Design and Engineering of Cathodic Protection Systems

Design & Engineering


Cathodic Protection (CP) is a vital electrochemical technique used to prevent corrosion in metallic structures, particularly those buried underground or submerged in water. The design and engineering of CP systems require a detailed assessment of the structure, environmental conditions, soil resistivity, and potential sources of interference. Electro Corr-Damp Pvt Ltd specializes in delivering comprehensive CP solutions, including Sacrificial Anode Cathodic Protection (SACP), Impressed Current Cathodic Protection (ICCP), and AC Mitigation Systems.


Sacrificial Anode Cathodic Protection (SACP)

SACP is a passive protection method that relies on more electrochemically active metals (anodes) to corrode in place of the protected structure. This system is widely used for smaller structures with low current demand, such as pipelines, storage tanks, and offshore platforms.


Features of SACP:
  • ✔ Uses sacrificial anodes like zinc, aluminum, or magnesium
  • ✔ Self-regulating, requiring minimal maintenance
  • ✔ Ideal for isolated or small-scale structures
  • ✔ No external power source required

Engineering Considerations for SACP:
  • ✔ Selection of anode type based on soil or water conditions
  • ✔ Calculation of anode consumption rates and placement for optimal protection
  • ✔ Potential monitoring to ensure adequate protection levels

Impressed Current Cathodic Protection (ICCP)

ICCP systems use an external DC power source to drive current through anodes, providing corrosion protection for large and complex structures like cross-country pipelines, underground tanks, marine structures, and reinforced concrete.


Key Features of ICCP:
  • ✔ Utilizes durable anodes such as Mixed Metal Oxide (MMO), Graphite, or Silicon Iron
  • ✔ Requires Transformer Rectifier Units (TRUs) to control current output
  • ✔ Can protect long-distance pipelines and high-current-demand structures
  • ✔ Allows for continuous monitoring and control

Engineering Considerations for ICCP:
  • ✔ Site-specific soil resistivity analysis for anode bed placement
  • ✔ Proper selection of anode material to ensure long-term performance
  • ✔ Power supply design and interference mitigation for adjacent structures
  • ✔ Remote monitoring integration for real-time CP performance tracking

AC Mitigation Systems for Pipelines

Pipelines running parallel to high-voltage AC power lines are susceptible to induced AC voltages, which can lead to accelerated corrosion and pose safety hazards. AC mitigation systems are engineered to reduce these effects and enhance pipeline integrity.


Key Features of AC Mitigation:
  • ✔ Zinc Ribbon or Gradient Control Mats to dissipate induced AC
  • ✔ Solid-State Decouplers (SSD) for controlled discharge of AC voltages
  • ✔ Low-Resistance Earthing Systems to provide safe discharge pathways
  • ✔ Continuous Monitoring Systems to detect AC interference

Engineering Considerations for AC Mitigation:
  • ✔ Conducting an AC Interference Study to assess risk levels
  • ✔ Installing mitigation devices at high-risk zones
  • ✔ Ensuring proper grounding and bonding techniques
  • ✔ Compliance with industry standards such as NACE, IEEE, and ISO

Comprehensive CP Design and Engineering Approach

Electro Corr-Damp Pvt Ltd follows a systematic approach for designing CP systems, ensuring compliance with industry standards and long-term corrosion protection.

  • 1. Site Survey & Data Collection – Soil resistivity testing, structure potential analysis, and environmental assessment
  • 2. System Design & Engineering – Selection of anodes, power sources, and monitoring systems
  • 3. Installation & Commissioning – Proper placement of anodes, rectifiers, and mitigation devices
  • 4. Performance Monitoring & Maintenance – Periodic inspections, surveys, and real-time data analysis

    • Our expertise in CP engineering ensures cost-effective, sustainable, and reliable protection solutions for underground and submerged metallic structures.