OTC 6053
Cathodic Protection Monitoring-Bullwinkle
by S.L. Wolfson, Shell Development Co., and J.J. Kenney, Pecten Brazil
Copyright 1989, Offshore Technology Conference
This paper was presented at the 21st Annual OTC in Houston, Texas, May 1-4, 1989.
This paper was selected for presentation by the OTC Program Committee following review of information contained in an abstract submitted by the author(s). Contents of the paper,
as presented, have not been reviewed by the Offshore Technology Conference and are subject to correction by the author(s). The material, as presented, does not necessarily reflect
any position of the Offshore Technology Conference or its officers. Permission to copy is restricted to an abstract of not more than 300 words. illustrations may not be copied. The
abstract should contain conspicuous acknowledgment of where and by whom the paper is presented.
ABSTRACT
The Bullwinkle Platform represents a major advance in the
drilling and production of oil and gas, but also in cathodic protection
design for deep ocean environments. A unique feature of the cathodic
protection design is the cathodic protection monitoring (CPM) system
which provides continuous assessment of the effectiveness of the
cathodic protection system. In addition, the monitoring system
provides information for future cathodic protection designs in
deepwater.
The CPM system monitors anode operating current and potential,
cathode current density, and cathode potential at the -120, -1015 and
-1190 ft elevations on the' jacket structure. The design, installation,
and testing of the system are discussed as well as some of its
performance.
INTRODUCTION
Cathodic protection (CP) is the principal means of corrosion
control for submerged structures. The process typically involves the
use of sacrificial anodes distributed throughout the structure to
supply protective current to the steel members. Cathodic protection
designs for a particular environment require the input of various
design criteria. These include the anode operating potential and the
required cathode current density for adequate protection. Tradi-
tionally, cathodic protection designs use design criteria which have
been determined empirically, especially for shallow water systems.
However, with the increasing depth of offshore CP systems, the need
for optimum design criteria and consideration of the change of
environmental parameters with depth is required.
The cathodic protection system installed on the Bullwinkle jacket
consists of approximately 6300 aluminum-zinc-mercury anodes
totalling approximately 2400 net tons of anode material. These anodes
are distributed throughout the structure depending on the current
requirements for particular depth zones, and are attached by welding.
The cathodic protection monitoring (CPM) system was designed
and installed on the jacket structure prior to launch in order to
provide a continuous assessment of the CP system and to provide
information for future CP designs in deepwater. In addition, data
References and figures at end ofpaper.
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obtained from the monitoring system can be used to help validate
numerical modelling techniques used for evaluating and optimizing
cathodic protection designs.
BACKGROUND
Fixed monitoring of offshore cathodic protection systems can vary
from simply the installation of reference electrodes throughout the
structure for potential measurements, to an elaborate array of
electronic sensors for measuring anode current and cathode current
density. The installation of reference electrodes for potential
measurements has had good success, however, the electronic sensors
for current and current density measurements have had very limited
success, especially after experiencing the forces associated with
platform launch and pile driving. In addition, these sensors typically
require input power which increases cabling requirements.
Data acquisition systems associated with CP monitoring systems
have taken several forms. Some systems simply have test points for
manually monitoring data while others employ a test panel with data
displays installed in the platform control room. Some monitoring
systems have been equipped with strip chart recorders or
computerized devices for recording data, however, they are typically
installed after the platform launch (1). The use of data acquisition
equipment installed prior to platform launch for recording initial
polarization has had very little success, again due to the forces
experienced during platform launch and pile driving.
CPM SYSTEM REQUIREMENTS AND DESIGN CONCEPTS
The requirements for the Bullwinkle CPM system were as follows:
1. Monitor all variables of the CP process (i.e., anode current output
and potential, cathode current density and potential).
2. Install data acquisition equipment for recording initial pOlariza-
tion ofthe jacket structure.
3. Monitor both shallow and deep locations on the jacket structure.
4. Design for platform life of 35 years.
With the design requirements outlined, a review of available
technology in the area of CP monitoring was undertaken. This review
indicated that two basic types of monitoring equipment were
available, These were acoustic and hard-wired systems both
incorporating either active electronic sensors or passive type sensors.
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2 CATHODIC PROTECTION MONITORING - BULLWINKLE
The acoustic systems were not considered due to the costs and
limited life of the systems which is related to existing battery
technology. The active electronic sensors were not considered since
prior use of them had shown them to be not reliable for long term
operation in deepwater. The design of the Bullwinkle CPM then
centered around a hard-wired system with passive type sensors. The
existing passive sensors were evaluated, and it was determined that
they may not withstand the conditions associated with platform
launch and pile driving as well as long term operation in deepwater.
The decision was made to redesign the existing passive sensor
technology to meet the requirements for the Bullwinkle system.
CPM SYSTEM DESCRIPTION AND DESIGN
The CPM system monitors anode operating current and potential,
cathode current density, and cathode potential at the -120, -1015, and
-1190 ft elevations on the jacket structure. The subsea sensors are
mounted on Leg A4 and are connected to data acquisition systems
located on the + 15 ft structure elevation by a cabling system. A
schematic diagram of the system is shown in Figure 1.
The subsea sensors consist of anode current sensors, current
density wrap sections, and reference electrodes for measuring both
anode and cathode potentials. The anode current sensors incorporate a
specialiy designed pipeline insulating joint and current measuring
shunt resistor. There are two monitored anodes at each monitored
structure elevation, and the current sensors are installed in both
anode standoffs. This provides not only redundancy for the anode
current measurements, but also minimizes the additional circuit
resistance associated with the current measuring shunt resistor. An
anode equipped with the current sensors is shown in Figure 2.
A current density wrap section measures the current per unit area
received by the structure (cathode), and consists of an outer steel wrap
attached to a coated member (2). This design electrically isolates the
outer steel wrap from the structure. Electrical continuity to the
structure is then made using a wire and current measuring shunt
resistor assembly. There are two current density wrap sections,
installed on a non-structural member, at each monitored elevation for
redundancy purposes. The current density wrap sections are shown in
Figure 3.
The reference electrodes measure anode operating potential, the
potential of the current density wrap sections, and the structure
potential in two locations at each monit(jred elevation. One reference
electrode location is in a free span area on the jacket leg, while the
other is in the structural node area.
The reference electrode sensors are a dual element type
incorporating both a zinc and silver/silver chloride (Ag/AgCl)
reference element. The dual element sensors were used for comparison
of zinc and Ag/AgCI potential measurements and for redundant
purposes. A dual element reference electrode installed in a structural
node area is shown in Figure 4.
The cabling system consists of six lengths of electromechanical,
double armored cable attached to the jacket leg using clamps. This
design eliminated the need for lengthy conduit runs down the leg, and
with the use of mechanical armor terminations allowed the weight of
the cable to be supported. Two cables terminate at each monitored
elevation for redundant purposes. The two cables for the -1190 ft
monitored elevation installed in clamps along the jacket leg are shown
in Figure 5. All cable connections were hot-molded using neoprene to
provide long term reliability in deepwater.
The data acquisition systems are contained in watertight pressure
housings and all cable connections to the systems are housed in oil-
filled, pressure compensated junction boxes. This design allows the
CPM system to be fully operational at launch. A radio telemetry link
to the data acquisition systems provides complete control of the
systems for setting record intervals, checking status of the system
prior to and immediately after launch, and for downloading data. The
data acquisition systems, radio telemetry systems, and junction boxes
installed on the + 15 ft structure elevation are shown in Figure 6.
After the deck facilities are installed, the radio link will be replaced
with a telephone link to computers onshore.
102
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OTC 6053
PROTOTYPE SENSOR AND SYSTEM TESTING
In order to evaluate the new designs of the anode current and
dual-element reference electrode sensors, prototype un.its were
fabricated and extensively tested. The prototype anode current sensor
and reference electrode were fabricated and electrically tested over
the expected measurement ranges. Subsequently, they were hydro-
statically tested to a pressure corresponding to two times the required
maximum working depth (1100 psi). The prototype sensors were then
electrically tested again to insure proper operation upon completion of
the first hydrostatic test.
In order to further evaluate the sensors under expected launch
and pile driving forces, the sensors were shock tested to accelerations
of 80 g's. Accelerations of this magnitude were the maximum
expected, and each sensor was subjected to ten accelerations in both
the "X" and "Z" directions. The'shock table and prototype sensors are
shown in Figure 7. The prototype sensors were electrically tested
again after the shock tests.
Upon completion of the shock tests, the prototype sensors were
hydrostatically tested for a second time to 1100 psi for a period of
24 hours. It was expected that if the shock testing had caused any
failures in the components of the sensors, the second hydrostatic test
should show any problems associated with water ingress.
After the second hydrostatic test the sensors were electrically
tested for proper operation. Both prototype sensors were functioning
as designed, however, there were signs of some water ingress. The
sensors were destructively evaluated and some design modifications
were made for the production sensors.
The testing of the production sensors was not as extensive.
However, all production sensors were electrically tested prior to and
after a hydrostatic test to 1100 psi for 24 hours. This insured proper
assembly and operation of the sensors to be installed on the jacket
structure.
Mter installation of the CPM system on the jacket structure, the
entire system was functionally tested. This consisted of putting known
currents between the monitored anodes and the structure, and the
current density wrap sections and the structure. The dual-element
reference electrode sensors were tested in place using a salt bridge and
saturated calomel reference electrode (SCE). All of the measurements
during the function tests were recorded by the data acquisition
systems.
CPM SYSTEM OPERATION
Prior to platform launch at the offshore site, the telemetry link
was used to check system status and set a recording interval of ten
minutes. The platform was successfully launched and after upending
the jacket, the system operation was verified. Data was downloaded
from the CPM system periodically, and system operation was verified
after all pile and conductor driving operations. To date all of the
sensors are functioning as designed, with the exception of one of the
reference elements associated with an anode potential measurement.
A sample of the data obtained from the cathode potential
measurements from the first month ofoperation is shown in Figure 8.
ACKNOWLEDGEMENTS
The authors want to especially thank Mr. T. E. Long and
Mr. W. F. Pollpeter of Shell Development Company without whose
help the project could not have been accomplished. Additionally, the
authors want to thank Dr. A. D. Goolsby and Ms. S. E. Lorimer of
Shell Development, and Shell Offshore lnc.-Bullwinkle Project
Group and specifically Mr. G. H. Sterling for their assistance and
support.
REFERENCES
1. Goolsby, A.D.: The Results ofMonitoring Platform Ellen Cathodic
Protection for Two Years, Materials Performance, (April 1984)
26-29.
2. Goolsby, A.D.: Cathodic Protection Monitoring System, United
States Patent No. 4,639,677 (January 27,1987).
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Figure 1. Bullwinkle Cathodic Protection Monitoring System

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 Figure 6. Data Acquisition Systems, Radio Telemetry Systems,
and Junction Boxes Installed on + 15 ft. Structure Elevation

Figure 7. Shock Table with Prototype Sensors Installed for Testing to 80g’s

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Figure 8. Average Structural Potential at -120, -1015, and -1190 ft.

Monotored Elevations for First Month of CPM System Operation

106

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