Project Abstract

Abstract
Cathodic protection is a widely used method to prevent corrosion in various structures, particularly in industries such as oil and gas, marine, and infrastructure. This research project focuses on the design and installation of a cathodic protection system using zinc anodes. Zinc has proven to be an effective sacrificial anode material due to its high negative electrochemical potential compared to steel, making it an ideal choice for protecting steel structures from corrosion. The project involves the design phase where factors such as structure size, current requirement, coating condition, and environmental conditions are considered to determine the number and placement of zinc anodes for optimal protection. Computer-aided design tools are utilized to simulate the protection system's performance and ensure adequate coverage. The installation phase is crucial in ensuring the effectiveness of the cathodic protection system. Proper surface preparation of the structure, secure attachment of the zinc anodes, and electrical connections are key steps in the installation process. Monitoring devices are also incorporated to track the system's performance over time and make any necessary adjustments. The effectiveness of the cathodic protection system using zinc anodes is evaluated through regular inspections and testing to measure the corrosion rate on the protected structure. Data collected from these assessments are analyzed to determine the system's efficiency in preventing corrosion and extending the structure's lifespan. Overall, the design and installation of a cathodic protection system using zinc anodes require careful planning, precise execution, and continuous monitoring. By implementing this system, industries can significantly reduce maintenance costs, minimize downtime due to corrosion-related issues, and ensure the integrity and longevity of their structures. This research project contributes to the advancement of corrosion protection techniques and provides valuable insights for engineers and professionals involved in safeguarding critical infrastructure and assets from corrosion damage.

Project Overview

INTRODUCTION

1.1 Background of study

Cathodic protection (CP) is a method of controlling corrosion or a means of preventing corrosion of metaland can be applied to any buried and/or submerged metallic structures. It is normally used in conjunction with coatings and can be considered as a secondary corrosion control technique.

Cathodic protection can, in principle, be applied to any metallic structure in contact salty media(electrolyte). In practice its main use is to protect steel structures buried in soil or immersed in water. Structures commonly protected, includes:

Cross country pipelines

Exterior surfaces of pipelines immersed in water

In plant piping

Above ground storage tank bases

Buried tanks and vessels

Internal surfaces of tanks, vessels, condensers and pipes

Well casings

Foundation piling, steel sheet-piling

Piling – tubular, sheet steel and foundation

Marine structures including jetties, wharfs, harbours, piers

Ships, hulls

offshore platforms

Reinforcing steel in concrete

Corrosion is a very serious problem. Three areas in which corrosion are important are in economic, improved safety and conservation of resources. The leakage of hazardous materials from a transport pipeline represents not only the loss of natural resources but also the potential for serious and dangerous environmental impact, and human fatalities. While pipelines are designed and constructed to maintain their integrity, diverse factors (e.g., corrosion) make it difficult to avoid the occurrence of leakage in a pipeline system during its lifetime.

All metals needs energy to be transformed from their oxide (natural) state to a refined state. The process of taking this energy away from the metal is called corrosion. Metals tend to revert back to their natural state when reacting with the environment. This corrosion reaction that occurs is an oxidation-reduction reaction. The purpose of cathodic protection is to stop this corrosive process.
Cathodic protection is the most important of all approaches to corrosion control techniques. One of the types of cathodic protection is sacrificial anode or galvanic cathodic protection. Corrosion occurs through the loss of the metal ions at anodic area to the electrolyte. Cathodic areas are protected from corrosion because of the deposition of hydrogen or other ions that carry current (Sandoval, A., et.al 2001). By using the sacrificial anode technique, the steel pipe will be protected from corrosion but the other metal which is the anode will corrode. In designing this method we must analyze parameters such as factor affecting corrosion, the amount of anode and rate of corrosion, the current densities and the total resistance.