Test Box
Liner Seal
Anode Ribbon Grade
Couple
Seal off
1 ½” dia. conduit
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Current Flow
• Current flows off magnesium anode into sand • Current flows through sand and onto underside of floor • Current returns in steel and cable to anode
Live Shell
Sand Protective current flow
Newer Tank Floor
To next anode
Test Box Weld
Liner Seal
Cable
Anode
New Floor
Old Floor
Cable connection to tank
Current return in cable
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Sand Contamination
Rain water enters at leak detection tubes
Rain water enters at chime (new floor to old shell)
Water bottoms seep through flaws in welds or floor plates
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Water Entering Sand
Live Shell
New Floor
Dead Shell
Leak detection port not sealed
Sand
Old Floor
Water entering sand
Chime
Lack of seal weld
Weld defect Defect in plate
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Impressed Current
• Rectifier supplies current to anodes in sand • Anodes deliver current to floor which is returned to rectifier • Reference cells are used to monitor protection levels
Anode
Shell
Floor
Foundation
Liner Reference Cells
Sand
Rectifier Negative Connection
Test Box
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Galvanic System Deficiencies
Anode ribbons are too far apart
Anode ribbons do not deliver sufficient current
Sand used as fill is conductive and corrosive
Water enters sand causing it to become corrosive
Galvanic anode ribbons are depleted
Reference cells are inaccurate or inoperable
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Impressed Current Deficiencies
Rectifier inoperable or not properly adjusted
Cables between rectifier and anode box are severed
Anodes are spaced too far apart
Anode ratings are too low
Anodes are grounded to tank bottom
Reference cells are inacurate or inoperable
Positive and negative cables are connected with the wrong polarity
Sand is too dry
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The CP System Doesn’t Work. Now What ?
Monitor tank bottom using API-653 inspection code, take action if corrosion losses are significant
Lift the tank or remove the floor and replace the cathodic protection system
Attempt to insert anodes between liner and floor through holes cored in ringwall
Inject inhibitors into sand in place of cathodic protection
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Retrofit Inserted Anode
Shell
Ringwall
Floor
Sand Cable Splice Box
Containment Liner Inserted Anode
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Inject Water Based Inhibitor
Shell
Inject Water Based Inhibitor
Electrical resistance probe or coupon
Monitor Discharge
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Conclusions
Best solution is to avoid the problem to start with; specific requirements for construction
Monitor tank floor using API-653 inspection code, take action based on inspection results
Inhibitor inject shows promise, concerns are accuracy of corrosion monitoring and life cycle of inhibitor
Inserting anodes between liners and floors is not practical in most applications
Lift tank/remove floor – be sure any replacement systems are design and installed to provide long term service
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Thank you.