Continuity Testing Procedure For

CONTINUITY TESTING PROCEDURE FOR
IMPRESSED CURRENT CATHODIC PROTECTION SYSTEMS
Fixed Cell – Moving Ground Continuity Test Procedure
1. Place reference electrode in contact with the soil at a location remote (25 – 100 feet) from
all cathodically protected structures. You must ensure that the remote reference electrode
placement is not in proximity to any other cathodic protection systems (e.g. natural gas
pipelines) or directly over any buried metallic structure in order to minimize the chances of
unwanted interference.
2. Be sure that reference electrode is firmly placed in moist soil and is not in contact with any
vegetation.
3. Connect reference electrode to the negative terminal of voltmeter using a long spool of
suitable wire.
4. Connect positive lead wire to voltmeter. This lead wire should have a sharp test prod
(scratch awl or similar) in order to assure good contact with the metallic structures under
test.
5. Place voltmeter on 2 volt DC scale.
6. Contact each buried metallic structure with the positive test lead without moving the
reference electrode. Typical items that would be tested during a continuity survey include:
all tanks, tank risers, submersible pump heads, piping, flex connectors/swing joints, vent
lines, electrical conduits, dispensers, utilities, etc.
7. Obtain voltage for each component and record on the continuity testing portion of the form
8. Voltages for each component that is tested must be obtained as quickly as possible since
the observed potential can change over time. This is because the conditions in the soil
where the reference electrode is placed can change over a relatively short period of time.
Fixed Cell – Moving Ground Data Interpretation
 If two or more structures exhibit potentials that vary by 2 mV or less, the structures are
considered to be electrically continuous.
 If two or more structures exhibit potentials that vary by 10 mV or greater, the structures are
considered to be electrically isolated.
 If two or more structures exhibit potentials that vary by more than 2 mV but less than 10 mV,
the result is inconclusive and further testing (point-to-point) is necessary.
Point-to-Point Continuity Test Procedure

 Turn off power to rectifier if testing an impressed current system. This is necessary to obtain
accurate results.
 Connect test leads to voltmeter. Both test leads should have a sharp test prod or suitable clip
lead in order to make good contact with tested structures.
 Place voltmeter on 2 volt (or lower) DC scale.
 Connect one voltmeter test lead to one of the structures for which continuity is being tested
and connect the other voltmeter test lead to the other structure that is being tested.
 Record voltages observed on each of the two structures that are being compared and record
on the continuity testing portion of the form DEP8052 and DEP8053.
Note: Testing with this method does not require a reference electrode. The two structures of interest
are simply connected in parallel with the voltmeter and a determination made as to whether or not
any potential difference exists between them.
Point-to-Point Data Interpretation
 If the voltage difference observed between the two structures is 1 mV or less, this indicates
that the two structures are considered to be electrically continuous with each other.
 If the voltage difference observed between the two structures is 10 mV or greater, this
indicates that the two structures are considered to be electrically isolated from each other.
 If the voltage difference observed between the two structures is greater than 1mV but less
than 10 mV, the result is inconclusive and further testing beyond the scope of this document
is necessary.
STRUCTURE-TO-SOIL TEST PROCEDURE FOR

IMPRESSED CURRENT CATHODIC PROTECTION SYSTEMS
1. rectifier for proper operation and document necessary information. This includes
measurement of output voltage/amperage with a multi-meter (do not rely on rectifier gauges)
and measurement of individual anode circuits (if installation allows such). Record all
necessary information under Section XI and XII of the impressed current cathodic protection
system evaluation form DEP8053 form.
2. Place voltmeter on 2 volt DC scale.
3. Connect voltmeter negative lead to reference electrode.
4. Place reference electrode in clean soil directly over the structure that is being
tested. At least one measurement must be taken for each tank - the preferred test point is
usually the center of the tank. Piping normally requires measurement at each end of the pipe.
 The reference electrode may not be placed on concrete or other paving materials.
 Ensure that the reference electrode is placed in a vertical position (tip down).
 Ensure that the soil where the reference electrode is placed is moist – add tap water if
necessary.
 Ensure that the soil where the reference electrode is placed is not contaminated with
hydrocarbons.
 Ensure that the reference electrode window is not exposed to direct sunlight.
5. Connect voltmeter positive lead to structure that is to be tested.
 Ensure that good metal-to-metal contact is made between the test lead clip/probe and the
structure.
 Ensure that no corrosion exists where the test lead makes contact with the structure.
 Ensure that your body does not come into contact with the electrical connections.
 Ensure that test leads are not submerged in any standing water.
 Ensure that test lead insulation is in good condition.
5. Obtain voltage potential with the protective current applied and record in the on column on
6. the Impressed current cathodic protection evaluation form DEP8053.
7. Without moving reference electrode from the position it was in during step 6 above, obtain
voltage potential with the protective current temporarily interrupted and record in the instant
off column on the impressed current cathodic protection evaluation form DEP8053.
 The instant off potential is the 2nd value that is observed on a digital voltmeter the instant
the power is interrupted. The first number that appears immediately after power interruption
must be disregarded. After the second number appears, a rapid decay (depolarization) of the
structure will normally occur.
 In order to obtain instant off potentials, a current interrupter or a 2nd person is necessary. If
a current interrupter is not available, have the second person throw the power switch at the
rectifier off for 3 seconds and then back on for 15 seconds. Repeat this procedure until you
are sure an accurate instant off reading has been obtained.
8. Conduct 100 mV polarization decay if you are unable to obtain an instant off potential of -850
mV or more negative in step 7 above. (Note: While not a requirement of this form,
consideration should be given to adjusting the rectifier output until an instant off potential of
-850 mV is achieved or the maximum safe output is reached.) It is only necessary to conduct
100 mV polarization where the lowest (most positive) instant off potential is observed on the
UST system.
 100 mV of polarization is determined by leaving the power interrupted on the structure until a
change of at least 100 mV in the structure-to-soil potential is observed. In calculating the 100
mV decay, the instant off potential obtained in Step 7 above is utilized as the starting point
(e.g. if instant off = -800 mV, power must be left off until decayed to -700 mV).
Calculate voltage change by subtracting final (or ending) voltage from the instant off voltage and
record these values in the appropriate columns on the impressed current cathodic protection
evaluation form
DEP8053.
Data Interpretation
 If the instant off potential is -850 mV or more negative, the 850 off criterion is satisfied and it
is judged that adequate cathodic protection has been provided.
 If the instant off potential is more positive than -850 mV, the tank may or may not be
adequately protected and a 100 mV polarization test is necessary.
 If the structure exhibits more than 100 mV polarization, the 100 mV polarization criterion is
met and it is judged that adequate cathodic protection has been provided. If you are unable
to meet either the 850 instant off or the 100 mV polarization criteria, it is judged that
adequate cathodic protection has not been provided and repairs/modification are indicated.
Alternatively, a person qualified as a corrosion expert could evaluate/conduct the survey and
determine that cathodic protection is adequate based on their interpretation.
GENERALIZED INTERPRETATION OF STRUCTURE-TO-SOIL POTENTIAL MEASUREMENTS

(VOLTAGES) OBTAINED ON IMPRESSED CURRENT CATHODIC PROTECTION SYSTEMS
Listed in this table are some generalized observations that can be applied to the interpretation of structure-to-
soil potentials. Depending on the site-specific conditions and other factors, differing interpretations are possible.
VOLTAGE (mV) GENERALIZED INTERPRETATION
ANY POSITIVE Can indicate that the structure you are attempting to measure is not bonded to the impressed
VOLTAGE OR current system (conduct continuity testing). Stray current could be affecting the protected
0 TO -100 structure (consult a corrosion expert). Positive and negative wires could be reversed
“ON” or “OFF” (negative must be to protected structure and positive to anode). Test leads are reversed
(positive lead must contact structure and negative lead must be connected to reference
electrode). Could indicate that you are measuring the potential of a copper wire.
-101 to -399 Try again – A reading in this range is not normally seen on an underground steel structure.
“ON” or “OFF” Could indicate that steel structure is electrically connected to a significant amount of a more
noble metal (e.g. copper). Very corroded low carbon steel may also be indicated.
-400 to -599 Usually means that the steel structure has no cathodic protection. Existing impressed
“ON” or “OFF” current anodes could be completely “burned-out”. Continuity of anode lead wires (positive
circuit) could be broken. Negative bonds on the protected structures may be broken or non-
existent.
Usually means that the steel structure has some protection but for whatever reason,
-600 to -849 something is causing a low reading that may indicate adequate cathodic protection has not
“ON” or “OFF” been provided. The impressed current system may be trying to protect a structure that
requires more current than it can produce (rectifier output too small). The impressed current
system may not be capable of effectively distributing the required current to all parts of the
structure you are trying to protect (not enough anodes, anodes improperly installed, soil
resistivity too high). The steel structure that is intended to be protected may not be electrically
continuous with the other metallic structures under protection (conduct continuity testing).
The environmental conditions may not be favorable at the time you are attempting to obtain
the reading. Retest during the next 90 days.
-850 or MORE Steel structure may or may not be adequately protected. Usually indicates that the impressed
NEGATIVE current system is providing current to the structure although the reading normally includes a
“ON” large voltage (IR) drop. Because the flow of current through the soil causes a voltage drop,
the on potential cannot be used to indicate that adequate cathodic protection has been
provided. Instant off potentials must be utilized to demonstrate cathodic protection.
-850 or MORE Steel structure protected by impressed current system meets regulatory requirements and
NEGATIVE cathodic protection is judged to be adequate. A potential measurement of -850 mV or more
“OFF” negative with the protective current temporarily interrupted (850 off) is considered to be the
best indicator that adequate cathodic protection has been provided.
MORE Instant off potentials more negative than -1220 mV are theoretically not possible. If you
NEGATIVE observe an instant off potential more negative than -1220 mV, you should suspect stray
THAN -1220 mV current is affecting the protected structure. Consult a corrosion expert immediately since
“OFF” stray current can cause a rapid corrosion failure of the protected structure.
Usually means that a high resistance exists in the ground bed that is causing a large
MORE voltage drop. This condition is normally evident by checking the rectifier output since the
NEGATIVE voltage is very high but the amperage is relatively low. However, you should be cautious
THAN -2000 when abnormally high voltages are observed since this can have a detrimental effect on
“ON” cathodically protected structures or the anodes may be rapidly depleted. Stray current may
also be generated that can adversely affect other buried metallic structures such as
waterlines and other utilities. Consult a corrosion expert whenever it is suspected that
too much voltage is being generated.
If the voltmeter readings vary, you should suspect that stray current may be affecting
VARIABLE the cathodically protected structure. Sometimes, the stray current can cause a pattern to
“ON” or “OFF” develop that is recognizable. An example would be the on/off pattern of a nearby DC
powered welding operation. A corrosion expert must be contacted immediately since stray
current can cause a corrosion failure in a relatively short period of time.
RAPIDLY If the voltmeter will not stabilize, it usually means that there is a high electrical resistance
somewhere. Check all lead wires and connections and make sure that you are making
FLUCTUATING a solid and clean metal-to-metal connection. Soil where the reference electrode is placed
“ON” or “OFF” could be too dry. Add water to the soil or wait until a heavy rain occurs and try again.
Petroleum contaminated soils may cause a high contact resistance. The tip of the reference
electrode may need to be cleaned or replaced.

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CONTINUITY TESTING PROCEDURE FOR

IMPRESSED CURRENT CATHODIC PROTECTION SYSTEMS

Fixed Cell – Moving Ground Continuity Test Procedure

Fixed Cell – Moving Ground Data Interpretation

Point-to-Point Continuity Test Procedure

STRUCTURE-TO-SOIL TEST PROCEDURE FOR

GENERALIZED INTERPRETATION OF STRUCTURE-TO-SOIL POTENTIAL MEASUREMENTS

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