Nace CP 1 User manual

CP 1–Cathodic
Protection Tester
Course Manual
February 2005
©NACE International, 2000

Acknowledgements
The time and expertise of a many members of NACE International have gone into the
development of this course. Their dedication and efforts are greatly appreciated by the
authors of this course and by those who have assisted in making this work possible.
The scope, desired learning outcomes and performance criteria were prepared by the
Cathodic Protection Training and Certification Program Task Group under the auspices
of the NACE Certification and Education Committees. Special thanks go to the
following:
On behalf of NACE, we would like to thank the following members who were
instrumental in the development and review of this program.
Buddy Hutson Florida Gas Transmission Company;Maitland, Florida
Steve Bean Southern California Gas Company, Los Angeles, California
Joe C. Bowles, Jr. Broussard, Louisiana
Raul Castillo Dow Chemical, Freeport, Texas
David Edwards Santa Fe Pipelines, Rocklin, California
Gerry Garleiser Exxon Co. USA, Houston, Texas
Kevin Garrity CC Technologies, Dublin, Ohio
Robert Gummow CorrEng Consulting Service Inc., Downsview, Ontario
Brad J. Lewis Kinder Morgan Energy Partners L.P., Tucson, Arizona
Thomas H. Lewis LORESCO, Inc., Hattiesburg, MS
Ed Ondak EJ Ondak Associates, Inc, Littleton, Colorado
Larry Rankin Corrpro Companies Inc., Houston, Texas
John Schmidt CC Technologies, Houston, Texas
David A. Schramm ENEngineering, Woodridge, IL
William H. Thomason Conoco, Inc. Ponca City, Oklahoma
This group of NACE members worked closely with the contracted course developers,
who were John Fitzgerald, John Wagner, and Walter Young of Corrpro Cos. Inc. Much
of the material in the courses is based on existing NACE cathodic protection training
material which was developed and refined over several years by members including
Robert A. Gummow, (CorrEng Consulting Service Inc., Downsview, Ontario), James R.
Myers (JRM Associates, Franklin, Ohio), Frank Rizzo (FERA Corporation, Houston,
Texas), Marilyn Lewis, P.E. (Lewis Engineering, Hattiesburg, Mississippi), Larry
Brandon (CorPre Tek, Inc., Carson City, Michigan) and James F. Jenkins, P.E. (Cambria,
California).

IMPORTANT NOTICE:
Neither the NACE International, its officers, directors, nor members thereof accept any
responsibility for the use of the methods and materials discussed herein. No authorization
is implied concerning the use of patented or copyrighted material. The information is
advisory only and the use of the materials and methods is solely at the risk of the user.
Printed in the United States. All rights reserved. Reproduction of contents in whole or
part or transfer into electronic or photographic storage without permission of copyright
owner is expressly forbidden.

CP 1 – Cathodic Protection Tester Course Manual
©NACE International, 2000
02/01/05
CP 1 – CATHODIC PROTECTION TESTER
TRAINING MANUAL
TABLE OF CONTENTS
General Information
Course Outline
Introduction
CP 1–Cathodic Protection Tester Certification Application
Section 1
Chapter 1 Basic Electricity
Introduction................................................................................................. 1:1
Electrical Terms.......................................................................................... 1:1
Electrons............................................................................................................................ 1:1
Voltage .............................................................................................................................. 1:1
Current............................................................................................................................... 1:2
Resistance and Resistivity ................................................................................................. 1:3
Electrical Schematic Diagram Symbols ............................................................................ 1:6
Electric Circuit............................................................................................ 1:7
Electrical Laws............................................................................................ 1:7
Ohm’s Law......................................................................................................................... 1:7
Power................................................................................................................................. 1:9
Kirchhoff’s Laws.............................................................................................................1:10
Series Circuit...................................................................................................................1:11
Parallel Circuit.................................................................................................................1:13
Series-Parallel Circuit......................................................................................................1:15
Direct Current (DC).........................................................................................................1:18
Alternating Current (AC).................................................................................................1:18
Meter Operation........................................................................................ 1:21
General ............................................................................................................................1:21
Analog Meters.................................................................................................................1:22
Digital Meters..................................................................................................................1:25
Exercise 1.1: Ohm’s Law......................................................................... 1:26

CP 1 – Cathodic Protection Tester Course Manual
©NACE International, 2000
02/01/05
Exercise 1.2: Series Circuit....................................................................... 1:27
Exercise 1.3: Parallel Circuit .................................................................... 1:28
Exercise 1.4: Resistor and Instrument Lab............................................... 1:29
Chapter 1 Appendices
Appendix 1–Meter Fuses–Instructions for Replacement
Appendix 2–Color Code for Resistors
Section 2
Chapter 2–Basic Chemistry & Basic Corrosion
Theory
Basic Chemistry.......................................................................................... 2:1
Elements............................................................................................................................ 2:1
Compounds (Molecules).................................................................................................... 2:2
Acidity and Alkalinity (pH)............................................................................................... 2:3
Basic Electrochemistry ............................................................................... 2:5
Oxidation and Reduction................................................................................................... 2:6
Electrochemical Circuits.................................................................................................... 2:8
Corrosion Cell............................................................................................. 2:9
Anode Reactions................................................................................................................ 2:9
Cathode Reactions...........................................................................................................2:10
Use of Voltmeters............................................................................................................2:12
Reference Electrodes (Half-Cells)...................................................................................2:15
Driving Force for Corrosion............................................................................................2:18
Corrosion Rate.......................................................................................... 2:19
Faraday’s Law.................................................................................................................2:19
Polarization......................................................................................................................2:20
Anode/Cathode Ratio ......................................................................................................2:21
Influence of the Environment..........................................................................................2:21
Causes of Corrosion.................................................................................. 2:23
General ............................................................................................................................2:23
Naturally Occurring Corrosion........................................................................................2:23
Experiment 2.1–Metal Electrode Potentials in Tap Water ..............................................2:27
Experiment 2.2–Corrosion-Cell.......................................................................................2:29
Experiment 2.3 Current Direction in the Electrolyte in Corrosion Cells.........................2:35
Chapter 2 Appendices
Appendix 1–Reference Cell Maintenance
Appendix 2–Conversions and Definitions
Appendix 3–Customary Metric Conversions for Units Commonly Used in Corrosion-related
Literature

CP 1 – Cathodic Protection Tester Course Manual
©NACE International, 2000
02/01/05
Section 3
Chapter 3–Underground Corrosion Control
Materials Selection...................................................................................... 3:1
Protective Coatings..................................................................................... 3:1
Underground or Submerged Structures............................................................................. 3:1
Types of Mill Applied Underground Coatings.................................................................. 3:2
Girth Weld and Other Field Coatings................................................................................ 3:3
Electrical Isolation...................................................................................... 3:4
Environmental Control................................................................................ 3:4
Inhibitors............................................................................................................................ 3:5
Adjustment of pH .............................................................................................................. 3:5
Maintenance of Environmental Control ............................................................................ 3:5
Cathodic Protection..................................................................................... 3:6
Theory ............................................................................................................................... 3:6
Definition........................................................................................................................... 3:7
Structures That Can be Cathodically Protected.......................................... 3:8
Galvanic Anode Systems................................................................................................... 3:9
Anodes............................................................................................................................... 3:9
Component Parts of Galvanic Systems............................................................................3:11
Anodes.............................................................................................................................3:11
Specifications of Galvanic Anode Systems.....................................................................3:13
Impressed Current Systems....................................................................... 3:14
Power Sources.................................................................................................................3:15
Limitations of Impressed Current Systems......................................................................3:16
Component Parts of Impressed Current Systems.............................................................3:16
Backfill............................................................................................................................3:18
Power Supply...................................................................................................................3:18
Factors Influencing Operation of Cathodic Protection............................. 3:22
Moisture Content of Soil .................................................................................................3:22
Coating ............................................................................................................................3:22
Soil Texture.....................................................................................................................3:22
Temperature.....................................................................................................................3:23
Oxygen Content...............................................................................................................3:23
Movement of Structure and Electrolyte...........................................................................3:23
Make up of the Electrolyte ..............................................................................................3:24
Electrical Shielding..........................................................................................................3:24
Criteria for Cathodic Protection................................................................ 3:25
NACE International Recommended Criteria...................................................................3:25
Other International Standards..........................................................................................3:32
Experiment 3-1–Demonstrate the Use of Cathodic Protection to Mitigate Local Action
Cell Corrosion .................................................................................................................3:11
Experiment 3-2–Demonstrate Change in Polarized Potential with Time........................3:25

CP 1 – Cathodic Protection Tester Course Manual
©NACE International, 2000
02/01/05
Section 4
Chapter 4–Safety
Introduction............................................................................................... 4:1
Electrical.................................................................................................... 4:2
Electrical Equipment (Rectifiers) ...................................................................................... 4:2
Cathodic Protection Surveyss............................................................................................ 4:6
HVAC Interference............................................................................................................ 4:7
Hazardous Material.................................................................................. 4:8
Material Safety Data Sheets (MSDS)................................................................................ 4:8
Explosions or Ignitions...................................................................................................... 4:5
Reaction Products.............................................................................................................. 4:9
General Precautions.................................................................................. 4:9
Section 5
Chapter 5–Field Measurements
Other Portable Reference Electrodes................................................................................. 5:1
Typical Applications.......................................................................................................... 5:3
Measuring Current...................................................................................... 5:8
Use of an Ammeter............................................................................................................ 5:8
Shunts..............................................................................................................................5:10
Typical Applications........................................................................................................5:15
Measuring Resistance ............................................................................... 5:22
Typical Measurements.....................................................................................................5:22
Using Ohm’s Law............................................................................................................5:22
Using an Ohmmeter.........................................................................................................5:23
Electrical Continuity................................................................................. 5:24
Electrical Isolation.................................................................................... 5:24
Purpose and Usage...........................................................................................................5:24
Isolation (Insulating) Joints .............................................................................................5:25
Accidental Contacts.........................................................................................................5:25
Testing Resistance Between a Pipe and Casing...............................................................5:26
Measuring Structure Continuity ......................................................................................5:26
Diode Bias................................................................................................. 5:27
Measuring Electrolyte Resistivity............................................................. 5:28
Wenner Four-Pin Method................................................................................................5:28
Soil Box...........................................................................................................................5:30

CP 1 – Cathodic Protection Tester Course Manual
©NACE International, 2000
02/01/05
Resistivity Probe..............................................................................................................5:31
Measuring pH............................................................................................ 5:31
Use of Pipe Locating Devices................................................................... 5:32
Conductive.......................................................................................................................5:33
Inductive..........................................................................................................................5:34
Use of Current Interrupters....................................................................... 5:35
Coupon Measurements.............................................................................. 5:35
Section 6
Chapter 6–Stray Current Interference
Definitions................................................................................................... 6:1
Effects......................................................................................................... 6:1
Sources........................................................................................................ 6:1
Types of Stray Current................................................................................ 6:2
Dynamic Stray Current...................................................................................................... 6:2
Steady State Stray Current................................................................................................. 6:2
Identification of Stray Current.................................................................... 6:3
Dynamic Stray Current...................................................................................................... 6:3
Steady State Stray Current................................................................................................. 6:4
Stray Current Corrosion Control................................................................. 6:6
Mitigation Bonds............................................................................................................... 6:6
Mitigation with Cathodic Protection.................................................................................. 6:8
Experiment 6.1 — Demonstration of Cathodic Interference............................................. 6:9
Section 7
Chapter 7–Monitoring Cathodic Protection Effectiveness
and Recordkeeping
Introduction................................................................................................. 7:1
Reasons for Monitoring .............................................................................. 7:1
Monitoring Requirements........................................................................... 7:2
Monitoring Cathodic Protection ................................................................. 7:2
Recordkeeping ............................................................................................ 7:4
Importance of Good Record Keeping......................................................... 7:4
Technical ........................................................................................................................... 7:4
Legal.................................................................................................................................. 7:4
Data Sheets.................................................................................................. 7:4
Date, Time, and Weather................................................................................................... 7:4
Sketches............................................................................................................................. 7:5

CP 1 – Cathodic Protection Tester Course Manual
©NACE International, 2000
02/01/05
Site Conditions .................................................................................................................. 7:5
Legibility ........................................................................................................................... 7:5
Computer Records and Spreadsheets.......................................................... 7:5
Facility Maps and Work Documentation.................................................... 7:5
Section 8
Chapter 8–Installing CP Components
Test Stations................................................................................................ 8:1
General........................................................................................................ 8:1
Location ...................................................................................................... 8:1
Environmental Factors................................................................................ 8:2
Construction Notes...................................................................................... 8:2
Types of Test Stations................................................................................. 8:3
Coupons .................................................................................................... 8:10
Wire Attachment....................................................................................... 8:12
Galvanic (Sacrificial) Anodes................................................................... 8:14
General...................................................................................................... 8:14
Prepackaged Anodes................................................................................. 8:15
Non Packaged Anodes.............................................................................8:17
Ribbon or Strip Anodes ............................................................................ 8:17
Bracelet Anodes........................................................................................ 8:17
Offshore Anodes....................................................................................... 8:18
Impressed Current Groundbeds ................................................................ 8:19
General...................................................................................................... 8:19
Handling and Inspection of Anodes and Cable........................................8:20
Surface Groundbed Configurations .......................................................... 8:22
Deep Anode Groundbed Configuration.................................................... 8:26
Negative Circuit........................................................................................ 8:28
Installation of Rectifiers or Other Power Sources .................................... 8:29
General...................................................................................................... 8:29
Rectifiers................................................................................................... 8:29
DC Output................................................................................................. 8:30
Section 9
Chapter 9–Troubleshooting
Introduction................................................................................................. 9:1
Electrical Isolation...................................................................................... 9:1
General .............................................................................................................................. 9:1
Testing a Pipeline ..............................................................................................................9:2
Casing Shorts..................................................................................................................... 9:4

CP 1 – Cathodic Protection Tester Course Manual
©NACE International, 2000
02/01/05
Isolating Joint Shorts......................................................................................................... 9:6
Cathodic Protection Levels......................................................................... 9:7
Groundbed Malfunctions............................................................................ 9:8
Galvanic and Impressed Current Groundbeds................................................................... 9:8
Rectifiers..................................................................................................... 9:9
Routine Maintenance......................................................................................................... 9:9
Output Problems..............................................................................................................9:10
Section 10
Appendices
Glossary of Terms
Ansuini, Frank J., James R. Dimond, “Factors Affecting the Accuracy of Reference
Electrodes”, MP, 33, 11 (1994): pp. 14-17.
RP0169 “Control of External Corrosion on Underground or Submerged
Metallic Piping Systems”
RP0285 “Corrosion Control of Underground Storage Tank Systems by
Cathodic Protection”
RP0176 “Corrosion Control of Steel Fixed Offshore Platforms Associated
with Petroleum Production”
RP0388 “Impressed Current Cathodic Protection of Internal Submerged
Surfaces of Steel Water Storage Tanks”
RP0177 “Mitigation of Alternating Current and Lightning Effects on Metallic Structures
and Corrosion Control Systems”
RP0575 “Internal Cathodic Protection Systems in Oil Treating Vessels”
RP0193 “External Cathodic Protection of On-Grade Metallic Storage Tank Bottoms”
RP0196 “Galvanic Anode Cathodic Protection of Internal Submerged Surfaces of Steel
Water Storage Tanks”
RP0290 “Cathodic Protection of Reinforcing Steel in Atmospherically Exposed
Structures”