N102-169 TITLE: Advanced Reference Cells for Corrosion Control Systems

TECHNOLOGY AREAS: Ground/Sea Vehicles, Materials/Processes

ACQUISITION PROGRAM: NAVSEA PMS450 Virginia Class Submarine Program, ACAT I

OBJECTIVE: Develop and demonstrate capabilities of increased reliability reference cells for use in naval applications including submerged platforms and enclosed spaces.

DESCRIPTION: The legacy reference cells in use on VIRGINIA Class submarines have several performance and reliability issues which must be addressed to improve operational availability and lower maintenance and repair costs. No VIRGINIA class submarine to date has been delivered with 100% operational reference cells This has resulted in nuisance alarms, non-optimal operation of the Impressed Current Cathodic Protection (ICCP) system, and substantial rework and repair. In addition, reference cells in tanks and other confined spaces are frequently damaged or destroyed due to the lack of ruggedness and ease of damage in these areas.

Long term performance of existing and next generation digital controlled ICCP systems requires a high level of performance from reference cells. Condition based maintenance diagnostics for ships� underwater hull and ballast tanks rely on reference cell gathered data. Unknown amounts of drift in reference cell readings and unplanned failures of reference cells can disable these advanced systems. The need exists for increased reliability/maintainability in reference electrode assemblies. New materials/chemistries or conceptual designs for a stable microprocessor controlled electrochemical half-cell for seawater environments, are of interest. These half cell sensor materials must be fully reversible under seawater conductivity and temperature regimes. They must be able to operate in seawater/freshwater solutions that have a range of resistivity from 18 Ohm-cm to 20,000 Ohm-cm, with an operating temperature range of 30-95F. Sensors that are able to survive harsh toxic environments (such as sulfide containing seawater solutions) that limit existing technologies, are of additional interest. Reference cells should be designed such that installation and power up is simple and straight forward and cabling connections should be designed to survive significant levels of hydrostatic pressure and pressure cycling. Life and reliability requirements are targeted at greater than existing technologies (12 years). Reference cell drift should be minimized, controllable and well defined. On-board reference cell diagnostic or prognostic features are desirable. These features will aid in development of systems that can fully exploit reference cell capabilities and performance over time. Reference cells developed must operate in a seawater environment of varying conductivity and temperature and be compatible with ship systems in general. Reference cells should require minimal maintenance and designed so that components are modular and underwater replaceable.

PHASE I: Develop and demonstrate prototype reference cell performance for long term evaluation in a laboratory environment simulating Navy operational needs. Demonstrate manufacturability and installation parameters which lead to consistent, repeatable measurements under realistic conditions.

PHASE II: New reference cells could be applied to a broad range of military and civilian maritime and infrastructure applications where ICCP systems are relied upon for corrosion protection � for example, commercial shipping and interstate highway bridge maintenance.

PHASE III: As part of Phase III complete electrode assemblies will be evaluated to provide proof of conformance with pertinent shipyard specifications (these will be provided during development). Final prototypes meeting the relevant performance exit criteria will be installed by shipbuilder trades to demonstrate installation ability. After these tests, if selected, the products will be included in the FNC transition path. The FNC transition strategy includes integration of components by PMS450 into the R&D programs for VIRGINIA Block IV.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: New reference cells could be applied to a broad range of military and civilian maritime and infrastructure applications where ICCP systems are relied upon for corrosion protection � for example, commercial shipping and interstate highway bridge maintenance.

REFERENCES:
1. K. E. Lucas, E. D. Thomas, K. I. Kaznoff and E. Hogan, "Design of Impressed Current Cathodic Protection Systems for US Navy Hulls," Designing Cathodic Protection Systems for Marine Structures and Vehicles, ASTM, STP 1370, pp. 17-38, 1999.

2. Underwater Ship Husbandry Manuals, Chapter 19, Cathodic Protection Systems, S0600-AA-PRO-190, NAVSEA 00C5 (Distribution A).

3. R. A. Adey (ed), Modelling of Cathodic Protection Systems, Chapter 2, Shipboard Impressed Current Cathodic Protection System Analysis, WIT Press, 2005.

KEYWORDS: Reference cells; electrochemistry; corrosion; condition based maintenance

** TOPIC AUTHOR (TPOC) **

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