Installation Services

Cathodic Protection Material Supply 

We can specify and supply cathodic protection materials required for the installation, monitoring, maintenance and repair of CP systems. Where required, materials can be supplied as a turnkey project package.

Materials can be supplied for both impressed currentand sacrificial anode systems, come examples are listed below:

• Sacrificial Magnesium, Zinc and Aluminium anodes
• Silicon iron and Titanium tube impressed current anodes and  groundbed assemblies
• Transformer rectifiers and CP control equipment
• Permanent and portable reference electrodes
• Test posts, junction boxes and monitoring stations
• Cable-to-structure connection materials; pin brazing, CAD welding etc
• Monitoring coupons and corrosion rate probes
• Isolation joints and insulating flange kits
• Polarisation cells, decouplers and surge-protection devices
• Interference bonds, resistors and shunts
• Cable markers, warning labels and installation accessories
• CIPS, DCVG, ACVG and general CP test equipment
• Built in and portable current interrupters/timers.

Equipment can be selected to suit the asset, operating environment, electrical requirements and applicable project specifications. Technical support can also be provided to confirm component compatibility, material suitability and correct system ratings.

Relevant product datasheets, certification,test records and installation guidance can also be provided.

Cathodic Protection Training

Cathodic protection training provides engineers, technicians and asset operators with the knowledge and practical skills required to understand, operate, monitor and maintain CP systems effectively.

Classroom and site training can be tailored to suit the client’s assets, procedures and personnel experience. Courses may cover:

• Principles of corrosion and cathodic protection
• Material selection
• Legislative requirements for operators
• Types of CP systems, such as galvanic anode and impressed current CP systems
• CP system components and operating principles
• Basic design overview for various types of structures and anode systems
• Routine monitoring including structure-to-electrolyte potential measurement, coupon and electrical resistance probe testing
• Maintenance and adjustment of CP equipment – transformer rectifiers, test/bond facilities, etc
• Specialist overline surveys including CIPS, DCVG, ACVG and  current-mapping techniques
• Use of data loggers, pin braze equipment and other specialist equipment.

Training may combine classroom-based theory with practical field exercises using operational or purpose-built CP equipment. Site-specific instruction can also be provided for personnel responsible for particular pipelines, tanks, marine structures or other protected assets.

Courses can be structured as introductory awareness training, practical technician instruction or advanced training for engineers responsible for CP design, assessment and troubleshooting. Supporting notes, worked examples and competency assessments can be included where required.

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Cathodic Protection Installation & Supervision

Cathodic protection system installation and/or supervision by trained and competent personnel ensures that CP systems are constructed correctly in accordance with the approved design, project specifications and applicable industry specific standards.

Installation activities may include:

• Sacrificial/galvanic anode installation for buried, submerged or embedded structures
• Impressed current system installations including transformer rectifiers, terminal boxes, anode groundbeds
• Test facilities including permanent test equipment such as reference-electrodes, coupons and electrical resistance probes
• Isolation/insulation joints or kits
• AC/DC mitigation equipment including bonds and earthing
• Surge-protection, decoupling device
• Cable-to-structure connections, including pin brazing or approved alternatives

Technical supervision provides inspection and quality control throughout the work. This includes confirming equipment locations, materials used and installation methods; witnessing critical connections and tests; checking cable routing and identification; reviewing contractor records; and resolving site issues or design changes.

Following installation, continuity, isolation, cable resistance and component checks are typically completed before the system is energised. The CP system is then commissioned and adjusted, with structure-to-electrolyte potential measurements used to confirm that the required protection criteria are achieved.

A completion package typically records the as-built installed equipment, test results, commissioning data, drawings, photographs, certificates and recommended operating settings, providing a reliable basis for future monitoring and maintenance.

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Cathodic Protection System Commissioning and Testing

Cathodic protection system commissioning and testing confirm that a newly installed, modified or repaired CP system is operating correctly and achieving the required level of corrosion protection.

Commissioning activities typically include:

• Inspection of the completed installation against approved drawings and specifications
• Verification of anodes, cables, test posts, junction boxes and monitoring equipment
• Electrical continuity and cable-resistance testing
• Isolation joint and insulating flange testing
• Polarity checks before energisation
• Testing of transformer rectifiers, control equipment and protection devices
• Measurement of anode or groundbed resistance
• Confirmation of reference-electrode and monitoring-coupon operation
• Base or natural potential measurements
• Initial energisation and controlled adjustment of the system output    
• Structure-to-electrolyte ON and instant OFF potential measurements
• Assessment of current distribution and attenuation
• Interference testing on nearby structures where required

The recorded results are assessed against the approved design criteria and applicable cathodic protection standards. System settings are adjusted to provide effective protection while avoiding overprotection, coating damage or unacceptable interaction with other structures.

Any defects or performance issues are identified and corrected before final acceptance. Follow-up testing may be recommended after a period of operation to confirm polarisation and stable system performance.

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Pin Brazing Services

Pin brazing is a controlled method of making a permanent electrical connection to a steel pipeline or structure by soldering. The technique can be used on live gas lines provided that the wall thickness is within acceptable wall thickness.  The pin brazing process is not dependent upon the pipe diameter size or placement.

It is commonly used to attach cables for cathodic protection, test posts, monitoring equipment and electrical bonds.

During the process, a specially designed brazing pin and cable lug are positioned on a small area of prepared pipe steel. A portable pin-brazing machine passes a controlled electrical current through the pin, generating an arc at the contact point. The brazing silver alloy melts and bonds the pin or cable lug to the pipeline surface.

The process is completed very quickly and is considered a low temperature process, which limits the amount of heat transferred into the pipe wall/parent metal.

Pin brazing is commonly used to connect:

• Cathodic protection cables
• Pipe-to-soil potential test leads
• Electrical bonding cables
• Monitoring and data-logging equipment
• Drainage and interference-mitigation connections

A typical procedure includes:

1. Confirming the pipeline material, wall thickness and approved procedure.
2. Exposing and cleaning a small section of pipe to bright metal.
3. Checking the equipment and selecting the correct pin and brazing settings.
4. Positioning the cable lug and completing the braze.
5. Inspect and electrically test the connection.
6. Sealing the connection with an approved protective coating.
7. Repairing the pipeline coating around the work area.

Pin brazing provides a mechanically secure, low-resistance electrical connection while introducing significantly less heat than conventional welding. However, it must only be completed by trained personnel using approved procedures as incorrect equipment settings or surface preparation could produce an unreliable connection.

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Pipeline Thickness Testing

Pipeline thickness testing is a non-destructive testing technique used to measure the remaining wall thickness of a pipeline and identify metal loss caused by corrosion, erosion or wear.

The most common method is Ultrasonic Thickness Testing (UTT). A technician places an ultrasonic probe on the prepared pipe surface using a coupling gel. The probe sends a high-frequency sound pulse through the pipe wall and measures the time taken for the echo to return from the internal surface. The instrument uses this travel time and the material’s sound velocity to calculate wall thickness.

A typical survey involves:

• Confirming the pipe material and the original or nominal wall thickness
• Removing the coating, corrosion products or scale where necessary
• Calibrating the instrument using a suitable reference block/coupon
• Taking readings at predetermined locations or across a measurement grid
• Repeating unusual or low readings for confirmation
• Recording the results and comparing them with the acceptance criteria and previous inspections
• Reinstating the protective coating after testing

Pipeline thickness testing helps to:

• Detect and quantify internal or external metal loss
• Determine the pipeline’s remaining wall thickness
• Monitor corrosion rates by comparing readings over time
• Identify areas requiring repair or further inspection
• Support remaining-life and fitness-for-service assessments
• Confirm whether the pipeline remains suitable for continued operation
• Prioritise maintenance and replacement work

Individual ultrasonic readings measure only small areas, so grid testing or ultrasonic scanning may be used where more complete coverage is required. Other inspection methods, including corrosion mapping and inline inspection tools, which may also be used for extensive areas.

In basic terms, pipeline thickness testing measures how much sound travels through the pipe wall to help us determine how much metal remains and whether corrosion or erosion has reduced its strength.

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Electrical Resistance Surveys

Electrical resistance surveys assess the electrical continuity, isolation and condition of cathodic protection circuits and connected metallic structures. They help identify high-resistance connections, damaged cables, short circuits and unintended current paths that can reduce CP system performance.

Testing may include:

• Resistance measurements across pipeline joints or flanges and connections
• Continuity testing of structures, casings and associated pipework
• Measurement of anode and groundbed circuit resistance
• Testing of structure, coupon, anode and reference-electrode cables and resistance to ground
• Assessment of cable-to-structure connections such as pin braze connections
• Checking bonds, shunts, junction boxes and test-post wiring
• Identification of unintended contact with foreign structures or earthing systems
• Comparison of measured values with design information and previous survey data

Low-resistance measurements may be completed using appropriate four-wire or specialised test methods to minimise the in fluence of test leads and contact resistance. For buried anode systems, resistance-to-earth testing may also be undertaken to assess ground bed condition and expected current output.

The results are analysed to locate defective or deteriorating components and determine their effect on current distribution and cathodic protection performance. Recommended actions may include repairing connections, replacing damaged cables, removing unintended bonds or carrying out further investigation.

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Magnetic Particle Inspection

Magnetic Particle Inspection (MPI) is a non-destructive testing technique used to detect surface and near-surface defects in ferromagnetic materials such as carbon steel and certain alloy steels.

The component is magnetised using suitable inspection equipment, and magnetic particles are applied to the test surface. Where a crack or discontinuity is present, magnetic flux leaks from the material and attracts the particles, producing a visible indication of the defect.

MPI can be used to inspect:

• The parent material before pin brazing or welded connections
• Welds and heat-affected zones
• Pipework, fittings and flanges
• Structural steelwork
• Tanks and pressure-containing equipment
• Fabricated components
• Areas around cathodic protection cable attachments
• Excavated pipeline defects and repair locations

Inspection may be undertaken using visible or fluorescent particles, depending on the required sensitivity and working conditions. The surface is prepared before testing, and any relevant indications are assessed against the applicable specification or acceptance criteria.

MPI is particularly effective for identifying cracking, lack of fusion, laps, seams and other discontinuities that may not be visible during a normal visual inspection. However, it is only suitable for materials that can be magnetised.

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Coating Assessment

A coating assessment evaluates the condition and effectiveness of protective coatings applied to pipelines, tanks, structures and other metallic assets. The objective is to identify deterioration, damage or defects that could expose the underlying metal to corrosion and increase cathodic protection current demand.

Assessment activities may include:

• Visual inspection for cracking, blistering, peeling, disbondment and mechanical damage
• Measurement of dry-film coating thickness
• Holiday detection to identify pinholes, voids and discontinuities
• Coating adhesion and hardness testing
• Assessment of surface preparation and coating application quality
• Inspection of field joints, repairs, welds and other vulnerable areas
• Investigation of coating damage identified by DCVG, ACVG or CIPS surveys
• Recording the location, dimensions and severity of coating defects
• Evaluation of compatibility with the cathodic protection system and operating environment

Where a pipeline is excavated, the coating can be inspected directly to determine the defect type, extent and likely cause. The exposed pipe surface may also be assessed for corrosion, with defects photographed and accurately referenced.

The findings are evaluated against the project specification, coating manufacturer’s requirements and applicable standards. Recommendations may include localised coating repairs, surface preparation, recoating, further inspection or ongoing monitoring.

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Hardness, Copper Penetration

Hardness testing and copper penetration assessment are used to verify that welding, brazing for cathodic protection cable attachment processes have not adversely affected the pipeline or parent material.

Testing is particularly relevant to pin-brazed cable connections and may include:

• Surface preparation and visual examination of the attachment
• Hardness measurements across the attachment and heat-affected zone
• Comparison of results with the specified maximum hardness limits
• Examination for cracking, localised hardening or other metallurgical damage
• Sectioning and metallographic examination of representative test samples
• Assessment of copper penetration into the parent steel
• Verification of the attachment procedure, equipment settings and consumables

Excessive hardness can increase susceptibility to brittle cracking, particularly in higher-strength steels or hydrogen containing environments. Copper penetration may also weaken the steel locally if molten copper enters grain boundaries during an incorrectly controlled brazing operation.

As copper penetration examination normally requires sectioning, it is generally undertaken on representative qualification samples rather than directly on an operational pipeline. The results are assessed against the approved procedure, project requirements and applicable acceptance criteria.

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