DEPARTMENT OF THE ARMY

U.S. Army Corps of Engineers

Washington, DC 20314-1000

CEMP-ET
Technical Letter
No. 1110-9-10

ETL 1110-9-10

5 January 1991

Engineering and Design

CATHODIC PROTECTION SYSTEM USING CERAMIC ANODES

Distribution Restriction Statement

Approved for public release; distribution is unlimited.

ETL 1110-9-10(FR)
CEMP-ET

DEPARTMENT OF THE ARMY

U.S. Army Corps of Engineers
Washington, D.C. 20314-1000

Engineer Technical
Letter 1110-9-10(FR)

5 January 1991

Engineering and Design

CATHODIC PROTECTION SYSTEM USING CERAMIC ANODES
1.
Purpose:
This letter provides criteria for the design of
impressed current cathodic protection systems using ceramic anodes.
The enclosure to this letter is the revised appendix E of TM 5-8117:
Electrical Design, Cathodic Protection.
2.
Applicability: This letter applies to all HQUSACE/OCE elements
and all Major Subordinate Commands (MSC) and District Commands (DC)
having Army military design and construction responsibility.
3.
Discussion: Development in ceramic anodes technology and the
recent years of experience with ceramic anodes indicate that
ceramic anodes can be used for general application. A wide variety
of ceramic anodes are manufactured to satisfy various needs in the
field of cathodic protection. The CEGS 16641 "Cathodic Protection
Systems for Steel Water Tanks" and CEGS 16642 "Cathodic Protection
Systems (Impressed Current)" permit the use of precious mixed metal
oxide anodes but no design guidance is provided in TM 5-811-7 for
the use of conductive ceramic coated titanium or mixed metal
anodes. The enclosed design procedures will assist in design using
these anodes.
4.
Action to be taken: Where the application of an impressed
cathodic protection system is required, the use of ceramic anodes
should be considered. Where ceramic anode application has been the
chosen type of cathodic protection, the enclosed design manual
shall be used in the preparation of final design documents.
5.
Implementation: This letter will have special application as
defined in paragraph 6c, ER 1110-345-100.
FOR THE DIRECTOR OF MILITARY PROGRAMS:

Encl

RICHARD C. ARMSTRONG
Chief, Engineering Division
Directorate of Military Programs

ETL 1110-9-10(FR)
5 Jan 91
IMPRESSED CURRENT CATHODIC PROTECTION SYSTEMS
USING CERAMIC ANODES
TABLE OF CONTENTS
Page
SECTION 1
1-1
1-2
1-3
SECTION 2

BASIS OF IMPRESSED CURRENT CATHODIC

PROTECTION DESIGN
Introduction
. . . . . . . . . . . . . . . . .
Cathodic Protection Design Using
Ceramic Anodes
. . . . . . . . . . . . . . . .
References

. . . . . . . . . . . . . . . . . .

4
4
15

EXAMPLES OF IMPRESSED CURRENT CATHODIC

PROTECTION DESIGN

2-1

Purpose

2-2

Steel Fuel Oil Lines

2-3

Underground Storage Tanks (UST's)

2-4

On-Grade Tank Bottoms

2-5

Gas Distribution System

2-6

Elevated Water Tank (Ice Is Expected)

. . . . .

70

2-7

Elevated Water Tank (No Icing

Will Occur) . . . . . . . . . . . . . . . . . .

78

On-Grade Water Storage Reservoir (Ice

Is Expected)
. . . . . . . . . . . . . . . . .

104

Horizontal Anodes (Underground

Applications) . . . . . . . . . . . . . . . . .

113

Backfilling Packaged Anodes With

Coke Breeze . . . . . . . . . . . . . . . . . .

116

2-8
2-9
2-10

SECTION 3: Tables

. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . .

18

. . . . . . .

31

. . . . . . . . . . . . .

39

. . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . .

SECTION 4: Identification of Variables

1

18

. . . . . . . . . .

58

117
128

ETL 1110-9-10(FR)
5 Jan 91
List of Figures
Page
2-1A

Cathodic Protection System for Fuel Oil Line

With Anode Bed Extended Perpendicular From
Pipeline

19

Cathodic Protection System for Fuel Oil Line

With Anode Bed Installed Parallel to Pipeline

20

Vertical Groundbed Layout Using Prepackaged

Ceramic Rod Anode

21

Prepackaged Ceramic Rod Anode for Underground

Use

22

2-4

Ceramic Anode Canister Prepackaged Rod

23

2-5

Cathodic Protection for Underground Storage

Tanks and Piping

33

2-6

On-Grade Tank Bottoms

41

2-7

Typical Deep Anode Groundbed Using Rod Angles

42

2-7A

Ceramic Rod Anode for Deep Groundbed Use

43

2-8

Ceramic Anode Tubular Power Rod Used In Deep

Anode Bed

44

2-8A

Ductile Ceramic Anode Tubular Power Rod

45

2-9A

Deep Anode Groundbed Resistance 25 to 50 ft.

48

2-9B

Deep Anode Groundbed Resistance 50 to 100 ft.

49

2-9C

Deep Anode Groundbed Resistance 100 to 150 ft.

50

2-10

Pole-Mounted Rectifier

57

2-11

Deep Anode Cathodic Protection for Gas

Distribution System

60

Typical Deep Anode Groundbed Using Tubular

Anodes

68

Ceramic Anode Tubular Power Rod Used

in Deep Anode Bed

69

2-1B
2-2
2-3

2-12
2-13

ETL 1110-9-10(FR)
5 Jan 91
2-14

Elevated Pedestal Tank (Icing Conditions)

With Hoop Ceramic Anode

76

A Pressure Entrance Fitting for Underwater

Power and Reference Cell Wire Penetrations
in Water Storage Tanks

77

Elevated Water Tank Showing Rectifier and

Anode Arrangement

80

2-16

Segmented Elevated Tank for Area Calculations

81

2-17

Equivalent Diameter Factor for Anodes in a

Circle in a Water Tank

86

2-18

Fringe Factor for Stub Anodes

87

2-19

Anode Spacing for Elevated Steel Water Tanks

89

2-20

Anode Suspension Arrangement for Elevated Steel

Water Tank

90

2-14A

2-15

2-21

2-22
2-23
2-24

Water Tank Hand Role Assembly for Roof-Supported

Anodes and Support Bracket for Submerged
Hoop Anodes

103

Submerged Cathodic Protection System for GroundLevel Water Storage Reservoir

105

Details of Wire-type Anode System Designed To

Withstand Icing conditions Within Tank

112

Horizontal Prepackaged Ceramic Anode Groundbed

114

ETL 1110-9-10(FR)
5 Jan 91
CATHODIC PROTECTION DESIGN
1-1.

Introduction.

Recently, ceramic coated anodes have been incorporated in

cathodic protection systems. Ceramic or metal-oxide anodes have
been used for cathodic protection since 1971 in Europe and since
1984 in the United States. One of the main advantage of ceramic
anodes are that they are not consumed.
Ceramic anodes consist of various shapes of high purity titanium
substrates with coatings of precious metal oxides tailored to the
environment in which they will be used.
Unlike most other metal oxides (or ceramics), these metal oxides
are conductive. Ceramic anodes are dimensionally stable. The
ceramic coating is already oxidized (corroded).
The current capacity is a function of constituent variables and
is rated by the manufacturers. They have design life
expectancies of up to 20 years at a rated current output. The
life can be extended by a reduction in output current density.
Their life is limited by time and current density. The end of
the ceramic anode life is marked by a chemical change in the
oxide form and a resultant loss in conductivity. Ceramic anodes
are made in a variety of shapes for various applications. Among
these are wire, rods, tubes, strips, discs, and mesh. Ceramic
anodes have excellent ductility, which has eliminated the concern
about mechanical damage during shipment and installation.
Ceramic anodes are also a fraction of the size and weight of
traditional anode materials.
Scratches or other minor physical damages to the coating result
in the formation of an inert and nonconductive oxide of the
substrate (titanium) when operated at less than 60 V in fresh
water and underground applications. If they are installed in
salt or brackish water, the DC design voltage should be limited
to 12 V. The overall function of the anode is not significantly
impaired.
1-2.

Cathodic Protection Design Using Ceramic Anodes.

The following steps are involved in designing a cathodic

protection system using ceramic anodes:

ETL 1110-9-10(FR)
5 Jan 91
a.

Collect data.
Design requirements should be established, and certain
assumptions will be made.
1)

History
Information from occupants in the area can indicate
the severity of corrosion problems. Data on failures
and failure rates of nearby structures can be invaluable and must be considered.

2)

Drawings
Drawings of the structure to be protected and the
area where it is or will be installed are needed to
provide the physical dimensions of the structure for
determining surface area to be protected, and
locations of other structures in the area that may
cause interference, of insulating devices, and of
power sources. Information on coatings should be
obtained.

3)

Tests
Current requirement test and potential survey test
results are needed for existing structures that will
be protected. Electrolyte (soil or water) resistivity tests and evaluation of conditions that could
support sulfate-reducing bacteria are needed for all
cathodic protection designs. This information will
indicate the size of the cathodic protection system
that will be required as well as the probability of
stray current problems. Soil resistivities contribute to both design calculations and location of the
anode groundbed.

4)

Life
The user must determine the required number of years
that the structure needs to be protected, or the
designer must assume a nominal life span. The structure will begin to deteriorate from corrosion at the
end of the cathodic protection system's design life
unless the system is rejuvenated.

ETL 1110-9-10(FR)
5 Jan 91
5)

Coatings
Cathodic protection complements the protective coating system. A good coating system substantially
reduces the amount of cathodic protection current
required. The coating efficiency has to be
assumed.

6)

Short circuits
All short circuits must be eliminated from both new
and existing structures for which a cathodic
protection system is being designed.

b.

Calculate surface area to be protected.

The overall current requirement of a cathodic protection
system is directly proportional to the surface area to be
protected. This includes underground or submerged pipes,
buried tanks, and wetted surfaces (up to high
water(level) of watertanks (including risers).

c.

Determine current requirement.

For existing structures, a current requirement test will
provide the actual current requirement at the time of the
test. Allowance should be made in the design for future
degradation of coatings or structure additions that will
increase the current requirement.
For new structures not yet installed, the amount of
current needed to provide protection as defined in National Association of Corrosion Engineers (NACE) RP-0l-69
(reference 22) will be dependent on a number of
variables. Table 3-1 gives guidelines for current
requirements in various soil and water conditions.
The efficiency of the coating
at the end of design life, is
range of current that will be
of the system. Total current
following equation:

system, both when new and

a determining factor in the
required over the lifetime
required is given by the

I = (A)(I')(l.0 - CE)

(eq 1-1)

where I is the total current requirement, A is the total

surface area to be protected, I' is the estimated current
density, and CE is the efficiency of the coating system.
This procedure should always be followed, even when a
6

ETL 1110-9-10(FR)
5 Jan 91
current requirement test has been performed, as a check
on assumptions made. Current density may be estimated
from information given in table 3-1.
d.

Select anode type.

Ceramic anodes are made in a variety of shapes, such as,
wires, rods, tubes, strips, disks, and mesh.
The 0.062-in. diameter anode wire has a 20-year life at a
maximum current rating of 115 mA per linear ft in fresh
water, 285 mA in salt water, and 170 mA in brackish
water. Wire anodes are well suited for applications in
water tanks. They are generally not used underground.
Ceramic rod anodes are manufactured bare for aqueous
environments and prepackaged for installation in soil.
Ceramic rod anodes are produced in diameters of 1/8 in.,
1/4 in., 3/8 in. and in. and in standard lengths of 4,
6, and 8 ft, although almost any length can be custom
fabricated with self-healing screw connections for field
assembly to the desired length, or with permanent,
factory-molded, cable-to-anode connections. For
underground applications, rods are frequently packaged in
2- or 3-in. diameter steel tubes filled with a high
carbon, low resistivity coke breeze. Their small size
and high current capacity make rods particularly well
suited for both underground shallow and deep anode
systems. For marine applications, the rod anode is often
encased in a perforated PVC package that provides
mechanical protection and prevents the possibility of the
anode contacting the protected structure. They are used
in a similar manner as high silicon cast iron and
graphite anodes.
For long ceramic anode wires and rods, the voltage drop
in the titanium substrate must be considered. While
titanium is a relatively good metallic conductor, its
resistance is approximately 33 times that of copper. The
maximum length for solid titanium wire and rod anode
applications to assure that uniform discharge of current
is achieved in several different environments is provided
below:
Maximum Anode Length From Connection Point
Solid Titanium Anodes
Anode Diameter

0.062 in. 0.125 in. 0.250 in.

7

ETL 1110-9-10(FR)
5 Jan 91
ENVIRONMENT

LENGTH (ft)

Sea Water
Coke Breeze
Fresh Water

3
6
30

5
10
50

9
20
100

Where a specific design requires longer length anodes than

provided for in the above table, the titanium wire or rod
can be provided with a copper core to reduce the effective
resistance. This type of construction has been in use for
over 15 years and has proved to be very durable.
The
titanium wall thickness should be a minimum of 20 percent of
the wire or rod diameter (e.g., for 0.062-in. diameter wire,
the titanium wall thickness should be 0.0124 in., minimum)
The maximum allowable length for copper-core titanium wire
and rod anodes is provided in the table below:
Maximum Anode Length From Connection Point
Copper Cored Titanium Anodes
Anode Diameter

0.062 in.

ENVIRONMENT

0.125 in.

0.250 in.

LENGTH (ft)

Sea Water
Coke Breeze
Fresh Water

7
12
70

12
24
135

24
54
300

A strip anode is presently manufactured as a 3- or 7-ft bar

of ceramic-coated substrate, molded into a multilayer
composite of
fiberglass-reinforced plastic
(FRP)
and
polyurethane 4 or 8 ft long and 4 in. wide that provides
impact resistance,
mechanical support,
and electrical
insulation.
A mesh anode is produced using highly expanded titanium
sheet metal and is used where a large area is to be
protected, where area for anode placement is confined, and
where future access is not practicable. Its use under a
structure's base such as an on-grade tank bottom with
secondary membrane containment or select reinforced
concrete bridges, wharfs, etc., would be appropriate.
Because of its size and the nature of its application, mesh
is generally restricted to use in new facilities.

ETL 1110-9-10(FR)
5 Jan 91
e. Calculate number of anodes (N) or length of bare anode wire
(LB).
1)

For required design life

Since ceramic anodes are not consumed during their
life, the quantity of ceramic material beyond that
required to form a coating is not relevant. The number
of
anodes
or
length of
anode wire required
is
determined from the total current required and the
manufacturer's published current rating for a given
life. For rod, strip, tube and disk anodes:
Number of anodes required =
Total current required
Manufacturers rated
current for specific
size, environment and life.

2)

(eq l-2a)

For wire anodes:

Total footage of anode =
Total current requirement
Manufacturers rated current
capacity per foot of wire
for a given environment and
life.

(eq l-2b)

The number calculated will determine the minimum number

of anodes or anode wire length required.
f. Calculate the total circuit resistance (RT).
The total circuit resistance (RT) consists of the anode-toelectrolyte resistance (RN) plus the interconnecting wire
resistance (RW) plus the structure-to-electrolyte resistance
(RC).
RT = RN + Rw + RC

(eq 1-3)

A criterion of 2-ohm maximum groundbed resistance is often

used to limit the rectifier output voltage and the associated hazards of overprotection. When the total required
current is low, a higher total resistance is often
9

ETL 1110-9-10(FR)
5 Jan 91
acceptable. As the required current increases, the total
resistance should be reduced. See table 3-10.
The total anode-to-electrolyte resistance (RN)
is
calculated in different ways according to the type of anode
installation. The anode-to-electrolyte resistance for a
single anode is given by RA.
For a single vertical anode:
RA =

(0.0052)

p
(L)

[ln (8L/d)-1]

(eq 1-4)

Where
RA is the anode-to-electrolyte resistance for a
single anode, p is the electrolyte resistivity in ohm-cm,
L is the length of the backfill column in feet, and d is
the diameter of the backfill column in feet.
It should be noted that the anode dimensions are the overall length and diameter including backfill, if the backfill
is coke breeze and is not significantly more than 2 ft
longer than the anode or not significantly more than 20 ft
longer than the anode column in a deep vertical groundbed
configuration.
For earth backfill, the backfill column
dimensions should be the dimensions of the manufacturer's
standard packaged anode can. Bare ceramic anodes shall not
be installed in ground without coke breeze backfill. Coke
breeze allows venting of gases and effectively reduces RA.
If vertical anode dimensions are assumed to be 6 in. in
diameter and 8 ft in length, the following empirical
relations may be used:
RA =

(eq 1-5)

p
398

If the anode dimensions are different, a different empirical relation may be used:
RA =

(eq 1-6)

p K
L

where RA is the anode-to-electrolyte resistance, p is the

electrolyte resistivity in ohm-cm, L is the length of the
backfill column in feet, and K is a shape function that is
selected from table 3-4.

10

ETL 1110-9-10(FR)
5 Jan 91
Deep anode groundbed resistance graphs are available for
deep vertical ground beds. (See figure 2-9a through 2-9c
located in section 2-4.)
For a single horizontal anode:
RA '

(0.0052) p
4L 2 % 4L (2h)2 % L 2
[1n
L
2 d h
%

(eq 1-7)

(2 h)2 % L 2
& 1]
L

2 h
&
L

where RA is the anode-to-electrolyte resistance in ohms, p

is the electrolyte resistivity in ohm-cm, L is the length
of the backfill cylinder in feet, d is the diameter of the
backfill cylinder in feet, and h is the depth of the
backfill cylinder in feet.
If the horizontal anode dimensions are assumed to be 6 in.
in diameter, 8 ft long, and buried 6 ft below the surface,
the following empirical expression may be used.
RA =

p
441

(eq 1-8)

where RA is the anode-to-electrolyte resistance in ohms and

p is the electrolyte resistivity in ohm-cm.
For multiple vertical anodes:
RN =

(0.0052) p
N L
+

2 L
Cc

[(ln (8L/d) -1)

ln (.656 N))

(eq 1-9)

where RN is the anode-to-electrolyte resistance, p is the

electrolyte resistivity in ohm-cm, N is the number of
anodes, L is the length of the backfill column in feet, d
is the diameter of the backfill column in feet, and Cc is
the center-to-center spacing of the anodes in feet. This
equation assumes a linear configuration of the groundbed
anodes.
If the number of anodes used does not produce a low enough
anode-to-electrolyte resistance, the number of anodes will
have to be increased accordingly.
11

ETL 1110-9-10(FR)
5 Jan 91
For optimum results, the length of the backfill column (L)
should be less than the anode spacing (Cc).
If multiple anodes are assumed to be 6 in. in diameter and
8 ft long, the following empirical expression may be used:
p FADJ

RN '

398

(eq 1-10)

where RN is the anode-to-electrolyte resistance in ohms, p

is the electrolyte resistivity in ohm-cm and FADJ is
selected from table 3-9, which compensates both for the
number and spacing of the anodes, which will be connected
together as one groundbed.
If the anode dimensions are different, another empirical
expression may be used:

RN '

RA

p PF

Cc

(eq 1-11)

where RN is the anode-to-electrolyte resistance, RA is the

anode-to-electrolyte resistance for a single anode, p is
the soil resistivity in ohm-cm, N is the number of anodes
used, PF is a paralleling factor selected from table 3-5,
and Cc is the center-to-center spacing of anodes in feet.
This equation assumes a linear configuration of the
groundbed anodes.
For multiple horizontal anodes:

RN '

p FADJ
441

(eq 1-12)

where p is the electrolyte resistivity in ohm-cm and FADJ is

an adj3sting factor for groups of anodes selected from
table 3-9.
For a circle of rod anodes (as in a water storage tank):
where RN is the anode-to-electrolyte resistance, p is the
electrolyte resistivity in ohm-cm, LB is the length of each
12

ETL 1110-9-10(FR)
5 Jan 91

RN '

0.0052 x p x 1n [D/2 AR x DE)]

LB

(eq 1-13)

rod anode in feet, D is the tank diameter in feet, AR is the

radius of the anode circle in feet, and DE is an equivalent
diameter factor from figure 2-17.
For wire anode circle or hoop (in a water storage tanks):

RN '

8DR
2 DR
0.0016 p
(1n
% 1n
)
DR
DA
H

(eq 1-14)

where RA is the anode-to-electrolyte resistance, p is the

electrolyte resistivity, DR is the diameter of the anode
circle in feet, DA is the diameter of the anode wire in
feet, and H is the depth below the high water level in
feet.
Experience has shown that the diameter of the anode wire
circle (D) should be typically between 40 and 70 percent of
the tank diameter.
Wire resistance (RW) is the sum of both the rectifier-toanode lead and the rectifier-to-protected-structure lead.

RW '

L W RMFT
100 ft

(eq 1-15)

where LW is the length of wire in thousands of feet and

RMFT is the resistance of the wire in ohms per 1000 ft.
The structure-to-electrolyte resistance (RC) is dependent
primarily on the condition of the coating.
Rc '

RS
A

13

(eq 1-16)

ETL 1110-9-10(FR)
5 Jan 91
where RS is the coating resistance in ohm-square feet and
A is the total surface area. If the structure surface is
bare, negligible resistance is assumed (RC = 0).
g.

Calculate required rectifier voltage and current.

The required rectifier voltage (VREC and maximum current
rating should include at least an extra 20 percent to allow
for variations in calculations from actual conditions and
for changes in the system over the system's life.
VREC = (I) (RT) (1.2)

(eq 1-17)

where I is the total current required and RT is the total

circuit resistance as calculated above.
IREC = (I) (1.2)

(eq 1-18)

where I is the total current required and IREC is the

minimum current rating for a rectifier for this particular
application.
Select a rectifier with DC voltage and current capacity of
a slightly larger size (as calculated above) from the
cathodic protection rectifier manufacturer's published
literature.
h.

Prepare life cycle cost analysis.

The life cycle cost analysis should be prepared according
to the guidelines given in TM 5-802-1 (reference 9).
Another source of information on performing life cycle cost
analyses is NACE RP-02-72 (reference 21). The choice of a
particular anode type and configuration for design
calculation is somewhat arbitrary.
The economics may
dictate switching to a different design configuration and
repeating the applicable design steps.

i.

Prepare plans and specifications.

Prepare plans that show the protected structure, locations
of anodes, rectifier, test stations, and power source, wire
routing, and details of wire-to-structure connections,
building or structure penetrations, wire color coding,
potential survey test points in paved areas, and other
pertinent information. Prepare a one-line diagram to show
the entire system including wire sizes, anode type(s),
power circuit, power circuit protection, and source of
14

ETL 1110-9-10(FR)
5 Jan 91
power. Prepare specifications to describe required features
of the system components.
1-3.

References.

The following documents describe corrosion fundamentals, traditional corrosion control techniques, and particular requirements of
U.S. Department of Defense agencies:
1.

Bryan, William T., ed., Designing Impressed Current Cathodic

Protection Systems With Durco Anodes (The Duriron Company,
Dayton, OH, 1970).

2.

Burke, N. Dennis, and David H. Kroon, Corrosion and Corrosion

Control, Liberty Bell Short Course (Philadelphia Section of
the
National
Association
of
Corrosion
Engineers,
Philadelphia).

3.

Bushman, James B., Corrosion Control and Cathodic Protection

Training Manual (Steel Tank Institute, Lake Zurich, IL,
March 1988).

4.

Bushman, James B., Cathodic Protection of Underground Storage

Tanks and Piping, Paper delivered to the National
Association of Corrosion Engineers North Central Regional
Conference (Chicago, 1988).

5.

Bushman, James B., and David H. Kroon, "Cathodic Protection of

Water Storage Tanks," Journal of the American Water Works
Association (Denver, 1984).

6.

Davy, Humphrey, "The Beginnings of Cathodic Protection," The

Philosophical Transactions of the Royal Society (London,
1824).

7.

Department of the Air Force, Civil Engineering Corrosion

Control - Cathodic Protection Design, Air Force Manual
88-45 (Headquarters, U.S. Air Force, Washington D.C.,
1988).

8.

Department of the Air Force, Maintenance and Operation of

Cathodic Protection Systems, Air Force Manual 85-5
(Headquarters, U.S. Air Force, 1985).

9.

Department of the Army, Economic Studies of Military Construction Design - Application, TM 5-802-1 (Headquarters,
Department of the Army, Washington D.C., 31 December 1988).
15

ETL 1110-9-10(FR)
5 Jan 91
10. Department of the Army, Electrical Design, Cathodic Protection,
TM 5-811-7 (Headquarters, Department of the Army, 22 April
1985).
11. Dwight, H.B.,
"Calculation of Resistance to Ground," AIEE
Transactions, vol. 55 (1939).
12. Electrical Engineering Cathodic Protection, Military Handbook
1004/10 (31 January 1990).
13. Fontana, Mars G., Corrosion Engineering, 3d ed. (McGraw Hill,
Inc., New York, 1986).
14. Hock, V., J. Givens, J. Suarez, and J. Rigsbee, "Structure,
Chemistry and Properties of Mixed Metal Oxide," Paper No.
230, Proceedings of the National Association of Corrosion
Engineers (1988).
15. Kumar, A., and M. Armstrong, "Cathodic Protection Designs Using
Ceramic Anodes," Materials Performance, vol. 27, No. 10
(Oct 1988), pp. 19-23.
16. Kumar, A., and M. Armstrong, "New Cathodic Protection Designs
Using Ceramic Anodes," Materials Performance, vol. 27, No.
10 (Oct 1988), pp. 19-23.
17. Kumar, A, and V. Hock, "Survey of Cathodic Protection Systems
Using Ceramic Coated Anodes," Paper No. 284, Proceedings of
the National Association of Corrosion Engineers (1989).
18. Morgan, John, Cathodic Protection, 2d ed., National Association
of Corrosion Engineers (Houston, 1987).
19. Myers, James R., Fundamentals and Forms of Corrosion (Air Force
Institute of Technology, October 1974).
20. Myers, J.R., and M.A. Aimone, Corrosion Control for Underground
Steel Pipelines: A Treatise on Cathodic Protection (July
1980).
21. NACE RP-02-72, "Recommended Practice - Direct Calculation of
Economic
Appraisals
of
Corrosion
Control
Measures"
(National Association of Corrosion Engineers, Houston,
1972).
22. NACE RP-0l-69,
"Recommended Practice - Control of External
Corrosion on Underground or
Submerged Metallic
Piping
Systems" (National Association of Corrosion Engineers,
Houston, 1969)
16

ETL 1110-9-10(FR)
5 Jan 91
23. NACE RP-02-85, "Recommended Practice - Control of External Corrosion on Metallic Buried, Partially Buried ,or Submerged
Liquid Storage Systems" (National Association of Corrosion
Engineers, Houston, 1985).
24. Paullin, Robert L., Pipeline Corrosion Protection: A Department
of Transportation Perspective (Materials Transportation
Bureau of the U.S. Department of Transportation, Washington
D.C., 1984).
25. Peabody, A.W., Control of Pipeline Corrosion (National Association of Corrosion Engineers, Houston, 1967).
26. Reding,
J.T., Performance of Mixed Metal Oxide Activated
Titanium
Anodes
(National
Association
of
Corrosion
Engineers, Houston, 1987).
27. Sunde, Earling D., Earth Conduction Effects in Transmission
Systems (D. VanNostrand Co., New York, 1949).
28. Treseder,
R.S.,
NACE Corrosion Engineer's Reference Book
(National Association of Corrosion Engineers, Houston,
1980).
29. Turner, Jane M., "Controlling Galvanic Corrosion in Soil With
Cathodic Protection," Gas Industries Magazine (Park Ridge,
IL, 1988).
30. Uhling, Herbert H., The Corrosion Handbook (John Wiley & Sons,
New York, 1948).
31. Uhling, Herbert H., and R. Winston Revie, Corrosion and
Corrosion Control: An Introduction to Corrosion Science and
Engineering, 3d ed. (John Wiley & Sons, New York, 1985).
32. West,
Lewis H.,
and Thomas F. Lewicki, Civil Engineering
Corrosion Control, Vol. 1: Corrosion Control - General;
Vol.
II:
Cathodic
Protection
Testing
Methods
and
Instruments; Vol. III: Cathodic Protection Design (Air
Force Civil Engineering Center, Tyndal Air Force Base, FL).

17

ETL 1110-9-10(FR)
5 Jan 91
EXAMPLES OF IMPRESSED CURRENT
CATHODIC PROTECTION DESIGN
2-1.

Purpose.

The following examples show the use of design procedures explained

in the previous section:
2-2
2-3
2-4
2-5
2-6
2-7
2-8
2-2.

Steel fuel oil lines

Underground storage tanks
On-grade tank bottoms
Gas distribution systems
Elevated water tanks (ice is expected)
Elevated water tanks (no icing will occur)
On-grade water storage reservoir (ice is expected)

Steel Fuel Oil Lines.

Impressed current cathodic protection is desired for the 6-in.

welded fuel oil line shown in figures 2-1A and 2-lB. Since this
pipeline is in existence, current requirement tests have already
been made. There are no other underground structures in the area,
so a surface point groundbed is chosen. Figure 2-2 illustrates a
surface point groundbed anode system using prepackaged ceramic rod
anodes. These prepackaged ceramic rod anodes are further detailed
in figures 2-3 and 2-4.
a. Design data.
1)

Soil resistivity in area where groundbed is desired is

2000 ohm-cm.

2)

Pipe has 6-in. diameter

in.)

3)

Pipe length is 6800 ft.

4)

Design life for cathodic protection anodes is 15 years

since the structure will no longer be needed after that
time.

5)

Design current density is 2-mA per sq ft of bare pipe.

6)

The pipe is coated with hot-applied coal-tar enamel.

7)

90 percent coating efficiency based

experience with this type coating.
18

(outside diameter

on

6.625

previous

ETL 1110-9-10(FR)
5 Jan 91

19

ETL 1110-9-10(FR)
5 Jan 91

20

ETL 1110-9-10(FR)
5 Jan 91

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ETL 1110-9-10(FR)
5 Jan 91

22

ETL 1110-9-10(FR)
5 Jan 91

23

ETL 1110-9-10(FR)
5 Jan 91
8)

Effective coating resistance at 15 years is estimated

at 2500 ohm-sq ft.

9)

The pipeline is isolated from the pumphouse and tank

with insulating joints.

10) For this example, we have decided that the cathodic

protection system circuit resistance should not exceed
2.5 ohms.
11) Electric power is available at 120/240 V single phase
AC from a nearby overhead distribution system.
12) Current requirement testing indicates that 2.8 amp are
needed for adequate cathodic protection.
b. Computations.
1)

2)

Calculate the external surface area of the pipe.

Pipe diameter

6 in.

Pipe length

6800 ft

Pipe surface
area per lin ft

1.734 sq ft/lin ft (from

table 3-2)

External pipe
surface area

6800 lin ft x 1.734 sq

ft/lin ft = 11,791 sq ft

Check the current requirement (I) using equation 1-1:

I = (A)(I')(l.0-CE)
Where:
A

11,791 sq ft - External pipe surface

area from previous calculation.

I'

2 mA/sq ft - Required current density

from item 5 of paragraph 2-2a.

CE

0.90- Coating efficiency expressed in

decimal form from item 7 of paragraph
2-2a.

11,791 sq ft x 2 mA/sq ft x (1.0 0.90)

24

ETL 1110-9-10(FR)
5 Jan 91
I

2358 mA or approximately 2.4 amp

which agrees well with the current requirement test

data provided in item 12 of paragraph 2-2a.
3)

Select an anode and calculate the number of anodes

required (N) to meet the design life requirements. Two
sizes are selected for trial calculations using
equation 1-2:
N =

I
IA

Where:
I

IA

2.8 amp (Current requirement from item

12 of paragraph 2-2a)
Current rating per anode, varies depending on anode size from table 3-3.

Several different size anodes could be chosen.

Experience has shown that for this type of groundbed,
60-in. long anode packages are desirable.
For a 3-in. by 60-in. packaged canisters with a 1/8-in.
by 48-in. ceramic anode rod, IA = 1.2 amp/anode (from
table 3-3 for 15-year design life).
N =

2.8
1.2

= 2.33; use 3 anodes.

For a 3-in. by 60-in. packaged canister with a 1/4-in.

by 48-in. ceramic anode rod, IA = 2.4 amp/anode (from
table 3-3 for a 15-year design life).
N =
4)

2.8
2.4

= 1.17; use 2 anodes.

Calculate the resistance of a single anode-to-earth (RA)

from equation 1-6:
RA =
Where:
p =

p K
L

2000 ohm-cm (Soil resistivity in area

where groundbed is desired from item 1
of paragraph 2-2a)
25

ETL 1110-9-10(FR)
5 Jan 91

5)

0.0213 (Shape function, from table 3-4

[where: L/d = 60 in./3 in. = 20])

5 ft (Effective anode length [canister

length))

3 in. (Anode backfill diameter [canister diameter])

RA =

2000 x 0.0213
5

RA

8.53 ohms

Calculate the number of anodes required to meet maximum

anode groundbed-to-earth resistance requirements from
equation 1-11:
RN '

Where:
RN =

RA

p PF
Cc

Groundbed-to-earth resistance.

RA

8.53 ohms
(Resistance of a single
anode-to-earth
from
the
previous
calculation)

Assume 5 anodes (discussed below)

2000 ohm-cm (Soil resistivity)

PF

0.00268 (Paralleling factor from table

3-5 [discussed below])

CC

20 ft
(Center-to-center spacing of
anodes [discussed below])

To determine PF, a figure for N must be assumed. This

paralleling factor compensates for mutual interference
between anodes and is dependent on spacing. From the
law of parallel circuits, it appears that five anodes
might give the desired circuit resistance of 2.0 ohms
maximum, i.e.:
8.53 ohms/anode
5 anodes

= 1.706 ohms
26

ETL 1110-9-10(FR)
5 Jan 91
This is the approximate resistance based on the law for
parallel circuits. (When equal resistance values are
joined together in a parallel circuit, the total resistance value of the circuit is approximately equal to a
single resistance value divided by the number of resistance values.)
To calculate the true anode resistance for five anodes,
we must perform the calculation from equation 1-11.
CC

20 ft (The spacing must be chosen

based on previous experience to solve
the equation.)
The spacing can
typically be from 10 to 50 ft.
For
this example, we will try 20 ft:

RN

8.53
5

RN

1.706 + 0.268

RN

1.974 ohms

2000 x 0.00268
20

This is within specification, but very close to

exceeding maximum specified circuit resistance.
Try
six anodes to allow for variations in soil resistivity
and to allow for wire and pipe-to-earth resistance.
Repeat calculation from equation 1-li,
Where:
N

6 anodes

PF

0.00252, paralleling factor from table

3-5

RN

RN

8.53

+
20

2000 x 0.00252

1.67 ohms

6)

Based on the previous selection of six anodes for the

number of anodes to be used,
the total circuit
resistance must be determined.

7)

Select an area for anode bed placement.

Here, the
selected area is 100 ft from the pipeline for improved
current distribution. The anode bed location for this
type design must be far enough away from the structure
27

ETL 1110-9-10(FR)
5 Jan 91
to be protected to assure uniform distribution of the
protective current to all structure components. The
higher the soil or water resistivity, the further away
the ground must be located. For this example, previous
experience has shown that the nearest anode should be
located a minimum of 100 ft from the structure to
assure good current distribution. Since there are no
other underground utilities in the area, the groundbed
may be installed either perpendicular or parallel to
the pipe (figures 2-IA and 2-lB).
8)

Determine the
equation 1-3:

total

circuit

resistance

(RT)

from

RT = RN + RW + RC
Where:
RN =
RW =
RC =
a)

Groundbed resistance-to-earth (ohms)

Header cable and resistance (ohms)
Pipe-to-earth resistance (ohms)

Groundbed-to-earth resistance (RN) from step 5.

RN

1.67 ohms

Specify anodes with individual lead wires of

sufficient length so that each anode wire can be
run directly to the rectifier without splices.
(This is virtually always true for anode bed
designs where the individual lead wire lengths
required do not exceed an average of 400 ft.)
b)

Anode lead wire resistance from equation 1-15:

c
RW '

Where:
LAVG =

1000 ft

Total of each actual lead wire

lengths/number of anodes
(140 ft + 120 ft + 100 ft + 80
ft + 60 ft + 40 ft)/6 anodes
90 ft per anode

=
=
=

LAVG/N
90/6
15 ft

LW

LW RMFT

28

ETL 1110-9-10(FR)
5 Jan 91

c)

Average anode lead wire length/

number of anodes. This is based
on the circuit resistance for 6
anode lead wires in parallel.

RMFT

2.58 ohms - Resistance for No.

14 AWG cable which has been
selected from table A-6.

RW

15 ft x 2.58 ohms
1000 ft

RW

0.039 ohms

Pipe-to-earth resistance (RC) from equation 1-16:

RS

Rc '

Where:

d)

e)

RS

2500 ohm-sq ft - Effective

coating resistance from item 8
of paragraph 2-2a.

11,791
sq
ft
External
pipe surface area calculated in
step 1 of paragraph 2-2b.

RC

2500 ohm-sq ft
11,791 sq ft

RC

0.212 ohm

Calculate the
equation 1-3:

total

circuit

resistance

RT

RN + RW + RC

RT

1.67 + 0.039 + 0.212

RT

1.921 ohms

(RT)

from

Since the design requirements call for a maximum

allowable groundbed resistance of 2.0 ohms and RT =
1.921 ohms, the design using six (3-in x 5-ft) ceramic
anode canisters will work.
29

ETL 1110-9-10(FR)
5 Jan 91
9)

Calculate the rectifier voltage (VREC) from equation

1-17:
VREC = (I) (RT) (120%)
Where:
I

c.

2.8 amps (Current requirement

from item 12 of paragraph 2-2a.

RT

1.92
ohms
resistance
calculation.

(Total
from

circuit
previous

120%

Rectifier
voltage
design safety factor.

capacity

VREC

2.8 amp x 1.92 ohms x 1.2

VREC

6.45 V

Select rectifier.
Based on the design requirement of 2.8 amperes and 6.45
volts, specify a 10-V, 5-amp rectifier, which is the
nearest standard capacity available from commercial
cathodic protection rectifier manufacturers.

30

ETL 1110-9-10(FR)
5 Jan 91
2-3.

Underground Storage Tanks (USTs).

The service station shown in figure 2-5 has three existing

underground tanks and associated pipe. The quality of the coating
is unknown and it is not feasible to install dielectric insulation
to isolate the UST system.
Because of the anticipated large
current requirement, an impressed current protection system is
chosen.
To distribute the current evenly around the tanks and
piping, and to minimize interference effects on other structures,
a distributed anode surface bed using vertical anodes is selected.
Vertical anodes can be installed with relative ease in holes cored
through the paving around the UST system. Wiring can be installed
several inches below the paving by cutting and hand excavating
narrow slots/trenchs through the paving.
a. Design data.
1)

Soil resistivity is 4500 ohm-cm.

2)

Pipe is 2 in., nominal size.

buried piping is 750 ft.

3)

Tanks are 8000 gal, 96 in. diameter by 21 ft 3 in.

long.

4)

Electrical continuity of tanks and piping has been

assured.

5)

It is not feasible to install dielectric insulation;

system is therefore not isolated electrically from
other structures.

6)

Design cathodic protection anodes for 20-year life.

7)

Coating quality is unknown, assume bare.

8)

The cathodic protection system

should not exceed 2.5 ohms.

9)

Electric power is available at 120 V single phase in

the station building.

10)

Current requirement test indicates that 8.2 amperes

are needed for cathodic protection.

Total length of all

circuit

resistance

b. Computations.
1)

Find the external surface area (A) of the storage

tanks and piping.
31

ETL 1110-9-10(FR)
5 Jan 91
Area of each tank = 2 B (tank radius)2 + B (tank
diameter) (tank length)

32

ETL 1110-9-10(FR)
5 Jan 91

33

ETL 1110-9-10(FR)
5 Jan 91
Area of 3 tanks = 3 [2 x 3.14 x 42 +3.14 x 8 x 21.25]
= 1905 sq ft
Area per lin ft of 2-in. pipe = 0.621 sq ft/ft (from
table A-2)
Total pipe area = 750 ft x 0.621 sq ft/ft = 466 sq ft
Total area = 1905 sq ft + 466 sq ft = 2371 sq ft
2)

Check the current requirement (I) using equation 1-1:

I = (A)(I')(1.0-CE)
Where:
A =

2371 sq ft (External tank and piping

surface
area
from
previous
calculation)

I' =

2 mA/sq ft (Required current density

[assumed])

CE

0.00 (Coating efficiency expressed in

decimal form from item 2 of paragraph
2-3a)

2371 sq ft (2 mA/sq ft) x (1.0 - 0.0)

4742 mA or 4.7 amp.

The 4.7 amp would be reasonable for the facility if it

were insulated. The actual current requirement of 8.2
amp occurs because of current loss to other
underground structures and is also reasonable in
relation to that calculated for an isolated facility.
3)

Select an anode and calculate the number of anodes

required (N) to meet the design life requirements.
Calculations can be run on several size anodes, but in
this case 2-in. by 60-in. packaged rod anodes (rod
size = 0.125 in x 4 ft long) are chosen for ease of
construction.
Using equation 1-2, the number of
anodes required to meet the cathodic protection system
design life can be calculated:
N =

I
IA
34

ETL 1110-9-10(FR)
5 Jan 91
Where:
I =

4)

8.2 amp (Current requirement from item

10 of paragraph 2-3a)

IA =

1.0 amps/anode (Current

anode from table 3-3)

8.2
1.0

per

8.2 anodes; use nine, 2-in.

by 60-in. packaged rod
anodes

Calculate the resistance of a single anode-to-earth

(RA) from equation 1-6:
RA =
Where:
P =

p K
L
4500 ohm-cm (Soil resistivity
item 1 of paragraph 2-3a)

from

0.0234 (Shape function from table A-4

[where: L/d = 60 in./2 in. = 30])

5
ft (60
length).

2 in. (Anode/backfill diameter)

RA =
RA
5)

rating

in.)

(Effective

anode

4500 x 0.0234
5
=

21.06 ohms

Calculate the number of anodes required to meet

maximum anode groundbed resistance requirement.
A
distributed anode array does not lend itself to an
exact calculation of equation 1-11 because the anodes
are positioned at various locations and are not
located in a straight line. Equation 1-11 assumes a
straight line configuration. However, to approximate
the total anode-to-earth resistance, equation 1-li may
be used.

35

ETL 1110-9-10(FR)
5 Jan 91

RN '

RA
N

Where:
RN =

p PF
Cc

Groundbed-to-earth resistance

RA

21.06 ohms (Resistance of a single

anode-to-earth
from
the
previous
calculation)
4500 ohm-cm (Soil resistivity from
item 1 of paragraph 2-3a)

CC

10 ft (Estimated approximate spacing

of anodes)

PF

0.00212
(Paralleling
factor
from
table 3-5; assume 9 anodes; reasoning
is the same as in step 5, paragraph
2-2b)

9 anodes (Estimated number of anodes

required; from step 3, paragraph
2-2b)

RN

RN

21.06
9

4500 x 0.00212
10

3.29 ohms.

Resistance is too high. Additional calculations using

an increasing number of anodes (i.e., 11, 12, 13, 14,
etc.) have to be made; these calculations show that
fourteen
anodes will yield
a groundbed-to-earth
resistance of 2.26 ohms.
6)

Select the number of anodes to be used.

determined are:

The numbers

For life = nine anodes maximum required

For resistance = fourteen anodes maximum required
Therefore, the larger number of anodes, fourteen, is
selected.
7)

Determine the
equation 1-3:

total

36

circuit

resistance

(RT)

from

ETL 1110-9-10(FR)
5 Jan 91
RT = RN + RW + RC
Where:
RN = Groundbed resistance (ohms)
RW = Header cable/wire resistance (ohms)
RC = Structure-to-earth resistance (ohms).
a)

Groundbed resistance (RN) from step 5.

RN = 2.26 ohms
b)

Header cable/wire resistance (RW) from equation 115:

RW '

Where:
LW =

RMFT

RW =
RW =
c)

LW RMFT
1000 ft

150 ft (Effective cable length. The loop

circuit makes calculating effective wire
resistance complex.
Since current is
discharged from anodes spaced all along the
cable, one-half the total cable length may
be
used
to
approximate
the
cable
resistance. Total cable length = 300 ft.
Effective cable length = (300 ft) = 150
ft.)
=

0.254 ohm (This is the resistance per

1000 lin ft of No. 4 AWG cable, which
has been
selected for ease of
handling.)
150 ft x 0.254 ohm
1000 ft
0.038 ohm; use 0.04 ohm

Structure-to-earth resistance.
Since the tanks and piping are essentially bare and
are not electrically isolated, structure-to-earth
resistance may be considered negligible. Therefore
RC = 0.

37

ETL 1110-9-10(FR)
5 Jan 91
d)

Calculate total
equation 1-3:

circuit

resistance

(RT)

from

RT = RN + RW + RC
RT = 2.26 + 0.04 + 0 = 2.30 ohms
Since the design requirements call for a maximum
groundbed resistance of 2.5 ohms and RT = 2.30
ohms, the design using fourteen 2-in. by 60-in.
packaged ceramic anodes will work.
8)

Calculate the rectifier voltage (VREC) from equation

1-17:
VREC = (I) (RT) (120%)
Where:
I = 8.2 amp (Current requirement from step 2,
paragraph 2-3b)
RT = 2.30 ohms (Total circuit resistance from
previous calculation)
120% = Rectifier voltage capacity design safety
factor.
VREC

= 8.2 amp x 2.30 ohms x 1.2

VREC

= 22.6 V

c. Select rectifier.
Based on the design requirement of 22.6 V and 8.2 amp, a
rectifier can be chosen.
A 12-amp, 24-V unit is selected
because this is the nearest standard commercial size
available.

38

ETL 1110-9-10(FR)
5 Jan 91
2-4.

On-Grade Tank Bottoms.

Four on-grade fuel oil storage tanks are to be constructed with the
configuration shown on figure 2-6. This design may be prohibited
if secondary containment uses a nonconductive membrane beneath the
tanks.
The membrane would not allow the cathodic protection
current to flow from the remotely located deep anode through the
nonconductive membrane to the tank bottoms.
If this situation
exists, a distributed anode design with the anodes located between
the membrane and the tank bottoms would have to be used.
All
piping will be above grade. To minimize the extent of underground
cable, it was decided to use a deep anode groundbed, located just
outside the spill containment dikes. (Note: Some county, state,
or federal agencies such as the EPA may have regulations that
affect the use of deep anode beds because they can provide a
conduit for the mixing of water between aquifer levels. In such
cases, regulations have sometimes required cementing of the annulus
between the deep anode bed casing and the augered hole to prevent
this water migration. The system designer should check with the
applicable agencies before committing to a deep anode design.
Figures 2-7, 2-7A, 2-8, and 2-8A illustrate a typical deep anode
groundbed using ceramic rod anodes. The tank bottoms will be bare.
All piping will be above ground. The tanks will be dielectrically
insulated from the structures. Field tests were made at the site
and the subsurface geology was determined to be suitable for a deep
anode groundbed (reference 25).
a. Design data.
1)

Soil resistivity at anode depth is 1500 ohm-cm.

2)

Tanks are 75 ft in diameter.

3)

Design cathodic protection anodes for a 15-year life.

4)

Design current density is 2 A per sq ft of tank bottom.

5)

Since the tanks are electrically isolated from each

other, intertank bonds will be required.

6)

The cathodic protection system

should not exceed 0.75 ohm.

7)

Electric power is available at a switch rack in an

unclassified (nonexplosion proof) area 125 ft from the
desired groundbed location, 230 V AC, single phase.

39

circuit

resistance

ETL 1110-9-10(FR)
5 Jan 91
8)

Since the exterior bottom of these type tanks are

always bare, the coating efficiency will equal 0.00.

40

ETL 1110-9-10(FR)
5 Jan 91

41

ETL 1110-9-10(FR)
5 Jan 91

42

ETL 1110-9-10(FR)
5 Jan 91

43

ETL 1110-9-10(FR)
5 Jan 91

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ETL 1110-9-10(FR)
5 Jan 91

45

ETL 1110-9-10(FR)
5 Jan 91
b. Computations.
1)

Find the surface area to be protected.

Area of each tank bottom = B r2:
A = B x 37.52 = 4418 sq ft
Area of the four bottoms:
A = 4 x 4418 = 17,672 sq ft

2)

Determine the current requirement (I) from equation

1-1:
I = (A) (I')(l.0-CE)
Where:

3)

17,672 sq ft (Total surface area from

previous calculation)

I'

2 mA/sq ft (Current density from item

4 of paragraph 2-4a)

CE

0.0 (bare) (Coating efficiency from

item 8 of paragraph 2-4a)

17,672 sq ft x 2 mA/sq ft x (1.0 0.0)

35 amp

Select an anode and calculate the number of anodes (N)

required to meet the design life.
The deep anode
groundbed will consist of a series of rods connected to
a continuous header cable. For physical strength, the
1/8-in. or 1/4-in. diameter rods are usually chosen. To
ensure good transmission of current in to the backfill
column, long anodes, typically 6 ft or 8 ft are used.
For this example, 1/4-in. diameter by 72-in. long rods
have been chosen. Using equation 1-2:
N =

I
IA

Where:
I = 35
amp
(Current
previous calculation)

requirement

from

IA = 6.6 amp/anode (Current rating per heavy

duty coated anode from table 3-3)
N =

35
6.6

= 5.3; use 6 anodes

46

ETL 1110-9-10(FR)
5 Jan 91
4)

Calculate the required length of the backfill column.

Spacing between anodes depends primarily on the
resistivity of both the backfill column (coke breeze).
If low resistivity calcined fluid petroleum coke is
used, than the spacing between rod anode (1/8-in. and
1/4-in. diameter) should not be greater than twice the
individual rod length.
Based on previous design
experience, a spacing between anode rods of 11 ft is
selected.
The minimum length of the backfill column is then
calculated as follows:
6 anodes at 6 ft per anode =
Spacing between anodes: 5 at 11 ft =
Space above and below anode string* =
Total length

36 ft
55 ft
20 ft
111 ft

* Generally, the coke breeze column extends from

10 ft below the bottom anode to 10 ft above the top
anode as shown in figures 2-7 and 2-8.
5)

Calculate
(RA).

the

backfill column-to-earth resistance

This can be done from equation 1-4. Because several

attempts may have to be made to obtain the required
groundbed resistance, the process is facilitated by
using the curves in figures 2-9A through 2-9C. Typical
hole diameters are 6 or 8 in.; a 6-in. diameter hole
has been selected for this groundbed. Figure 2-9C will
be used for this design.
Figure 2-9C shows that, for a 111-ft long coke breeze
backfill column, the resistance to earth per 1000 ohmcm is 0.31 ohm.
In 1500 ohm-cm soil, the resistance
is 0.31 x 1500/1000 = 0.47 ohm (groundbed resistance in
1000 ohm-cm soil, times actual soil resistivity in ohmcm per 1000).
This is well below the design
requirement of 0.75 ohm.
6)

Determine total circuit resistance (RT) from equation

1-3 :
RT =

RA + RW + RC (Because the cathodic

protection system utilizes a single
deep anode groundbed RA = RN)
47

ETL 1110-9-10(FR)
5 Jan 91

48

ETL 1110-9-10(FR)
5 Jan 91

49

50

ETL 1110-9-10(FR)
5 Jan 91
Where:
RA =

a)

Backfill column-to-earth resistance

(ohms), calculated in step 5 above

RW

Header cable/wire resistance (ohms)

RC

Structure-to-earth resistance (ohms).

Backfill column-to-earth resistance (RA)

5:

from step

RA = 0.47 ohm
b)

Wire resistance
A deep anode groundbed is defined as one where the
top of the backfill column is at least 50 ft below
the surface of the earth. Actual depth will vary,
depending on subsurface geology and the distance
over which the current is expected to spread. In
this example, 65 ft was selected as the depth to
the top of the coke breeze column. The anodes can
be supplied through a single or dual feed. Dual
feed is preferred to reduce both the resistance of
the circuit and the chance of a failure due to a
cable break.
No. 4 AWG cable has been chosen.
Cable lengths
have been calculated based on the following
distances,
illustrated in the deep groundbed
example shown in figure 2-7.

51

ETL 1110-9-10(FR)
5 Jan 91
From grade to top of backfill column 65 ft
From top of backfill column to
top anode

10 ft

From grade to bottom of backfill

column

176 ft

From bottom anode to bottom of

backfill column

10 ft

From anode hole to rectifier 2

cables at 125 ft

250 ft

From top of anode assembly to

bottom of anode assembly

91 ft

Total cable length from top anode

feed to rectifier 125 ft +
65 ft + 10 ft=

200 ft

Total cable length from bottom

anode feed to rectifier
125 ft + 176 ft - 10 ft =

291 ft

Calculate
top
equation 1-15:

RWT '

cable

resistance

(RWT)

from

LWT RMFT
1000 ft

Where:
LWT

200 ft (Cable
calculation)

RMFT

0.254 ohm (Resistance per 1000 lin ft

of No. 4 AWG cable which has been
selected for installation.
These
resistance values can be found in
table 3-6).

RWT

200 ft x 0.254 ohm

1000 ft

Calculate bottom
equation 1-15:

cable

52

length

from

previous

= 0.051 ohm

resistance

(RWB)

from

ETL 1110-9-10(FR)
5 Jan 91
Where:
LWB

291 ft (Cable
calculation)

RMFT

RWB

length

from

previous

0.254 ohm (Cable resistance per 1000

lin ft [same as above])
291 ft x 0.254 ohm
1000 ft

= 0.074 ohm

These two cables are in parallel, so that their wire

resistance (RT/B) is calculated from the law of
parallel circuits:
1
RT/B

1
RWT

1
RT/B

1
0.051

1
RT/B

1
RWB
+

1
0.074

= 19.6 + 13.5 = 33.1

RT/B = 0.030 ohm

Since current is dissipating along the portion of the
cable to which the anodes are connected, the
resistance of this cable (RPOS) is taken as one half
its total resistance as was done in example 2-2.
RPOS '

LW R MFT
1000 ft

1
91 ft( x 0.254 ohm/ft
1
'
x
2
1000 ft
2

*91 ft is the overall anode column length including the

interconnecting wire from the top of the top anode to the bottom
of the bottom anode (see item 4 from paragraph 2-4b.)

RPOS = 0.012 ohm

Negative circuit
calculated:

wire

resistance

must

also

be

Negative cable from rectifier to closest tank = 125 ft

of No. 4 AWG
Intertank bonds = 170 ft of No. 4 AWG**
**The two intertank bond circuits are in parallel and of about the
same length. From the law of parallel circuits, total resistance
of two parallel circuits of equal resistance is one half the
resistance of each circuit.

53

ETL 1110-9-10(FR)
5 Jan 91
Therefore, one half the cable length is used in this
calculation. The calculation is also conservative since not
all the current flows through the complete intertank bond
circuit.

Total ft of negative circuit wire = 295 ft of No. 4 AWG cable

Negative resistance if calculated from equation
1-15:

RNEG '

Where:
LW =
RMFT =

1000 ft

295 ft (Negative cable length)

0.254 ohm (Negative cable resistance
per 1000 un ft of No. 4 AWG cable
[table A-6])

RNEG =
RNEG =

LW RMFT

295 x 0.254
1000
0.074

Total wire resistance therefore is:

RW

RT/B + RPOS + RNEG = 0.030 + 0.012 + 0.074

RW

0.116 ohm

Cable
insulation
is
also
important.
High
molecular
weight
polyethylene
insulation,
commonly used for cathodic protection work, tends to
blister, become brittle, and then crack in deep
groundbed use where chlorine gas generation can occur.
This has been most prevalent in open holes containing
brackish water, but may occur in coke breeze
backfilled holes also. Consequently, to minimize the
chances of cable failure, one of the two following
types of insulation, which show good resistance to
these oxidizing environments should be used:
Polyvinylidene fluoride (Kynar)1
____________________
1

Registered trademark of Penwalt Corp.

54

ETL 1110-9-10(FR)
5 Jan 91
Copolymer of chlor-tri-fluorethylene and ethylene
(Halar)2
To
protect
the
insulation
itself
and
to
facilitate
handling,
cables
for
deep
anode
groundbeds also have an outer jacket of highmolecular weight polyethylene extruded over the
Kynar or Halar insulation.
c)

Structure-to-earth resistance (Rc).

Since
the
tank
bottoms
are
bare,
their
resistance-to-earth
is
considered
negligible,
therefore, RC is taken as zero.

d)

Calculate total circuit resistance

equation 1-3:
RT

= RN + RW + RC

RT

= 0.470 + 0.116 + 0.0

RT

= 0.586 ohm

(RT)

from

This is well below the design requirement and,

therefore, this groundbed with 6 - 1/4 in. by 6 ft
ceramic anode rods with total backfill column
length of 111 ft will be used.
7) Calculate rectifier voltage (VREC) from equation 1-17:
VREC = (I) (RT) (120%)
Where:
I =

35 amp (Current requirement from step

2, paragraph 2-4b)

RT

0.586 ohm (Total circuit resistance

from previous calculation)

120%

Rectifier capacity safety factor

VREC =

35 amp x 0.586 ohm x 120%

VREC =

24.6 V

c. Select rectifier.
____________________
2

Registered trademark of Allied Chemical Corp.

55

ETL 1110-9-10(FR)
5 Jan 91
Based on the design requirement of 24.6 V and 35 amp, a
rectifier can be chosen.
A 30 V, 42 ampere unit is
commercially available and is selected. This rectifier can
be pole mounted as illustrated in figure 2-10.
d. Installation.
Figures 2-7 and 2-8 show this deep anode design.

56

ETL 1110-9-10(FR)
5 Jan 91

57

ETL 1110-9-10(FR)
5 Jan 91
2-5.

Gas Distribution System.

It has been decided to install cathodic protection on the gas

distribution piping in a post housing facility. Figure 2-11 shows
a portion of the piping.
The water distribution system has recently been replaced with
nonmetallic pipe. On this basis, it has been decided that the gas
piping can be protected with impressed current from a deep anode
groundbed without causing interference to the water pipe. (Note:
Some county, state, and federal agencies such as the EPA may have
regulations which prevent the use of deep anode beds because they
can provide a conduit for mixing of waters between aquifer layers.
In such cases, regulations have required cementing of the annulus
between the deep anode bed casing and the augered hole to prevent
this water migration. The system designer should check with the
applicable agencies before committing to a deep anode design.)
a. Design data.
1)

Experience
in
the
area
shows
the
subsurface
resistivity at a depth of 50 and 200 ft to be 2000 ohmcm.

2)

Piping consists of:

28,000 ft of 1 1/4-in. diameter pipe
1,200 ft of 4-in. diameter pipe
3,600 ft of 6-in. diameter pipe

3)

Design cathodic protection anode for a 20-year life.

4)

Experience with similar pipe in the same general soil

type has shown that a design current density of 2 A per
sq ft of bare pipe is conservative.

5)

Piping is welded steel, poorly coated; considered to be

bare for protection purposes and, therefore, the
coating efficiency is 0.0 (CE = 0.0).

6)

Piping is isolated at each house and at the tie-in to

the main supply line.

7)

The cathodic protection circuit resistance should not

exceed 1 ohm.

8)

120/240 V AC, single phase power is available.

58

ETL 1110-9-10(FR)
5 Jan 91
9)

Current requirement tests are not practiced in this

case, so design will be based on calculations. (Note:
Current requirement tests should be conducted whenever
practicable.)

59

ETL 1110-9-10(FR)
5 Jan 91

60

ETL 1110-9-10(FR)
5 Jan 91
b. Computations.
1)

Calculate the external surface area of the pipe (A) to

be protected.
Pipe diameter

Length

1 1/4 in.
4 in.
6 in.

28,000 ft
1,200 ft
3,600 ft

*from table A-2

2)

Unit Area*
(sq ft/lin ft)
0.434
1.178
1.734
Total

Area (sq ft)

12,152
1,414
6,242
19,808

Determine current requirement (I) from equation 1-1:

I = (A)(I')(l.0-CE)
Where:
A

3)

19,808 sq ft (Surface area of pipe to

be protected from previous calculation)

I' =

2 mA/sq ft (Current density, from item

4, paragraph 2-5a)

CE =

0.0 (Coating efficiency [bare pipe])

19,808 sq ft x 2 mA/sq ft x (1.0 - 0.0)

39,616 mA or 39.6 amp; use 40 amp

Select an anode and calculate the number of anodes

required (N) to meet the design life.
For this
design, tubular anodes have been chosen.
The
groundbed will consist of a series of anodes attached
to a continuous header cable. A typical size tubular
ceramic anode used in deep anode beds, 1-in. diameter
by 39.4 in. long, is selected. The number of anodes
are determined using equation 1-2:
N =
Where:
I =
IA =

I
IA
40
amp
(Current requirement
previous calculation)

from

8.0 amp/anode (Current rating per anode

from table 3-3 [in coke breeze])
61

ETL 1110-9-10(FR)
5 Jan 91
N =

40
8

= 5 anodes

To allow a factor of safety, use 6 anodes

4)

Calculate the required length of the backfill column.

The maximum allowable spacing between anodes depends
primarily on the resistivity of the backfill column
(coke breeze). For tubular anodes of -in. diameter or
greater, maximum spacing between anodes should not
exceed four times the anode tube length.
For this
example, we will try the maximum allowable spacing of
13 ft (39.4 in. x 4/12 = 13.1 ft).
The minimum length
calculated as:

of

the

backfill

6 anodes at 39.4 in. (3.3 ft) =

Spacing between anode: 5 at 13 ft =
Space above and below anode string*
Total length

column

is

19.8 ft
65.0 ft
20.0 ft

104.8 ft
(use 105 ft)

* Generally, the coke breeze column extends from 10 ft below the

bottom anode to 10 ft above the top anode.

5)

Calculate
(RA).

the

backfill column-to-earth resistance

This can be done from equation 1-4. Because several

attempts may have to be made to obtain the required
resistance-to-earth, the process is facilitated by
using the curve in figure 2-9C.
Typical hole
diameters are 6 or 8 in.; a 6-in. diameter hole has
been selected for this groundbed.
From figure 2-9C for a 105 ft long coke breeze backfill
column, the resistance to earth per 1000 ohm-cm is
0.325 ohm.
In 2000 ohm-cm soil, the resistance is
0.325 x 2 = 0.65 ohm, which is below the design
requirement defined in item 7 of paragraph 2-5a.
6)

Determine total circuit resistance (RT) from equation

1-3:

62

ETL 1110-9-10(FR)
5 Jan 91
RT = RA + RW + RC (Because the cathodic protection
system uses a single deep anode groundbed RA = RN)
Where:
RA =

a)

Backfill
(ohms).

column-to-earth

resistance

RW

Wire resistance (ohms).

RC

Structure-to-earth resistance (ohms).

Backfill
step 5.

column-to-earth

resistance

(RA)

from

RA = 0.65 ohm
b)

Wire resistance (RW) from general equation 1-15:

RW '

LW RMFT
1000 ft

A deep anode groundbed is defined as one where the top

of the backfill column is at least 50 ft below the
surface of the earth.
Actual depth will vary,
depending on subsurface geology and the distance over
which the current is expected to spread.
In this
example, the depth to the top of the coke breeze
backfill column was determined to be 100 ft. The
anodes can be supplied through a single or dual feed.
Dual feed is preferred to reduce both the resistance
of the circuit and the chance of a failure due to a
cable break.
The assembly is made on a single length of cable,
beginning at the rectifier, running down through the
tubular anodes to the bottom anode and then back up
adjacent to the anodes to the rectifier. Resistance
calculations are made as though there were three
cables as noted below. The conductor provided with
some tubular ceramic anodes is designated EPR/HY5O for
one-in. diameter anodes and EPR/HY16 for 0.63-in.
diameter anodes. These cables have an ethylenepropylene
rubber
inner
insulation
and
a
chlorosulphonated polyethylene outer jacket and are
suitable for deep anode use if the insulation is
protected with a chlorine-resistant sheath or shield.
63

ETL 1110-9-10(FR)
5 Jan 91
EPR/HY50 cable has been chosen.
The cable
lengths have been calculated based on the
following distances, which are illustrated in the
deep groundbed examples shown in figures 2-12 and
2-13:
From grade to top of backfill column
From top of backfill column to top anode
From grade to bottom of backfill column
From bottom anode to bottom of backfill
column
From anode hole to rectifier 2 cables
at 10 ft
From top of anode assembly to bottom of
anode assembly

100 ft
10 ft
205 ft
10 ft
20 ft
85 ft

Total cable length from top anode feed

to rectifier 10 ft + 100 ft + 10 ft =

120 ft

Total cable length from bottom feed

to rectifier 10 ft + 205 ft - 10 ft =

205 ft

Calculate top
equation 1-15:

RWT '

cable

resistance

(RWT)

from

LWT RMFT
1000 ft

Where:
LWT
RMFT
RWT

120
ft
(Cable
length
previous calculation)

from

0.1183 ohm (Resistance per 1000

lin ft of EPR/HY5O [table 3-6])

120 ft x 0.1183 ohm = 0.014 ohm

1000 ft

Calculate bottom
equation 1-15:

cable

resistance

(RWB)

from

Where:
LWB

205
ft
(Cable
length
previous calculation)

64

from

ETL 1110-9-10(FR)
5 Jan 91
RMFT

0.1183 ohm (Cable resistance per

1000 lin ft [same as above])

RWB

205 ft x 0.1183 ohm = 0.024 ohm

1000 ft

These two cables are in parallel, so that total

resistance (RT/B) is calculated from the law of
parallel circuits:
1
RT/B

1
RWT

1
RT/B

1
0.014

1
RT/B
RT/B

1
RWB
+

1
0.024

= 71.43 + 41.66 = 113.1

= 0.009 ohm

Since current dissipates along the portion of the

cable to which the anodes are connected, the
resistance of this cable (RPOS) is taken as one half
its total resistance, as was done in example 2-2.
RPOS '

L W RMFT
1000 ft

1
85 x 0.1183 ohm/ft
1
'
x
2
1000 ft
2

RPOS = 0.005 ohm

Negative cable resistance:
The rectifier is
placed 25 ft from the connection to the piping,
using No. 4 AWG HMWPE insulated cable. Negative
resistance is calculated from equation 1-15:

RNEG '

Where:
LW

LW RMFT
1000 ft

=
25 ft (Length of cable)

65

ETL 1110-9-10(FR)
5 Jan 91
RMFT =

0.254 ohm (Resistance per 1000

lin ft of No. 4 AWG HMWPE
insulated cable [table A-6])

RNEG =

25 x 0.254
1000

RNEG =

0.006 ohm

Total wire resistance therefore is:

RT/B
+
0.006

c)

RPOS

RW
+

=
RNEG

RW

=
0.020 ohm

0.009

0.005

Structure-to-earth resistance (RC).

The piping is essentially bare, so structure-toearth resistance is negligible (RC = 0.0).

d)

7)

Calculate total circuit resistance

equation 1-3:

(RC)

from

RT

= RA + RW + RC (Because the cathodic

protection system uses a single deep
anode groundbed RA = RN)

RT

= 0.65 + 0.020 + 0.0

RT

= 0.670 ohm

Calculate rectifier voltage (VREC) from equation 1-17:

VREC

= (I) (RT) (120%)

Where:
I

40 amp (Current requirement from step

2, paragraph 2-5b)

RT

0.670 ohm (Total circuit

from previous calculation)

120%

Rectifier
voltage
safety factor

66

resistance

capacity

design

ETL 1110-9-10(FR)
5 Jan 91
VREC =

40 amp x 0.670 ohm x 1.2

VREC =

32.2 V

c. Select rectifier.
Based on the design requirement of 32.2 V and 40 amp, a
rectifier can be chosen.
A 36-V, 50-amp unit is
commercially available and is selected.
d. Installation.
Figures 2-12 and 2-13 show how the deep anode groundbed
might look.

67

ETL 1110-9-10(FR)
5 Jan 91

68

ETL 1110-9-10(FR)
5 Jan 91

69

ETL 1110-9-10(FR)
5 Jan 91
2-6.

Elevated Water Tank (Ice Is Expected).

Impressed current cathodic protection is designed for an elevated

water tank (figure 2-14). The tank is already built and current
requirement tests have been done. Anodes must not be suspended
from the tank roof because heavy ice (up to 2 ft thick) covers the
water surface during winter. The anode cables could not tolerate
this weight,
so another type of support must be used.
An
internally supported hoop shaped wire anode system is selected.
a.

Design data.
1)

Tank is a pedestal supported spheroid with a 10-in.

riser pipe. Only the bowl will be protected because
the riser pipe is less than 30 inches in diameter. For
riser pipes see section 2-7.

2)

Tank dimensions are:

Capacity = 400,000 gal
Diameter of bowl = 51 ft 6 in.
High water depth = 35 ft
Height of bowl above ground = 100 ft

3)

Water resistivity is 2000 ohm-cm.

4)

Design cathodic protection anodes for a 15-year life.

5)

Wire type ceramic anode will be used.

6)

Wetted surfaces are uncoated.

7)

Area above high water level is kept well coated.

8)

Tank is subject to freezing.

9)

The cathodic protection circuit resistance must not

exceed 2 ohms.

10) The available electrical power is 120/240 V AC, single

phase.
11) Based on structure current requirement testing
recently performed on this tank, the current required
for adequate cathodic protection is 25 amp. This high
current requirement indicates that the tank internal
coating is severely deteriorated.
b.

Computations.
70

ETL 1110-9-10(FR)
5 Jan 91
1)

Calculate the length of wire in ft (LB) needed for the

current required from a modification of equation 1-2:
LB =
where:
I =

IA =

I
IA

25 amp (Current requirement from

adequate cathodic protection from
item 11 of paragraph 2-6a)
Allowable amp per ft of anode wire
(varies depending on desired anode
life and diameter), found in table
A-3.

Select 0.0625-in. diameter copper cored anode

wire based on the current requirement of 25 amp,
81 ft of anode wire will be required to provide
an anode life of 15 years.
Length of Anode Ring
Wire
Diameter (DR)
For 0.0625 in. LB =
2)

25
0.31

81 ft

25 ft 9 in.

Calculate the desired diameter of the anode wire ring

(DB). Experience shows that the diameter of the anode
wire ring should be between 40 and 70 percent of the
bowl diameter. For this example, use a hoop diameter
equal to 40 percent of the tank bowl diameter:
DR = 51.5 ft x 40% = 20.5 ft

3)

Select anode wire:

Prior to calculating the circuit resistance of the
anode wire ring, it must first be checked to determine
if the length is adequate for the desired anode life.
For an anode ring diameter of 20.5 ft, the
circumference is 20.5 x B = 64.4 ft. This length is
inadequate for the 0.0625-in. wire (which requires a
minimum of 81 ft to meet the desired anode life).
Therefore, we will increase the hoop diameter by 10
percent to 50 percent of the tank diameter:
DR = 51.5 x 50% = 25.75 ft
71

ETL 1110-9-10(FR)
5 Jan 91
But this diameter provides an anode length that is
still slightly less than that required for a 15-year
mode life.
Therefore, we will use a hoop diameter
that is 55 percent of the bowl diameter:
DE = 51.5 x 55% = 28.3 ft
4)

Calculate the anode-to-water resistance (RA) for a

0.0625-in. diameter anode wire using equation 1-14:
RA '

8 DR
2 DR
0.0016 p
(1n
% 1n
)
DR
DA
H

Where:
p =

2000 ohm-cm (Water resistivity from

item 3 of paragraph 2-6a)

DR =

28.3 ft (Anode ring diameter from

step 2 of paragraph 2-6b)

DA =

0.00521 ft (0.0625 in)(Diameter of

anode determined in step 3 of
paragraph 2-6b)

H =

21 ft (Anode depth below water

surface.) (Anode depth determined
from the following calculations).

The anode depth below the high water line is

approximately 60 percent of the distance between the
high water line and the bottom of the tank. Water
depth = 35 ft, cf. design data section 2-6a.
Calculate RA:
RA =

0.0016 (2000)
28.3

[ln

8 x 28.3
0.00521

+ ln

2 x 28.3
21

RA = 0.113 [ln 43,455 + ln 2.70]

RA = 0.113 (10.68 + 0.99)
RA = 1.32 ohms
This is within the design limitation of 2.0 ohms.

72

ETL 1110-9-10(FR)
5 Jan 91
5)

Determine the total circuit resistance (RT), from

equation 1-3:
RT = RN + RW + RC
Where:
RN =
RW =
RC =

Anode-to-water resistance
Wire resistance
Tank-to-water resistance.

a)

Anode-to-water resistance (RN) = 1.32 ohms from

step 4 above. (RN = RA since RA is equal to one
continuous wire anode).

b)

Header cable/wire resistance (RW) is solved using

equation 1-15:
LW RMFT
RW '
1000 ft
Where:
LW = 115 ft (Effective wire length. The
positive wires from the rectifier
to each end of the anode circle
will be approximately 115 ft long)
RMFT =

c)

0.51 ohm (Effective wire resistance

per 1000 lin ft. Since there are
positive wires from the rectifier
to each end of the anode circle,
each wire will carry about one half
of the current [12.5
amp].
The
wires selected are No. 10 AWG.
Because the two wires are in
parallel, the effective resistance
is
one half the single wire
resistance [1.02 ohms per 1000 lin
ft/2 = 0.51 ohm])

RW

RW

115 ft x 0.51 ohm

1000 ft
0.06 ohm

Tank-to-water
resistance
circuit resistance.

(RC)

and

negative

The negative wire is connected to the tank

structure near the rectifier, so its resistance
73

ETL 1110-9-10(FR)
5 Jan 91
is negligible. The tank-to-water resistance is
also negligible because the coating is very
deteriorated.
d)

Calculate RT:
RT

= 1.32 + 0.06 + 0.00

RT

= 1.38 ohms

This is well below the design requirement.

6)

Calculate rectifier voltage (VREC) from equation 1-17:

VREC = (I) (RT) (120%)
Where:
I
RT

c.

= 25 amp (Current requirement from

step 11, paragraph 2-6a)
= 1.38
ohms
resistance
calculation)

(Total
from

circuit
previous

120%

= Rectifier voltage capacity design

safety factor

VREC

= 25 amp x 1.38 ohms x 1.2

VREC

= 41.4 V

Select rectifier.
Based on the design requirements of 41.4 V and 25 amp, a
commercially available 48-V, 28-amp unit is selected. To
prevent over- or under-protection as the water level
varies, automatic potential control is specified.
The
tank-to-water potential is maintained by the controller
through two permanent copper-copper sulfate reference
electrodes suspended beneath the anode wire circle. The
reference electrodes should have a life of at least 5
years.
The tank-to-water potential measured by the
controller should be free of IR drop error.

74

ETL 1110-9-10(FR)
5 Jan 91
d.

Installation.
Figure 2-14 shows a typical installation while figure 2-14A
provides a typical detail for a pressure entrance fitting
for underwater power and reference cell wire penetrations.

75

ETL 1110-9-10(FR)
5 Jan 91

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2-7.

Elevated Water Tank (No Icing Will Occur).

This impressed current design is for a tank (figure 2-15) that has
not been built; thus, it is not possible to measure current
requirements and other factors. Calculated estimates are used.
a.

Design data.
1)

Tank will be ellipsoidal on both top and bottom.

2)

Tank dimensions will be:

Capacity = 500,000 gal
Diameter = 56 ft
Tank height (from ground to bottom of bowl) = 115 ft
Overall tank depth = 39 ft
Vertical shell height = 11 ft
High water level = 35 ft
Riser pipe diameter = 5 ft

3)

Water resistivity is 4000 ohm-cm.

4)

Design for a 20-year life.

5)

The tank water will not be subjected to freezing.

6)

Segmented rod anodes will be used; 4-ft long by 0.138in. diameter. Note: Segmented rods have an advantage
in that they can be field assembled using factory-made
connections.
On the other hand, continuous wire
(.0625-in. diameter) is also available in long lengths
(typically 500 ft).
These can be fabricated with
factory-made wire connections but their overall length
must be specified. Continuous wire will almost always
be less expensive.

7)

All wetted inner surfaces will be uncoated.

above water will be coated.

8)

Electric power available will be 120/240 V AC, single

phase.

9)

Design for a current requirement of 2.5 A per sq ft

for the bowl and 8.0 A per sq ft for the riser. Due
to the velocity of the water in the riser, the riser's
current requirement is typically much higher than the
bowl.

78

Area

ETL 1110-9-10(FR)
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b.

Computations.
1)

Find the area of wetted surface or tank bowl (A) shown

in figure 2-16 from equation 2-1:

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A = AT + AC + AB

(eq 2-1)

Where:
AT = Wetted area of the top section
AC = Area of the center section
AB = Area of the bottom section.
a)

Find the appropriate wetted area of the top

section (AT) using equation 2-2:
AT = 2 B rh

(eq 2-2)

Where:
r
h

b)

=
=

28 ft (Tank radius)
10 ft (Water height)

AT =

2 x 3.1416 x 28 ft x 10 ft

1759 sq ft (approximate).

Find the wetted area of the center section (AC)

using equation 2-2:
AC = 2 B rh
r
h

c)

=
=

28 ft (Tank radius
11 ft (Water height)

AC =

2 x 3.1416 x 28 ft x 11 ft

1935 sq ft

(eq 2-2)

Find the wetted area of the bottom section (AB)

from equation 2-3:
AB '

2 A r h2 % r2

Where:
r = 28 ft (Tank radius)
h = 14 ft (Water height)
AB '

2 3.1416 28 (14)2 % (28)2

AB = 3894 sq ft

82

(eq 2-3)

ETL 1110-9-10(FR)
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d)

Calculate (A):
A
A

2)

=
=

1759 sq ft + 1935 sq ft + 3894 sq ft

7588 sq ft

Find the riser pipe area (AR) using equation 2-2:

AR = 2 B rR hR

(eq 2-2)

Where:

3)

rR =
hR =

2.5 ft (Riser radius)

115 ft (Height of riser)

AR =

2 x 3.1416 x 2.5 ft x 115 ft

AR =

1806 sq ft

Find the maximum design current for the tank bowl (IT)
using equation 1-1:
IT = (A) (I) (1.0 - CE)
Where:
A =
I =
CE =
IT =
IT =

4)

7588 sq ft (Total wetted area of

tankbowl from step 1 of paragraph
2-7b)
2/5 mA/sq ft (Required current
density from item 9 of paragraph
2-7a)
0.0 (Coating efficiency, wetted
inner surfaces will be uncoated,
from item 7 of paragraph 2-7a)
7588 sq ft x 2.5 mA/sq ft x (1.0 0.0).
18,970 mA; use 19.0 amp

Find the maximum design

(IR),using equation 1-1:)

current

for

the

riser

IR = (AR) (I) (1.0 - CE)

Where:
AR =

1806 sq ft (Total surface area of

riser pipe from step 2 of paragraph
2-7b)

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5)

I' =

8.0 mA/sq ft (Required current

density for riser pipe from item 9
of paragraph 2-7a)

CE =

0.0 (Coating efficiency.

Inner
surfaces will be uncoated, from item
7 of paragraph 2-7a)

IR =

1806 sq ft x 8.0 mA/sq ft x (1.0 0.0).

IR =

14,448 mA; use 14.5 amp.

Select the number of anodes required for the bowl, to

meet the anode system's 20-year design life using
equation 1-2:
N =
Where:
I =

19
amp
(Current
determined in step 3)

IA =

6)

I
IA
requirement

1 amp/anode (Current rating per

anode from table 3-3 for 4-ft long
by 0.138-in. diameter ceramic rods)
19
1
19 rod segments (4-ft long segment)

Select the number of anodes required for the riser to

meet the anode system's 20 year design life using
equation 1-2:
N =
Where:
I =
IA =

I
IA
14.5
amp
(Current
determined in step 4)

requirement

1 amp/anode (Current rating per

anode from table 3-3 for 4 ft long
by 0.138-in. diameter ceramic rods)
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7)

14.5
1
14.5; use 15 rod segments (4 ft.
long)

Calculate the radius of the main anode circle (AR),

using equation 2-4:
AR '

D x N
2 (A % N)

Where:
D =
N

AR =
AR =
AR =

(eq 2-4)

56 ft (Tank diameter, from item 2 of

paragraph 2-7a)
10 anode strings (assumed: it is
necessary to assume a number of
anode strings since there are two
unknowns in this equation.
56 ft x 10
2 (3.1416 + 10)
560 ft
26.28
21.3 ft; use 22 ft for the main
anode circle radius

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8)

Determine the center-to-center spacing (Cc) for the

main anode strings.
a)

To find circumference spacing (CC), use equation

2-5:
CC '
Where:
AR =
N

CC =
CC =

b)

9)

2 A AR
N

(eq 2-5)

22 ft (Radius of main anode circle

from previous calculation.
10 anode strings ([Assumed] Used in
previous calculation)
2 x 3.1416 x 22 ft
10
13.8 ft; use 14 ft for center-tocenter
spacing
between
anode
strings.

The cord spacing is approximately the same as

circumferential spacing;
14 ft will be used
(figure 2-19).

Select main anode system

Number of 4-ft long rod segments needed for the
current requirement (from step 5) = 19.
Number of
anode strings utilized (from step 7) = 10. Using two
rod segments per string will provide twenty anodes,
which is sufficient for the current requirement.
However, for rod type anode designs, the main anode
rods should extend from a distance of 4 ft above the
tank bottom to within 4 ft of the HWL. Due to the
curvature of the tank bottom, the total water depth at
the location of the main anodes is approximately 30
ft. Therefore, the minimum rod length should be 22 ft
(30 ft - 4 ft - 4 ft = 22 ft). Since these rods come
in 4 ft lengths, we will use six segments per anode
with a total length of 24 ft.

10) Calculate the resistance of the main anodes to water

(RN) using equation 1-13:

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RN '

0.0052 p 1n [D/(2 AR x DE)]

LB

Where:
p =
D

4000 ohm-cm (Water resistivity from

item 3 of paragraph 2-7a)

56 ft (Tank diameter from item 2 of

paragraph 2-7a)

AR =

22 ft (Radius of main anode circle

from step 7 of paragraph 2-7b)

DE =

0.275 (Equivalent
from figure 2-17)

LB =

24 ft (Length of each anode from

step 9 of paragraph 2-7b)

RN =

0.0052 x 4000 x ln(56/(44 x 0.275))

24

RN =

1.33 ohms.

diameter

factor

If the anode rod length-to-diameter ratio (L/d) is

less than 100, the anode-to-water resistance needs to
be adjusted by the fringe factor. (See step 12 for a
discussion of fringe factor.)
In this case, L = 24 ft and d = 0.0115 ft. L/d,
therefore, is (24/0.0115) = 2086. No fringe factor
correction is required.
11) Calculate the stub anode requirement (NS):
a)

The main anode radius has been calculated to be

22 ft.
The main anodes are spaced to provide
approximately the same distance from the sides
and the bottom of the tank. The main anode will
protect a length inward along the tank bottom
equal to approximately the same spacing that the
anode is spaced away from the tank wall.

b)

The anode suspension arrangement for the tank

being considered is shown in figure 2-20. It can
91

ETL 1110-9-10(FR)
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be seen that stub anodes are required for this
design. For a two-ring anode design (main and
one-stub anode ring), which is usually sufficient
for tanks up to 1 million gal storage capacity,
the 4-ft long stub anodes are located on a radius
one-fourth of the bowl radius, or 7 ft (28 ft x
0.25 = 7 ft). Typically, there will be about one
half as many stub anodes (two ring design) as
there are main anodes so we will plan for five 4ft long stub anodes on a 7-ft radius.
The
outside radius of the area to be protected by the
stub anodes is approximately 13 ft and the inside
radius is 2.5 ft (riser radius). The stub anodes
are thus located on an 7-ft radius to place them
in the center of the area to be protected. (Note:
For smaller diameter tanks, stub anodes may not
be required.)
c)

Find the current division between main and stub

anodes.
(1)

The area of tank bottom protected by stub

anodes (As) is found by equation 2-6 (see
figure 2-20):
ASB = B (r22 - r12)

Where:
r1 =
r2 =

(eq 2-6)

2.5 ft (Riser radius)

13 ft (Radius of protected segment.)
This is based on the fact that the
main anode string is 6 ft from the
tank wall and that the anode will
protect another 9 ft (1.5 x 6 ft in
toward the center on the tank bottom
due to arc shape of the tank
bottom). Outside radius of the area
to be protected by the stub anodes
is, therefore:

28 ft (tank radius) - 6 ft - 9 ft = 13 ft
ASB =

3.1416 [(13 ft)2 - (2.5 ft)2]

ASB =

3.1416 x 162.75

ASB =

511.3 sq ft; use 512 sq ft as the area to

be protected by the stub anodes.
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ETL 1110-9-10(FR)
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(2)

The current requirements for stub anodes

is, therefore;

512 sq ft x 2.5 mA/sq ft = 1280 mA or 1.3 amp

(3)

The total current requirement for the bowl

is 19.0 amp (from step 3).

(4)

The current
therefore;
19.0

d)

for

the

main

anodes

is,

amp - 1.3 amp = 17.7 amp

Select number of stub anodes (NS).

In step 11, five stub anodes were assumed.
the number required from equation 1-2:
NS
Where:
I =
IA =

N5 =
NS =

Check

I
IA

1.3 amp (Current requirement from

previous calculation)
1 amp/anode current rating per anode
from table 2-4
for 4-ft long by
0.138-in. diameter ceramic rods.
1.3
1
1.3; use 2 - 4 ft anode rods

The five anodes selected to provide proper

coverage over the bottom are more than sufficient
for the desired anode life.
12) Calculate the stub anodes-to-water resistance (RN).
Find the stub anode resistance from equation 1-13:
RN '

0.0052 p 1n [D/(2 A R DE)]

LB

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5 Jan 91
Where:
p =
D

4000 ohm-cm (Water resistivity from

item 3 of paragraph 2-7a)

56 ft (Tank diameter from item 2 of

paragraph 2-7a)

AR =

7 ft (Radius of stub anode circle

from step lib of paragraph 2-7b)

DE =

0.07 (Equivalent
from figure 2-17)

LB =

4 ft (Length of each stub anode)

RN =

0.0052 x 4000 x ln [56/(14 x 0.07)]

4

RN =

21.03 ohms.

diameter

factor

Because the stub anodes are

short,
their
anode-to-water resistance may have to be adjusted
by the fringe factor. The fringe factor depends on
the ratio of length-to-diameter (L/d). If L/d is
less than 100, obtain the fringe factor from figure
2-18. Multiply the calculated stub anode-to-water
resistance by the fringe factor (F) to obtain the
adjusted resistance (RADJ).
RADJ = RN x F
Where:
RN =
F

(eq 2-7)

Stub anode-to-water resistance from

step 12.
Fringe factor from figure 2-18.

In this example, L/d for the stub anodes is:

L = 4 ft

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d = 0.0115 ft
L/d =

4
0.0115

= 348

In this case L/d is greater than 100, 50 no fringe

factor correction is required.
13) Determine total resistance of main and stub anodes
(RT) from equation 1-3:
RT = RN + RW + RC
Where:
RN =
RW =
RC =
a)

Anode-to-water resistance.
Header cable/wire resistance.
Tank-to-water resistances.

Main anode rods:

RN

= 1.33 ohms (from step 10)

RW

= 0.13 ohm

Header cable/wire resistance is calculated from

equation 1-15:
RW '
Where:
LW

LW RMFT
1000 ft

200 ft (After reviewing figure 2-20,

it is estimated that 200 ft of wire
will be required to connect the
rectifier to the anode distribution
wiring at the top of the tank)

RMFT

0.640 ohm (Wire resistance per 1000

lin ft of No. 8 AWG HMWPE insulated
wire)

RW

200 ft x 0.640 ohm

1000 ft

95

= 0.13 ohm

ETL 1110-9-10(FR)
5 Jan 91
RC

b)

0.0 ohm (Resistance of the tank-towater

and
negative
wire
is
negligible)

Calculate the total resistance of the main anode

rods circuit (RT):
RT = 1.33 +0.13 + 0.0
RT = 1.46 ohms for main anodes.

c)

Calculate the total resistance of the stub anode

rods circuit (RT):
Where:
RN = 21.03 ohms (from step 12)
RW = 0.13 ohm (same as main anode header)
RC = 0.0 ohm (negligible)
RT = 21.03 + 0.13 + 0.0
RT = 21.16 ohms for stub anodes.

14) Design riser anode.

a)

Current requirement = 14.5 amp (from step 4)

b)

Number of anode rods required from step 6 = 15

rod segments (4-ft long each)

c)

Select riser anode system.

For proper current distribution in the riser
pipe, the anode units should not be placed too
far apart. It is generally considered that each
anode unit protects a length along the riser pipe
equal to 1 times the spacing of the anode from
the riser pipe wall plus the length of the anode.
The length of riser protected by one 4-ft long
anode located 2.5 ft from the riser wall is
therefore:
(2.5 x 1.5) + 4 = 7.75 ft
Number of anode required for a 115-ft riser:
N =

115
7.75

= 14.8 or 15 anodes

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The number of anodes required for current
distribution equals the number needed for the
current requirement. To allow for a factor of
safety, use twenty anodes.
d)

Determine anode spacing.

Total riser length = 115 ft
Distance from bottom of riser to bottom of bottom
anode = 1.5 ft
Space consumed by anodes = 20 anodes x 4 ft each
= 80 ft
Total space consumed = 80 + 1.5 = 81.5 ft
Space remaining = 115 - 81.5 = 33.5 ft
For twenty anodes, there are nineteen spaces
Spacing =

33.5
19

= 1.76 ft or 1 ft 9 in.

Such an assembly is possible since anode rod

segments can be connected together with wire.
Since the anodes are spaced so close together, it
is better to use one long anode. Such an anode
has less flexibility than the disjointed cable
connected string, so there is less chance of its
vibrating or being damaged by water turbulence.
For one long anode made of 4-ft segments screwed
together, the number of anodes required is:
115 ft - 1.5 ft (distance from bottom) = 113.5 ft
113.5
4

= 28.4 anodes

Use 28 anode segments to keep the top segment

within the riser.
Total anode length = 28 anodes x 4 ft/anode = 112
ft.
Weight of the anode string will be:
2.4 oz/anode x 28 anodes = 67.2 oz = 4.2 lb

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Weight is not a factor in supporting the string.
15) Calculate the anode-to-water resistance of a single
anode rod (RA), using equation 2-8:
RA '

0.0052 p 1n(D/DA)
LB
Where:
p =

(eq 2-8)

4000 ohm-cm (Water resistivity from

item 3 of paragraph 2-7a)

D =

5 ft (Riser diameter from item 2 of

paragraph 2-7a)

DA =

0.0115 ft (0.138 in) (Diameter of

anode rod from item 6 of paragraph
2-7a)

LB =

112 ft
(Length of anode rod from
previous discussion)

RA =
RA =

0.0052 x 4000 x 1n (5./0.0115)

112
1.13 ohms

16) Determine the total circuit resistance (RT) of the

riser anode, from equation 1-12:
RT = RA + RW + RC
Where:
RA =

Anode-to-water
resistance
single anode rod.

RW =

Wire resistance.

RC =

Tank-to-water resistance.

of

a)

Anode-to-water resistance (RA) = 1.13 ohms from

step 15 of paragraph 2-7b.

b)

Header cable/wire resistance (RN) from equation

1-15:

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RW '
Where:
LW =

RMFT =

RW =

LW RMFT
1000 ft
240 ft (After reviewing figure 2-20,
it is estimated that 240 ft of wire
will be required to
connect
the
rectifier to the riser anode string)
0.640 ohm (Wire resistance per 1000
lin ft of No. 8 AWG HMWPE insulated
wire)
240 ft x 0.640 ohm
1000 ft

= 0.15 ohm

Since this anode string is very long, the metal

of
the anode can represent a significant
resistance. Since the current discharges all
along the anode, one half of its length is used
in the resistance calculation.
Manufacturer's
data
show
the
longitudinal
resistance of a single 4-ft anode segment to be
0.053 ohm.
Effective resistance of the string
is:
0.053 ohm/anode x 28 anodes
2

= 0.74 ohm

This resistance is very high compared to the

anode resistance (greater than 10 percent) as a
result, too much current will discharge near the
top of the anode and not enough current will be
discharged near the bottom of the anode.
Therefore, either a double-end feed method will
have to be used or copper-cored rods must be
used. (Note: This is usually only a problem in
fresh water applications when the anode rod
length is greater than 30 ft.) In this case, we
will elect to use copper cored 1/8-in. diameter
rods. Manufacturer's data show the longitudinal
resistance of a single 4-ft long copper-cored rod
of this diameter is 0.0034 ohm.
Effective
resistance of this string is therefore:
0.0034 ohm/anode x 28 anodes
2
99

= 0.048 ohm

ETL 1110-9-10(FR)
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Thus, the copper cored anode longitudinal
resistance
is less than
10 percent of the
anode-to-water resistance (0.048 ohm/1.13 ohm 0.043 = 4.3 percent) making this an acceptable
riser anode design.
c)

Tank-to-water
resistance (RC)
circuit resistance = 0.0 ohm.

and

negative

d)

Calculate total resistance of the riser circuit

(RT):
RT = 1.13 + 0.15 + 0.0
RT = 1.28 ohms for riser anode.

17) Calculate the rectifier voltage (VREC) and current:

a)

First, determine the voltage requirement (E) for

each circuit using Ohm's Law:
E = I RT
Where:
I =
RT =

Current requirement.
Total circuit resistance.

Main Anodes:
I = 17.7 amp (from step 11c).
RT = 1.46 ohms (from step 13b).
E = 17.7

x 1.46 = 25.8 V

Stub Anodes:
I =
RT =

1.3 amp (from step 11c).

21.16 ohms (from step 13c).

E = 1.3 x 21.16 = 27.5 V

Riser Anodes:
I =
RT =

14.5 amp (from step 4)

1.28 ohms (from step 16d)

E = 14.5 x 1.28 = 18.6 V

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ETL 1110-9-10(FR)
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b)

Summarize each circuit's resistance,

requirement and voltage requirement:
Circuit
(amp)

Main anodes
Stub anodes
Riser anodes
Total current
requirement
c)

Current Resistance
(ohm)

17.7
1.3
14.5

current

Voltage Required
(V)

1.46
21.16
1.28

25.8
27.5
18.6

33.5

Determine the rectifier voltage (VREC) based on

the largest circuit voltage requirement of 27.5
V, because voltage requirement varies for all
three circuits. With a 120 percent safety factor
as in equation 1-17, the rectifier voltage is
calculated:
27.5 x (120%) = 33 V
Total current required = 33.5 amp.

c.

Select rectifier
1)

Rectifier capacity.
A commercially available rectifier having a rated
output of 40 V, 42 amp is selected.
Because of the different circuit resistances, separate
control of each circuit is required.
This is best
handled by a rectifier having three separate output
circuits.

2)

Automatic potential control

To prevent over or under protection as the water level
varies, automatic potential control is specified. The
tank and riser-to-water potentials are maintained by
the controller through permanent copper-copper sulfate
reference electrodes suspended within the bowl and
riser. The reference electrodes should have a life of
at least 15 years.
The automatic controller is located in the rectifier
unit. The controller must be capable of sensing the
potential accurately and free of IR (voltage) drop
error.
The control does this by turning off the
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ETL 1110-9-10(FR)
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rectifier for a fraction of a second, during which
time the tank-to-water potential is measured.
The
measurement is then compared with a preset standard
and the output adjusted accordingly.
d.

Installation details.
Figures 2-19, 2-20, and 2-21 show typical details.

e.

Guidelines for number of anode rings required.

The number of rings of anodes required varies with tank
diameter. Table 3-7 gives suggestions.

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2-8.

On-Grade Water Storage Reservoir (Ice Is Expected).

Impressed current cathodic protection is to be designed for the

existing ground level water reservoir shown in figure 2-22.
Coating is in poor condition and expected to deteriorate in the
future.
As the tank is not heated, ice forms in the winter.
Current requirement tests have been made.
a.

Design data.
1)

Tank is cylindrical with a flat bottom.

2)

Water resistivity is 2000 ohm-cm.

3)

Tank dimensions are:

Capacity = 250,000 gal
Diameter of bowl = 46 ft
High water depth = 20 ft.

4)

Design cathodic protection anodes for a 15-year life

since tank will be repainted at that time.

5)

Wire type ceramic anode will be used.

6)

Design current density is 2.5 A per sq ft of tank area

to be protected.

7)

Wetted surfaces are poorly coated.

As coating is
expected to deteriorate, design for bare tank.

8)

Area above high water level will be kept well coated.

9)

Tank is subject to freezing and therefore a hoop type

anode support system will be used.
10) Electrical power available is 120 V AC, single phase.
11) Current requirement at present for adequate cathodic
protection is 9.0 amp.
b.

Computations.
1)

Find the area of the tank to be protected (A).

A = 2 B r h + B r2

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Where:
r =

2)

23 ft (Tank radius
paragraph 2-8a)

from

item

of

h =

20 ft (High water depth from item 3 of

paragraph 2-8a)

A =

2 it x 23 x 20 + it x 232

A =

2890 + 1662

A =

4552 sq ft

Compute the current requirement (I) using equation

1-11:
I = (A)(I')(l.0 - CE)
Where:
A =

4552 sq ft
(Area of tank to be
protected from previous calculation)

I' =

2.5 mA/sq ft (Required current

from item 6 paragraph 2-8b)

density

CE =

0.0 (Coating efficiency, assuming tank

will eventually be essentially bare)

Current required:
I =

2.5 IDA/sq ft x 4552 sq ft

I =

11,380 IDA; use 12 amp

Since the computed 12 amp is larger than the tested

requirement of 9 amp, use the 12 amp as the required
current.
3)

Calculate the length of anode wire in ft (LB) needed

for the current required, using a modification of
equation 1-2:
LB =
Where:
I =

I
IA

12
amp
(Current
requirement
previous calculation)
106

from

ETL 1110-9-10(FR)
5 Jan 91
IA =

Allowable amp per ft of anode wire

(varies
depending
on desired anode
life and diameter), found in table A3.

Based on
selecting a wire anode of
0.0625-in.
diameter, the minimum wire length and hoop diameter
can be calculated:
For 0.0625 in. LB

4)

12 amp
0.31 amp/ft

38.7 ft
(Length of
Wire for
15-Year Life)

12 ft 4 in
(Minimum
Diameter of
Wire Circle)

Calculate the desired diameter of the anode wire

circle (DR). Experience shows that the diameter of
the anode wire circle should be between 40 and 70
percent of the tank diameter for a cylindrical tank.
In this case, we will try a hoop shape with a diameter
equal to 60 percent of the bowl diameter:
DR = 60% x 46 ft = 27.6 ft; use 27 ft 6 in

5)

Calculate the anode anode-to-water resistance (RA)

from equation 1-14:
RA '

8 DR
2 DR
0.0016 p
(1n
% 1n
DR
DA
H
Where:
p =

2000 ohm-cm (Water resistivity from

item 2 of paragraph 2-8a)

DR =

27.5 ft (Anode ring diameter from

previous calculation)

DA =

Assume
0.0052
ft
(0.0625
in)
(Diameter of anode wire from step 3
of paragraph 2-8b)

107

ETL 1110-9-10(FR)
5 Jan 91
H =

12 ft (Anode depth below water

surface)
Anode
depth
has
been
determined
from
the
following
calculations:

The distance from the bottom of the tank to the anode

wire circle should be about 40 percent of the water
depth.
Water depth
2-8a.

20 ft from item 3 of paragraph

20 ft x 40% = 8 ft
Anode depth below water surface (H):
H = 20 ft - 8 ft = 12 ft
Calculate RA:
RA

= 0.0016 x 2000 [in 8 x 27.5 + in 2 x 27.5]

27.5
0.0052
12

RA

= 0.1164 [ln 42,307.7 + ln 4.6]

RA

= 0.1164 [10.65 + 1.531

RA

= 1.42 ohm

At a current requirement of 12 amp, voltage required

for this resistance, from Ohm's Law is:
E

= I x RA

= 12 x 1.42 = 17.2 V

This is a reasonable voltage, so the resistance of

1.42 ohms is acceptable.
6)

Determine the total circuit resistance (RT), from

equation 1-3:
RT = RN + RW + RC
Where:
RN = RA = Anode-to-water resistance.
RW = Header cable/wire resistance.
RC = Tank-to-water resistance.
108

ETL 1110-9-10(FR)
5 Jan 91
a)

Anode-to-water resistance = 1.42 ohms from step

5.

b)

Header cable/wire resistance (RW) from equation

1-15:
LW RMFT

RW '
Where:
LW =

RMFT =

1000 ft
The positive wire from the rectifier
to the first splice is 15 ft long.
The power feed then continues on
around the hoop to the opposite
side. The length of this run is
about 43.2 ft but since only half
the current is passing through this
portion, its effective length is
43.2/2 = 21.6 ft.
1.02 ohms (From table 3-6, based on
selecting No. 10 AWG cables)

RW =
RW =
c)

(15 ft + 21.6 ft) x 1.02 ohms

1000 ft
0.037 ohm

Negative circuit and tank-to-water resistance

(RC).
The negative wire is connected to the tank
structure near the rectifier, so its resistance
is negligible. Tank-to-water resistance is also
negligible.

d)

Calculate RT:
RT = 1.42 + 0.037 + 0.00
RT = 1.457 ohms; use 1.5 ohms
This is well below the design requirement.

7)

Calculate the rectifier voltage (VREC) from equation 117:

109

ETL 1110-9-10(FR)
5 Jan 91
VREC = (I) (RT) (120%)
Where:
I
=

c.

12 amp (Current requirement from

step 3)
1.5 ohms (Total circuit resistance
from previous calculation)
Rectifier voltage capacity design
safety factor.

RT

120%

VREC

12 amp x 1.5 ohms x 1.2

VREC

21.6 V

Select rectifier.
Based on the design requirements of 21.6 V and 12 amp, a
commercially available 24-V 16-amp unit is selected.

d.

Automatic potential control.

To prevent over- or under-protection as the water level
varies, automatic potential control is specified. The tank
and riser to water potential is maintained by the
controller
through
permanent
copper-copper
sulfate
reference electrodes suspended with the bowl and riser. The
reference electrodes should have a design life of at least
15 years.
The automatic controller is located in the rectifier unit.
The controller must be capable of sensing the potential
accurately and must be free of IR (voltage) drop error.
The controller does this by turning off the rectifier for
a fraction of a second, during which time the tank-to-water
potential is measured. The measurement is then compared
with a present standard
and the output adjusted
accordingly.

e.

Installation details.
Figures 2-22 and 2-23 show typical details.

f.

Loop anode attachment guidelines.

110

ETL 1110-9-10(FR)
5 Jan 91
The wire circle, or loop anode is supported from the sides
of the tank by polyester rope as shown in figure 2-22. The
number of supports varies with the tank diameter as
recommended in table 3-8.

111

ETL 1110-9-10(FR)
5 Jan 91

112

ETL 1110-9-10(FR)
5 Jan 91
2-9.

Horizontal Anodes. (Underground Applications)

There are times when it is advantageous to install anode
horizontally as shown in figure 2-24. For further information,
see paragraphs 10.91 through 10.93 of TM 5-811-7 (reference
10). This configuration is particularly helpful when using
packaged ceramic anodes (figure 2-24) since earth backfill can
be solidly tamped around them. The anodes can be laid on the
bottom of a trench or excavation with compacted backfill. This
often achieves better compaction than when tamping in vertical
holes.
The design is undertaken in the same manner as
described in Section 2-2 and 2-3. The single anode-to-earth
resistance is calculated by using equation 2-11:
(eq 2-11)

Where:
RA
p
L
d
h

=
=
=
=
=

Anode-to-electrolyte resistance in ohms.

Electrolyte resistivity in ohm-cm.
Length of anode in ft.
Diameter of anode in ft.
Depth of anode in ft.

This equation is used to calculate the resistance

of a single anode-to-earth.
For multiple anode installations, equation 1-11 may be used to
approximate total resistance:

RN '

RA
N

p PF
CC

113

ETL 1110-9-10(FR)
5 Jan 91

114

ETL 1110-9-10(FR)
5 Jan 91
Where:
RN =

Resistance-to-electrolyte of "N" number

of anodes

RA

Resistance-to-electrolyte of a single
horizontal anode

Number of anodes

Electrolyte resistivity in ohm-cm

PF

Paralleling factor (table 3-5)

CC

Spacing between anodes in ft. (The

spacing between anodes is taken as the
center-to-center
distance
between
horizontal anode.)

As before, when equation 1-11 is applied to horizontal anodes,

it yields approximate results. This is because the equation is
based on vertical anodes.
However, the results are
sufficiently accurate for cathodic protection design.

115

ETL 1110-9-10(FR)
5 Jan 91
2-10.

Backfilling Packaged Anodes With Coke Breeze.

Although the calculations shown in Sections 2-2 and 2-3 assume

that the packaged ceramic anodes will be buried directly in
the earth, the accepted fail-safe design practice is to bury
the packaged anode canister in a coke breeze backfill.
Backfilling the packaged anodes in coke breeze offers three
advantages. First, it reduces anode-to-ground resistance. A
typical example would be to backfill a 3-in. by 60-in. anode
in a 8-in. diameter by 84-in. long coke breeze column. These
dimensions, d = 0.66 ft and L = 7.0 ft, are then used in
equation 2-8 or 2-10 to calculate resistance-to-earth.
The second advantage of using coke breeze backfill around
packaged anodes is that coke breeze often results in better
compaction then does soil. This also reduces anode-to-ground
resistance and improves anode performance.
The most important reason, however, for backfilling these (as
well as any other) prepackaged anode is that gas-blocking of
the anodes will not occur.
Gases (primarily oxygen) are
released at the anode package surface. These can be entrapped
by the soil at the anode package surface which can prevent
further current discharge by the anode.
The coke breeze
provides a porous media through which these gases can migrate
and dissipate preventing the possibility of gas blocking.

116

ETL 1110-9-10(FR)
5 Jan 91
SECTION 3
TABLES
Table 3-1. Range of current density requirements for cathodic
protection of uncoated steel.

Environment

Neutral soil
Wellaerated neutral soil
Wet soil
Highly acidic soil
Soil-supporting active sulfatereducing bacteria
Heated soil
Stationary freshwater
Moving freshwater
Moving freshwater containing
dissolved oxygen
Seawater (depending on velocity,
temperature & oxygen content

Current density
APM 88-9a
0.4
2
1
3

to 1.5
to 3
to 6
to 15

(mA/sq ft of bare steel)

Gerrardb
Othersc
0.4
2
2.5
5

to 1.5
to 3
to 6
to 15

6
to 42
3
to 25
1
to 6
----- ------

Up to 42
5 to 25
Up to 5
--------

to 15

5 to 15

to 10

5 to 25

0.5
1.5
1
3

to 1.5
to 3
to 3
to 15

---------3 or more
1.5 to 3
3
to 8
----------

to 50

Corrosion Control, Air Force Manual (AFM) 889 (Headquarters, U.S. Air Force,
August, 1962), ch. 4, p. 203.
b
J.S. Gerrard, Practical Applications of Cathodic Protection, Corrosion,
(Newnes-Butterworths, London, 1976), vol. 2, p 11:65. Used with permission.
c
Data based on the experience of other Professional Cathodic Protection
engineers.

117

ETL 1110-9-10(FR)
5 Jan 91
Table 32. Typical Surface Area Per Linear Foot of Common Size
Pipe.
Nominal Pipe Size

Outside Diameter (in.)

3/4
1
1 1/4
1
2
2
3
3
4
5
6
8
10
12
14
16
18
20
22
24

0.840
1.050
1.315
1.660
1.900
2.375
2.875
3.500
4.000
4.500
5.563
6.625
8.625
10.750
12.750
14.000
16.000
18.000
20.000
22.000
24.000

Sq Ft/Lin Ft

0.220
0.275
0.344
0.434
0.497
0.621
0.752
0.916
1.047
1.178
1.456
1.734
2.258
2.814
3.338
3.665
4.189
4.712
5.236
5.760
6.283

___________
NOTE: Data on anodes shapes and sizes as well as recommended operating limits
were obtained from the following manufacturers:
APSMaterials Inc.
153 Walbrook
Dayton, OH 45405
(513) 2786547
FAX: (513) 2784352

Oronzio De Nora S.A.

P.O. Box 3387
Houston, TX 772533387
(713) 9783925
FAX: (713) 9783930

Materials Protection Company

P.O. Box 31354
Houston, TX 772311354
(713) 2700952
FAX: (713) 9880673
As their specifications change from time to time, it is recommended that the
designer contact the companies prior to specifying a particular anode to
determine what is currently available.

118

2"
3"
3"
3"

60"
60"
60"
96"

119
3" x 96"
3" x 96"
3" x 120"
3" x 120"

1/8" x 6'
1/4" x 6'

1/8" x 8'
1/4" x 8'

lbs.
lbs.
lbs.
lbs.

44 lbs.
44 lbs.

35 lbs.
35 lbs.

22 lbs.
23 lbs
24 lbs

12
22
22
35

6 lbs.
14 lbs.
26 lbs.

Weight

5.4
11.0

4.0
8.2

7.5
10.0
15.0

2.7
2.7
5.5
4.0

1.3
1.5
1.5

amps
amps

amps
amps

amps
amps
amps

amps
amps
amps
amps

amps
amps
amps

10-Year
Design Life
HDC*

_________
*Heavy Duty Coating Tubular Anodes (in Coke Breeze)
**Standard Coating Tubular Anodes (in Coke Breeze)

3"
3"
3"

x 60"
x 60"
x 60"

x
x
x
x

3/8" x 4'
" x 4'
3/4" x 4'

4'
4'
4'
6'

1/8"
1/8"
1/4"
1/8"

x
x
x
x

2"
2"
3"

1/8" x 2'
1/16" x 5'
1/16" x 5'

x 30"
x 72"
x 72"

Package
Size

Anode Element
Dimension

amps
amps
amps
amps

4.4 amps
8.8 amps

3.3 amps
6.6 amps

6.0 amps
8.0 amps
12.0 amps

2.2
2.2
4.4
3.3

1.10 amps
1.25 amps
1.25 amps
amps
amps
amps
amps

2.4 amps
4.8 amps

1.8 amps
3.6 amps

3.6 amps
4.8 amps
7.2 amps

1.2
1.2
2.4
1.8

0.6 amps
0.7 amps
0.7 amps

15-Year
Design Life
HDC*
SC**

amps
amps
amps
amps

3.6 amps
7.0 amps

2.7 amps
5.3 amps

5.1 amps
6.8 amps
10.0 amps

1.8
1.8
3.5
2.7

0.9 amps
1.0 amps
1.0 amps

amps
amps
amps
amps

2.0 amps
4.0 amps

1.5 amps
3.0 amps

3.0 amps
4.0 amps
6.0 amps

1.0
1.0
2.0
1.5

0.5 amps
0.6 amps
0.6 amps

20-Year
Design Life
HDC*
SC**

Current Rating - Amperes

Wire and Rod Anodes (Packaged)

Table 33. Dimensions and ratings of ceramic anodes.

Underground Usage

ETL 1110-9-10(FR)
5 Jan 91

ETL 1110-9-10(FR)
5 Jan 91
Table 3-3. (Cont*d)

Current Rating - Amp

20-Year
Design Life

Anode Element
Dimension
1" x 9.8"
1" x 19.7"
1" x 39.4"
0.63" x 9.8"
0.63" x 19.7"
0.63" x 39.4

2.00
4.00
8.00
1.25
2.50
5.00

120

amp
amp
amp
amp
amp
amp

ETL 1110-9-10(FR)
5 Jan 91
Table 33 (Cont*d). Fresh and Seawater Usage
Wire and Rod Anodes (Bare)

Life
(years)

Fresh Water

Brackish Water

Seawater

Maximum Current/1-ft Length for 20-Year Design Life of .0625 in. Dia. Wire
10
15
20

0.39
0.31
0.26

0.51
0.44
0.39

0.85
0.74
0.67

Maximum Current/1-ft Length for 20Year Design Life of .125 in. Dia. Rod or
Wire
10
15
20

0.79
0.62
0.52

1.02
0.88
0.79

1.70
1.47
1.33

Maximum Current/1-ft Length for 20Year Design Life of .25 in. Dia. Rod
10
15
20

1.58
1.24
1.04

2.04
1.76
1.58

3.41
2.95
2.66

Maximum Current/1-ft Length for 20-Year Design Life of .325 in. Dia. Rod
10
15
20

2.37
1.85
1.56

3.06
2.63
2.37

5.11
4.42
3.99

Maximum Current/1ft Length for 20-Year Design Life of .5 in. Dia. Rod
10
15
20

3.16
2.47
2.08

4.08
3.51
3.16

6.81
5.90
5.33

Maximum Current/1-ft Length for 20Year Design Life of .625 in. Dia. Rod
10
15
20

3.95
3.09
2.60

5.10
4.39
3.95

8.52
7.37
6.66

Maximum Current Per 1-ft Length for 20Year Design Life of .75 in. Dia. Rod
10
15
20

4.74
3.71
3.12

6.12
5.27
4.74

121

10.22
8.85
7.99

ETL 1110-9-10(FR)
5 Jan 91
Tubular Anodes (Bare)

Seawater Current in amp per anode (15Year Design Life)

1 in. x 19.7 in.
1 in. x 39.4 in.
0.63 in. x 19.7 in.
0.63 in. x 39.4 in.

25
50
15
30

amp
amp
amp
amp

Sea Mud - Current in amp per anode (20-Year Design Life)

1 in. x 19.7 in.
1 in. x 39.4 in.

6 amp
12 amp

Fresh Water Current in amp per anode (20Year Design Life)

1 in. x 19.7 in.
1 in. x 39.4 in.
0.63 in. x 19.7 in.
0.63 in. x 39.4 in.

4.00
8.00
2.50
5.00

amp
amp
amp
amp

Current Density Limitations

Wire and Rod Anode
Anode Life Versus Maximum Current Density (ampere/sq ft)

Life
(years)

Coke

Fresh Water

Brackish Water

10

19

24

31

52

15

15

19

27

45

20

13

16

24

41

_________________
* Anode packaged in coke breeze

122

Seawater

ETL 1110-9-10(FR)
5 Jan 91
Tubular Anodes
Anode Life Versus Maximum Current Density (ampere/sq ft)

Life
(years)

Coke

Fresh Water

Brackish Water

Seawater

20

9.3

9.3

9.3

56 **

_________________
*Anode packaged in coke breeze
**15-Year Design Life

Disc Anodes (see figure 2-28)

Size:
Active Area:
Weight:

5in, diameter (Typical Other sizes available)

19 sq in.
2.0 lb
Fresh Water
Salt Water

Current Capacity - 20-year life (amp/anode)

0.84

5.0

Operating voltage - 20-year life (V)

20.0

10.0

Segmented Rod Anodes (see figure 2-2 9)

Size:
Active Area:
Weight:

4ft lenglth; 0.138 in. diameter

22 sq in.
2.3 oz
Fresh Water

Current Capacity - 20-year life (amp/anode)* 1.00

Operating voltage - 20-year life (V)

50.0

_______________
*Standard Coating

123

Salt Water
2.5
10.0

ETL 1110-9-10(FR)
5 Jan 91
Table 34. Shape functions (K) for impressed current cathodic
protection anodes where L is effective anode/backfill length and
d is anode/backfill diameter.

L/d

L/d

5
6
7
8
9
10
12
14
16
18

0.0140
0.0150
0.0158
0.0165
0.0171
0.0177
0.0186
0.0194
0.0201
0.0207

20
25
30
35
40
45
50
55
60

0.0213
0.0224
0.0234
0.0242
0.0249
0.0255
0.0261
0.0266
0.0270

Table 3-5. Anode paralleling factors (P) for various numbers of

anodes (N) installed in parallel.

2
3
4
5
6
7
8
9
10
12

0.00261
0.00289
0.00283
0.00268
0.00252
0.00237
0.00224
0.00212
0.00201
0.00182

14
16
18
20
22
24
26
28
30

0.00168
0.00155
0.00145
0.00135
0.00128
0.00121
0.00114
0.00109
0.00104

124

ETL 1110-9-10(FR)
5 Jan 91
Table 36. Resistance and other parameters for stranded copper
conductors.

Size **
AWG
14
12
10
8
6
4
3
2
1
1/0
2/0
3/0
4/0
250 MCM
EPR/HY-50*
EPR/HY-16*

Overall
Diameter
Not Incl.
Insulation
(in.)
0.0726
0.0915
0.1160
0.1460
0.1840
0.2320
0.2600
0.2920
0.3320
0.3730
0.4190
0.4700
0.5280
0.5750
0.3730(1)
0.1840(2)

Approximate
Maximum
Weight
Maximum
Allowable
Not Incl.
Maximum DC Resistance DC Current
Insulation Breaking
at 20 EC
Capacity
(lb/M ft) Strength (lb)(ohms/M ft)
(ampere)
12.68
20.16
32.06
50.97
81.05
128.90
162.50
204.90
258.40
325.80
410.90
518.10
653.30
771.90
75.0(1)
87.0(2)

130
207
329
525
832
1320
1670
21.10
2660
3350
4230
5320
6453
7930
1896
628

2.5800
1.6200
1.0200
0.6400
0.4030
0.2540
0.2010
0.1590
0.1260
0.1000
0.0795
0.0631
0.0500
0.0423
0.1183
0.3658

15
20
30
45
65
85
100
115
130
150
175
200
230
255
150
50

___________
(1)
With insulation: Overall diameter = 0.88 in.; weight 610 lb/l000 ft.
(2)
With insulation: Overall diameter = 0.51 in.; weight - 200 lb/1000 ft.
* Data from Dow Chemical
** Data from Rome Cable Company

125

ETL 1110-9-10(FR)
5 Jan 91
Table 37. suggested number of anode rings for various size
tanks.

Tank Diameter
(ft)
24
30
36
42
48
54
60
66
72
78
84

Number of rings of anodes

Coated

Bare
1
1
1
1
1
1
2
2
2
2
2

1
1
1
1
2
2
2
2
2
3
3

Table 38. Recommended number of support points for loop anode

systems.

Tank Diameter (ft)

Number of Support Points

24
30
36
42
48
54
60
66
72
78
84

6
6
6
6
6
8
8
8
10
10
10

126

ETL 1110-9-10(FR)
5 Jan 91
Table 3-9. Adjusting factors for parallel anodes.

No. of Anodes
in Parallel
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
22
24
26
28
30

Adjusting Factors
5 ft
10 ft

Anode
15 ft

0.652
0.586
0.520
0.466
0.423
0.387
0.361
0.332
0.311
0.292
0.276
0.262
0.249
0.238
0.226
0.218
0.209
0.202
0.194
0.182
0.171
0.161
0.152
0.145

0.551
0.418
0.340
0.289
0.252
0.224
0.204
0.185
0.170
0.158
0.143
0.139
0.131
0.124
0.117
0.112
0.107
0.102
0.098
0.091
0.085
0.079
0.075
0.070

0.576
0.460
0.385
0.333
0.295
0.265
0.243
0.222
0.205
0.192
0.180
0.169
0.160
0.152
0.144
0.138
0.132
0.127
0.122
0.114
0.106
0.100
0.094
0.089

Spacing in Feet
20 ft
25 ft
0.538
0.397
0.318
0.267
0.231
0.204
0.184
0.166
0.153
0.141
0.132
0.123
0.116
0.109
0.103
0.099
0.094
0.090
0.086
0.079
0.074
0.069
0.065
0.061

0.530
0.384
0.304
0.253
0.218
0.192
0.172
0.155
0.142
0.131
0.122
0.114
0.107
0.101
0.095
0.091
0.086
0.082
0.079
0.073
0.067
0.063
0.059
0.056

Table 310. Cathodic Protection System Recommended Allowable

Circuit Resistance

System
Current (I)
(amp)
5
10
20
30
40
60
80

Resistance (RT) in ohm

Maximum
Typical
10
6
3
2
1.5
1.0
0.75

127

5
3
2
1.3
1.0
0.6
0.4

ETL 1110-9-10(FR)
5 Jan 91
SECTION 4
IDENTIFICATION OF VARIABLES
A

Total surface area to be protected.

AR

Radius of anode circle (rod system).

AS

Area protected by a single anode.

ASB =

Area protected by stub anodes.

CC

Center-to-center spacing of anodes.

CE

Coating efficiency in decimal form (0 to 0.99)

Anode backfill diameter.

Tank diameter.

DA

Diameter of anode wire or rod.

DE

Equivalent diameter factor for anodes in a circle

(for submerged applications).

DR

Diameter of anode ring (wire anode system).

Rectifier efficiency expressed in decimal form.

Fringe factor (for submerged rod anodes).

FADJ =

Adjusting factor for parallel anodes.

Anode depth below water surface.

Total current requirement based on field test or

assumed current density per square foot of bare
steel.

Required current density.

IA

Maximum current per anode for the anode's desired

life.

Shape function.

Effective anode length.

128

ETL 1110-9-10(FR)
5 Jan 91
LAVG =

Average lead wire length of anodes with

individual lead wires run in parallel.

LB

Bare anode length (used in submerged applications).

LF

Expected anode life.

ln

Natural or Napierian logarithm.

LW

Header cable/wire length.

Anode depth below water surface in centimeters.

Number of anodes required to meet the desired life of

a cathodic protection system.

NS

Number of stub anodes required.

Greek letter pi, or 3.14159.

PF

Paralleling factor.

Greek letter rho, or Electrolyte resistivity in

ohm-centimeters.

Average coating resistance in ohm-square feet.

RA

Single anode-to-electrolyte resistance.

RADJ =

Adjusted resistance.

RC

Structure-to-electrolyte resistance.

RH

Single horizontal anode-to-electrolyte resistance.

RL

Single anode wire hoop-to-electrolyte resistance.

RMFT =

Resistance per 1000 linear feet of

cable/wire.

RN

Multiple anodes to electrolyte resistance.

RNEG =

Resistance of the rectifier-to-structure

negative (ground) cable.

Rs

Effective coating resistance.

RT

Total circuit resistance.

129

ETL 1110-9-10(FR)
5 Jan 91
RN

VREC =

Header cable/wire resistance.

Rectifier voltage.

130