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Cathodic Protection Calculation

SYME-ELBASC-ENEL-CNEL-0001-B02

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Cathodic Protection Calculation

B02

08-Apr.-2014

Issued for Design

L.Zahedi

R.Hajinajaf

A.Bodaghi

B01

03-Feb.-2014

Issued for Comment

L.Zahedi

S.Garjani

A.Bodaghi

Rev.

Date

Description

Prepared

Checked

Approved
SAZ. POI :

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IFD1

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Table of Contents
1. Purpose..................................................................................................................... 4
2. Applicable Documents .............................................................................................. 4
3. Definitions ................................................................................................................. 4
4. Overview ................................................................................................................... 4
4.1

Introduction .................................................................................................................... 4

5. General Requirements .............................................................................................. 4

5.1 Language ....................................................................................................................... 4
5.2 Climate data ................................................................................................................... 4
6. Standards and Codes ............................................................................................... 5
6.1 IPS (Iranian Petroleum Standard) .................................................................................. 5
6.2 NACE Standard ............................................................................................................. 5
7. Basis of Design for Cathodic Protection System ....................................................... 5
7.1
7.2
7.3

Design Requirements .................................................................................................... 5

Structures to be protected .............................................................................................. 6
Cathodic Protection Systems Calculation ...................................................................... 7

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1. Purpose
This document covers the technical requirements for design and calculation of Cathodic
protection system for the south YARAN Project.

2. Applicable Documents
Document references which shall be used in conjunction with this general specification are
listed below, but shall not be limited to the below documents;
SYME-ELBASC-ENEL-CIDE-0001
Electrical Design Criteria
SYME-PLBASC-ENPN-DWPL-0015
Grand Plan for Gas and Crude Oil Export Pipe
lines (10" & 18" Crude,14" Gas) and Service Water Pipeline standard for Cathodic
Protection
SYME-PLBASC-ENPN-DWPL-0016
Grand Plan for Well-Head Facility Location and
Flow lines Orientation towards Cluster
SYME-ELBASC-ENEL-SPEL-0002-B01 Specification for Cathodic protection system
SYME-PLBASC-ENPN-CNPL-0001-B02 Pipeline wall thickness calculation

3. Definitions
OWNER
CLIENT
CONSULTING ENGINEER
PROJECT
LOCATION
APPROVED

:NIOC
: Petroleum Engineering and development Co.(PEDEC)
: Sazeh Consultants
: South Yaran oil Field Development (Basic Engineering)
: Khuzestan Province-120Km west of AHWAZ
: Approved by Client

4. Overview
4.1

Introduction
South Yaran oil field is located in Khuzestan province 120KM west of Ahwaz with 20Km
length and 2.5Km width at south part of Yaran oil field.
24 No wells considered at this area consisting of 14 No Sarvak wells, 8 No Fahlian &
Gadvan wells and 2 No appraisal wells for sarvak and fahlian&Gadvan layers with total
estimated output between 50,000 to 60,000 STB/Day.
Flow of wells is transferred to the 2 phase separation unit (Cluster) for separation of gas
from liquids and dehydrating of gas.
The dehydrated gas is transferred to NGL 3200 and the liquids are transferred to Karoon
production plant for further processing.

5. General Requirements
5.1

Language
All documents, drawings and submittals shall be in English.

5.2

Climate data
Max absolute temperature
Min temperature

50 oC
0 oC

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Max & Min Wind speed

Storm wind speed
Soil temperature
Maximum sun temperature
Rain fall volume
Barometric pressure
Maximum & Minimum Humidity

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9.6 & 6.2 m/s

68 m/s
40 oC (1m under finish grade)
85 oC
170-250mm/y
736 mmHg
74% & 41%

6. Standards and Codes

Unless otherwise specified by OWNER, all design, engineering and EQUIPMENT shall be
in accordance with NACE standards and relevant American Fire Code. The British
Standard Institution (BSI) codes of practice for cathodic Protection will also be applied if not
in conflict with NACE standard. This calculation shall be read in conjunction with the latest
edition of applicable IPS (Iranian Petroleum Standard). It is VENDORs responsibility to
ensure that the relevant IPS is reviewed and in the event of conflict between IPS and this
Specification the issue shall be referred to OWNER for approval. Equipment shall comply
with the requirements of the following reference documents and other standards referenced
therein:
6.1

IPS (Iranian Petroleum Standard)

6.2

IPS-E-TP-820: Engineering standard for electrochemical protection

IPS-E-EL-100: Engineering standard for electrical system design
IPS-E-EL-110: Engineering standard for hazardous area
IPS-I-TP-820: Inspection standard for monitoring cathodic protection systems
IPS-C-TP-820: Construction standard for cathodic protection
IPS-M-TP-750: Material and equipment standard for cathodic protection
IPS-M-EL-155:Material and equipment standard for transformer rectifiers for cathodic
protection
NACE Standard

RP-01-69-92 "Control of External Corrosion on Underground or Submerged Metallic

Piping Systems
RP-02-86-86 The Electrical Isolation of Cathodically Protected Pipelines
letters on white background and fixed by means of stainless steel screws. Fixing by
adhesive is not acceptable.

7. Basis of Design for Cathodic Protection System

7.1

Design Requirements
Following requirement are considered as basis of design:

Method of cathodic protection system: Impressed current

Design Life: 20 years
Protective current density for bare steel: 20 (m A/m)
Pipe coating: 3layer PE
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Cathodic Protection Calculation

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Minimum protective current density of coating (includes coating breakdown during

the design life): 0.01 (m A/m)
Efficiency of coating: 95%
Considered type of installation: Deep ground bed (vertical anodes surrounded in
coke backfill)
Considered safety factors for calculation: 20%
Considered 20% spare space
Considered anode type: High Silicon cast iron anode tubular type
Considered current density of anode in coke back fill : 20 A/m2
Diameter of coke hole: 10 inches
Anode dimension: 2 (inch) x 6 (inch)
Cable cross section: 25 mm2
Resistance of steel: 18X10-8 Ohm.m2
Resistance of covering: 5000 Ohm.m2
Pipes wall thickness: Base on Doc. No.SYME-PLBASC-ENPN-CNPL-0001-B02 for
crude pipeline and 0.312" for Gas export pipe line and 0.344" for flow lines have
been considered.
Natural potential of pipes: -600 mV
Considered Sulfate reduced bacteria exist in soil
Range of protective potential of structure: -950 mV(minimum voltage)and
1300mV(Maximum voltage)
Maximum allow able protective potential of coating:-1.5 Volts
Soil resistivity: 301 Ohm.cm

Structures to be protected
Cathodic protection systems of the project are considered for the underground pipes
Table 1 structures to be protected by cathodic protection system

Pipeline Designation
12" Gas Pipeline
6" Oil Crude Pipeline
12" Oil Crude Pipeline
6" Pipe to cluster
6" Pipe to cluster
6" Pipe to cluster
6" Pipe to cluster
6" Pipe to cluster
6" Pipe to cluster
6" Pipe to cluster
6" Pipe to cluster
6" Pipe to cluster
6" Pipe to cluster
6" Pipe to cluster
6" Pipe to cluster
6" Pipe to cluster
6" Pipe to cluster
6" Pipe to cluster

Approximate Length (m)

47,500
60000
60000
6342.9697
1692.7208
4734.2859
3310.6286
1586.7557
3615.477
4788.3072
2296.6367
1263.7203
3459.7337
1562.5224
403.4216
1923.8075
3548.8019
2256.0423

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Cathodic Protection Calculation

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Pipeline Designation

Approximate Length (m)

6" Pipe to cluster

6" Pipe to cluster
6" Pipe to cluster
6" Pipe to cluster
6" Pipe to cluster
6" Pipe to cluster
6" Pipe to cluster
6" Pipe to cluster
6" Pipe to cluster

2295.1957
1210.2313
4310.5392
5244.9814
4248.4231
3043.7201
3480.4096
3066.7605
2219.7258

7.3

Cathodic Protection Systems Calculation

7.3.1

Symboles

Symbol
A
Dpipe
Lpipe line
I
Eff
i coating
i bare
Lr
Lt
Lx
Rsteel
RCover
twall
Ex
En
Emax
Lanode
Nanode
dhole
Rcable
Rcoating
Ra
Rtotal
ITrans
VTrans

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Description
Pipeline surface area
Pipe outer diameter
Pipe length
Current demand
Coating efficiency
Current density of coating
Current density of bare pipeline
Longitudinal resistance
Transversal resistance
Maximum protected length of pipe line
Steel resistance
Cover resistance
Pipe wall thickness
Attenuation constant
Potential at end of pipe line
Average natural potential
Maximum allowable protective potential
Soil resistivity
Length of anode
Number of anodes
Diamiter of vertical hole
Resistivity of cable
Resistivity of coating
Resistivity of deep ground bed
Total resistivity
Transformer current
Transformer voltage

Units
m2
mm
m
A
mA/m2
mA/m2
Ohm/m
m.ohm
m
ohm
ohm
mm
1/m
V
V
V
Ohm.m
m
m
ohm
ohm
ohm
ohm
A
V

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7.3.2

Cathodic Protection Calculation

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Calculation Formula

,
.

7.3.3
B02

Detail calculation for Oil crude pipelines and Gas pipeline

We consider Pipeline names as bellow:

6" Oil Crude Pipeline: P1
12" Gas Pipeline: P2
12" Oil Crude Pipeline: P3
Step1:
Surface of P1: *0.1524*60000=28726.72322 m2
Surface of P2: *0.3048*47500=45483.97844 m2
Surface of P3: *0.3048*60000=57453.44645 m2
Step2: Calculation of current demand
Ip1= (0.95*0.01+0.05X20)*10^ (-3)* 28726.72322=28.99963 A
Ip2= (0.95*0.01+0.05X20)*10^ (-3)* 45483.97844=45.91608 A
Ip3= (0.95*0.01+0.05X20)*10^ (-3)* 57453.44645=57.99925 A
Total demand=28.99963+45.91608+57.99925=132.9 A
Step3: Maximum protected length of pipe line
P1:
Lr=18*10^ (-8)/ ( (0.1524-0.0079248)*0.0079248=5.00747*10^ (-5) /m
Lt=5000/(0.1524*)=10443.24 .m
= (5.00747*10^ (-5)/ 10443.24)^0.5=6.92234*10^(-5)
Lx=-Ln[(-0.95+0.6)/(-1.5+0.6)]/ 6.92234*10^(-5)= 13643.676 m
P2:
Lr=18*10^ (-8)/ ( (0.3048-0.0079248)*0.0079248=2.43534*10^ (-5) /m
Lt=5000/ (0.3048*) =5221.619 .m
= (2.43534*10^ (-5)/ 5221.619) ^0.5=6.8293*10^(-5)
Lx=-Ln[(-0.95+0.6)/(-1.5+0.6)]/ 6.8293*10^(-5)= 13829.507 m
P3:
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Lr=18*10^ (-8)/ ( (0.3048-0.0079248)*0.0079248=2.43534*10^ (-5) /m

Lt=5000/ (0.3048*) =5221.619 .m
= (2.43534*10^ (-5)/ 5221.619) ^0.5=6.8293*10^ (-5)
Lx=-Ln[(-0.95+0.6)/(-1.5+0.6)]/ 6.8293*10^(-5)= 13829.507 m
Step4: Maximum protected length of pipe line for all pipelines
Min (Lxp1, Lxp2, Lxp3) = 13829.507 m
Step5: Cathodic protection station
P1: Roundup (60000/ (2*13829.507)) =3
P2: Roundup (47500/ (2*13829.507)) =2
P3: Roundup (60000/ (2*13829.507)) =3
Maximum of above values is 3 which will be used in bellow formula:
CP=Roundup [max (3, (132.9*1.2/100))]=3
So we need 3 stations for crude and gas pipelines.
For one cathodic protection station we follow the steps:
Step6:
Surface of P1: *0.1524*(60000/3) =9575.57 m2
Surface of P2: *0.3048*(47500/3) =15161.33 m2
Surface of P3: *0.3048*(60000/3) =19151.15 m2
Step7: Calculation of current demand
Ip1= (0.95*0.01+0.05X20)*10^ (-3)* 9575.57=9.67 A
Ip2= (0.95*0.01+0.05X20)*10^ (-3)* 15161.33 =15.31 A
Ip3= (0.95*0.01+0.05X20)*10^ (-3)* 19151.15 =19.33 A
Total demand=9.67+15.31+19.33=44.31 A
Step8: Calculation of minimum anode required
Current output of one 2"x6" anode is 2.4354 A
Nmin-anode=Roundup (44.31*1.2/2.4354)=22
Step9: Resistivity calculations
Ground resistivity:
Ra= (0.159*3.01/1.52*22)*[ln (8*1.52*22/0.254)-1]=0.0853 ohm
Coating resistivity:
P1:
Rcoatingp1=5000/9575.57=0.5222 ohm
P2:
Rcoatingp2=5000/15161.33=0.3298 ohm
P3:
Rcoatingp3=5000/19151.15=0.2611 ohm
Considering parallel pipelines:
R Coating (total) =0.1139 ohm
Cable Resistance
R Cable=1.785*10^(-8)*100/25=7.14*10^(-8) ohm
Total resistance=0.1992 ohm
Step10: Transformer Sizing
Transformer Current
ITrans=44.31*1.2~54 A
Transformer Voltage
VTrans=54*0.1992+2~13
Method of Calculations for Cluster Pipes are same as above steps.

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Cathodic Protection Calculation

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Calculation results
Approximate
Length (m)

Area (m2)

Current (A)

Maximum protected
length of pipe line
(m)

6" Oil Crude Pipeline

60000

28726.72322

28.99963

13643.676

12" Gas Pipeline

47,500

45483.97844

45.91608

13829.507

12" Oil Crude Pipeline

60000

57453.44645

57.99925

13829.507

6" Pipe to cluster

6342.9697

3036.878917

3.065729

14285.920

6" Pipe to cluster

1692.7208

810.4386986

0.818138

14285.920

6" Pipe to cluster

4734.2859

2266.675345

2.288209

14285.920

6" Pipe to cluster

3310.6286

1585.058525

1.600117

14285.920

6" Pipe to cluster

1586.7557

759.7048636

0.766922

14285.920

6" Pipe to cluster

3615.477

1731.013452

1.747458

14285.920

6" Pipe to cluster

4788.3072

2292.539594

2.314319

14285.920

6" Pipe to cluster

2296.6367

1099.58078

1.110027

14285.920

6" Pipe to cluster

1263.7203

605.0423882

0.61079

14285.920

6" Pipe to cluster

3459.7337

1656.446874

1.672183

14285.920

6" Pipe to cluster

1562.5224

748.1024753

0.755209

14285.920

6" Pipe to cluster

403.4216

193.1496774

0.194985

14285.920

6" Pipe to cluster

1923.8075

921.0780932

0.929828

14285.920

6" Pipe to cluster

3548.8019

1699.090833

1.715232

14285.920

6" Pipe to cluster

2256.0423

1080.145046

1.090406

14285.920

6" Pipe to cluster

2295.1957

1098.89086

1.10933

14285.920

6" Pipe to cluster

1210.2313

579.4329932

0.584938

14285.920

6" Pipe to cluster

4310.5392

2063.794442

2.0834

14285.920

6" Pipe to cluster

5244.9814

2511.185483

2.535042

14285.920

6" Pipe to cluster

4248.4231

2034.054576

2.053378

14285.920

6" Pipe to cluster

3043.7201

1457.268415

1.471112

14285.920

6" Pipe to cluster

3480.4096

1666.346055

1.682176

14285.920

6" Pipe to cluster

3066.7605

1468.299668

1.482249

14285.920

6" Pipe to cluster

2219.7258

1062.757478

1.072854

14285.920

Pipe

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Cathodic Protection Calculation

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Cathodic protection station calculation

With evaluating cathodic station formula total number of required stations will be 4 for all
plant. Three stations for 12" and 6" crude and gas pipelines with maximum protection
length of 13600 meters and one station for 6" flow lines to cluster with maximum
protection length of 14200 meters should be considered.

7.3.6

Required Anode Calculation

Minimum number of required anodes for crude and gas pipelines stations will be 22 with
considering total current for each station. Minimum number of required anodes for cluster
area station will be 18.

7.3.7
B02

Circuit resistance and voltage drops

The total worst case scenario circuit resistance can be determined as follows:
(6", 12" crude and gas pipelines station) circuit resistance
Rcable

0.0000000714

Ohm

0.1139
0.0853
0.1992

Rcoating Ohm
Ra
Ohm
Rtotal Ohm
Voltage dropcable

Voltage dropcoating V
Voltage dropground bed

Rcable

Ohm

Rcoating Ohm

5.048
3.16*10^(-6)

(6" flow line station) circuit resistance

0.0000000714
0.1452

Ra

Ohm

0.1007

Rtotal

Ohm

0.24597

Voltage dropcable

3.5

Voltage dropcoating V
Voltage dropground bed

7.3.8

3.78

5.048
2.48*10^(-6)

Transformer Rectifier Output Rating

Impressed current systems require a permanent source of power, which has to supply
direct current and voltage. This is achieved by utilizing a transformer rectifier converting
alternating input current/voltage into direct output current/voltage supply. The DC output
rating of the transformer rectifier is determined for the end of life situation i.e. at greatest
current demand from the steel structure.
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Current Output

The current output shall be based on total current required of each station (IT) and 20%
safety factor. In this case, the calculated direct current output required to protect the pipe
line is 54 Amps for oil and gas crude pipe lines stations and 42 Amps for cluster station.

Voltage Required

The worst case scenario voltage output of the transformer rectifier units shall be
determined by using Ohms Law and taking in to account a back e.m.f. generated by a
Cathodic protection system ground bed thus required DC voltage will be 13 volts for oil
and gas crude pipe lines stations and 13 volts for cluster station.
Above calculation has been done in the worse condition.
The transformer / rectifier with output rating of 60 A DC / 15 V DC, and input rating of
1000 VA , 400 V AC, 50Hz Oil cooled type will be required for oil and gas crude pipe
lines stations and transformer / rectifier with output rating of 45 A DC/ 15 V DC, and input
rating of 800 VA , 400 V AC, 50Hz Oil cooled type will be required for cluster station.

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