MINISTRY OF ENERGY

IRAN POWER DEVELOPMENT COMPANY

I.P.D.C PROJECT: SHIRVAN 6X159 MW GAS TURBINE POWER PLANT

CATHODIC PROTECTION SYSTEM CALCULATION

IN-HOUSE REVISIONS
D C B A 0
Rev.

FOR APPROVAL DESCRIPTION

A.P. DESIGNED

2005.03.09 DATE

H.KH. CHECK

2005.03.09 DATE

E.A APPR.

2005.03.09 DATE

D C B A 0 Rev. FOR APPROVAL DESIGNATION A.P. DESIGNED 2005.03.09 DATE H.KH. CHKD 2005.03.09 DATE E.A. APPROVED 2005.03.09 DATE

MINISTRY OF ENERGY
ORIGINATOR: MAPNA CO.
(PRIVATE JOINT STOCK)

DOCUMENT NO.:
MP-SVG-31ED-08-AE0-001

Rev: 0

PROJECT:
SHIRVAN 6X159 MW GAS TURBINE POWER PLANT
Intel. Rev. 0 PAGE: 1 OF 10

KHERAD WATER TREATMENT CO.

IRAN POWER PLANT PROJECT MANACEMENT CO.

IRAN POWER DEVELOPMENT COMPANY PROJECT:

REVISION C D

I.P.D.C SHIRVAN 6X159 MW GAS TURBINE POWER PLANT

REVISION C D

PAGE

REMARKS

PAGE

REMARKS

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1. DESIGN BASIS
1.1 GENERAL

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KHERAD WATER TREATMENT CO.

IRAN POWER PLANT PROJECT MANACEMENT CO.

This study covers the basis & design of cathodic protection system for SHIRVAN GAS TURBINE POWER PLANT of IRAN POWER DEVELOPMENT COMPANY located in Shiravn/Iran.
1.2 REFERENCES

1.3

National Association of Corrosion Engineers (NACE) British Standard BS 7361 (CP 1021) American Society for Testing and Materials (ASTM) Iranian Petroleum Standards IPS-E-TP-820
CLIMATIC CHARACTERISTICS

1.4

Min. Absolute Temp. : Max. Absolute Temp. : Average humidity: Elevation above sea level: Design temperature: Design wind velocity:

-30 C + 42.3 C 48% 1115m 15 C 144 Km/h

STRUCTURES TO BE PROTECTED

In the following project, the cathodic protection system shall be only applied to the external surface of underground natural gas line (carbon steel) pipes.
1.5 SOIL RESISTIVITY

The maximum and minimum measured values of soil resistivity are as follows: Table "1" Depth (M) Soil resistivity Soil resistivity Min.( OHM.CM) Max.( OHM.CM) 1 8000 12000 2 3500 5000 3 3000 4500 The measured soil resistivity at the nearest point to groundbed location (TP5) is as follows: Table "2" Soil resistivity ( OHM.CM) 8000 3300 3100

Depth (M) 1 2 3
1.6 COATING SYSTEM

ORIGINATOR: MAPNA CO.

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KHERAD WATER TREATMENT CO.

IRAN POWER PLANT PROJECT MANACEMENT CO.

All protected pipes are externally coated with coal tar enamel. For current requirement calculations 80% coating efficiency is taken into account.
1.7 PROTECTION LEVEL

The pipe to soil potential shall be in the range of -0.85 V to -1.2 V in reference to a sulphate reference electrode.
1.8 CURRENT DENSITY

copper /copper

The soil surrounding the pipes is moderately corrosive to progressively less corrosive. The protective mean current density (MCD) is considered to be 20 mA/m.
1.9 DESIGN LIFE

The cathodic protection system shall be designed for 25 years.

1.10 ELECTRICAL ISOLATION

The underground protected steel pipes shall be electrically isolated by insulation joints (flanges, couplings or valves) from other metallic structures such as above ground pipe(s), metallic casings, reinforcing steel rods/bars in concrete structures, and pipe stanchions that are not intended as part of the cathodic protection system. The insulating joints located in hazardous area should be protected against high voltage surges, arcing or sparking by use of explosion proof spark gaps.
1.11 ELECTRICAL CONTINUITY

The electrical continuity shall be maintained at all non-welded connections of pipes such as valves, flanges and couplings by means of bonding both sides of joints with proper cables and connections.
1.12 CATHODIC PROTECTION SYSTEM

Despite the very low current required for protection (see para. 2.2), sacrificial anode system can not be effective because of high soil resistivity. So, impressed current cathodic protection system shall be applied to pipes. The ground bed shall be of vertical surface type using 360 inch high silicon cast iron anodes.

2.

CALCULATIONS
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MP-SVG-31ED-08-AE0-001

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KHERAD WATER TREATMENT CO.

IRAN POWER PLANT PROJECT MANACEMENT CO.

2.1

AREA TO BE PROTECTED

The table below shows the surface of pipes to be protected: Table "3" Pipe size (inches) DN 400 DN 65 Outside diameter( mm) 406.4 73 Total surface area The total bare surface area of pipes is: Ab = A (1 C ) ) In which, Ab : Bare surface area (m) C : Coating efficiency A : Total surface area (m) So: Ab = 2009 X ( 1-0.8) Ab = 402 m2
2.2 TRANSFORMER- RECTIFIER DC OUTPUT CURRENT

Length ( m) 1460 630

Surface( m2) 1864 145 2009

The required protective current is calculated as below: I P ( A) = Ab (m 2 ) MCD( A) I P ( A) = 402 20 10 3 8.1 A

Considering future extensions, leakage currents through pipes conductive fluid, flange insulation damages, currents attracted by other underground structures, flexibility and reliability of the system, the output DC current of transformer- rectifier shall be: I = 15A

2.3

REQUIRED ANODE QUANTITY

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2.3.1

REQUIRED ANODE QUANTITY BASED ON ANODE WEIGHT

Considering a 25% safety factor for anode consumption, required anode weight will be calculated by the following formula: W = 1.25 Y C r I In which, I : Transformer- rectifier output current (15 amps) Y : Required anode life (25 years) Cr : Anode consumption rate (0.45 Kg/A-yr) Therefore: W = 1.25 25 0.45 15 = 210 Required anode quantity is: n= W 210 = = 4.2 Wa 50 Kg

In which Wa is the weight of one anode (50Kg). Therefore: Qty of Anodes = 5 Nos.
2.3.2 REQUIRED ANODE QUANTITY BASED ON CURRENT DENSITY

Maximum allowable current for each 3 60 inch high silicon cast iron anode is about 4 amps. Considering 3 anodes, the extracted current from each anode will be: I 15 = =3 n 5 4

Hence 5 nos. are enough to meet the maximum allowable current requirement.
2.3.3 REQUIRED ANODE QUANTITY BASED ON GROUNDBED RESISTANCE

The groundbed resistance is calculated by the following formula: 1 R RG = RV + ' n S Where, ORIGINATOR: MAPNA CO.
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RG : Groundbed resistance (ohms) n : number of vertical anodes R : Soil resistivity (ohm-cm) P/ : Paralleling factor, given by the attached table (appendix A " paralleling factor"- extracted from IPS-E-TP-820) S : Spacing between adjacent anodes (cm) Rv : Anode to earth resistance of a single vertical anode by the following formula: RV = R 8 L 1 Ln 2 L d

Where, L : Length of anode including backfill ( cm) d : Diameter of anode including backfill ( cm) So: RV = 8000 8 250 1 = 16 Ln 2 250 30

With 5 anodes the ground bed resistance will be: RG = 1 8000 16 + 0.00268 = 3.3 5 300

This resistance (3.3 ohms) is so high, therefore a greater number of anodes are required to decrease the groundbed resistance. On the other hand, with increasing the anode numbers the required room for placing them will increase too. 12 anodes are considered to decrease the groundbed resistance to a reasonable value and to keep distance from neighboring structures. 1 8000 16 + 0.00182 = 1.4 12 300 Qty = 12 nos. RG =
2.4 WIRING RESISTANCE

The following formula is used for calculation of wiring resistance: RW = 0.01786 L S

In which, Rw : Wire resistance (ohm) L : The length of wire (m) S : Cross sectional area of conductor (mm2) (I) For anodic cable: ORIGINATOR: MAPNA CO.
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DOCUMENT NO.:
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KHERAD WATER TREATMENT CO.

IRAN POWER PLANT PROJECT MANACEMENT CO.

RW = 0.01786

450 0.23 35 1 0.001116 16 1 = 0.01786 0.000516 35

(II) For cathodic cables: Unit Resistance of 16mm2 Conductor RW 16 = 0.01786 Unit Resistance of 35mm2 Conductor RW 35 /m /m

RWC1 = L1 RW 35 + L2 RW 16 = 0.0568 + 0.02655 0.083 RWC 2 = L1 RW 35 + L2 RW 16 = 0.037 + 0.018 0.055 RWC 3 = L1 RW 35 + L2 RW 16 = 0.0826 + 0.0251 0.108 There is a 0 ~ 1 ohm variable resistor in series with each cathodic cable (in negative resistance box), and the two cathodic circuits are parallel so the equivalent resistance will be. RWC = 1 RWC1 + 1 1 1 RWC 2 + 1 1 RWC 3 + 1 = 0.36

Total wiring resistance is: RW = RWa + RWC = 0.23 + 0.36 0.6

2.5 PIPE RESISTANCE

The pipe resistance is calculated by the following formula: RPU = 18 10 5 R P = R PU L In which, 1000 S

RP: Resistance of total length of pipe DN400 (ohms) RPU: Resistance of one meter of pipe DN400 (ohms) S : cross sectional area of pipe (mm2)

(I) For DN400 pipe: ORIGINATOR: MAPNA CO.

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KHERAD WATER TREATMENT CO.

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S = 6006.117 mm2 R PU 400 = 18 10 5 1000 = 0.00003 6006.117 /m

R 1 400 = 0.00003 L1 = 0.00003 675 = 0.02025 P

2 R P 400 = 0.00003 L2 = 0.00003 765 = 0.02295 1 1 R P 400 = = 0.011 1 1 1 1 + 2 + 1 0.02025 0.02295 R P 400 R P 400

(II) For DN65 pipe as same as above mentioned method: S = 570.776 mm2 R PU 65 = 18 10 5 1000 = 0.000315 570.776 /m

R P 65 = 0.000315 L = 0.000315 630 0.199

The DN65 & DN400 pipes are in parallel circuits. So the total pipe resistance will be considered to be the maximum one which is about 0.2 .
2.6 TRANSFORMER- RECTIFIER DC OUTPUT VOLTAGE

The required DC output voltage of transformer rectifier is given by: V = I ( RG + RW + R P ) + V B Where, VB : the back EMF of silicon iron relative to protected steel (2V) V = 15 (1.4 + 0.6 + 0.2) + 2 = 35 So the DC output voltage of transformer-rectifier shall be 50 volts.

APPENDIX A:
ORIGINATOR: MAPNA CO.
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DOCUMENT NO.:
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KHERAD WATER TREATMENT CO.

IRAN POWER PLANT PROJECT MANACEMENT CO.

Table B.5 from IPS-E-TP-820

PARALLELING FACTOR FOR GROUNDBED RESISTANCE CALCULATIONS
n 2 3 4 5 6 7 8 9 10 12 14 16 18 20 22 24 26 28 30 ' 0.00261 0.00289 0.00283 0.00268 0.00252 0.00237 0.00224 0.00212 0.00201 0.00182 0.00168 0.00155 0.00145 0.00135 0.00128 0.00121 0.00114 0.00109 0.00104

ORIGINATOR: MAPNA CO.

(PRIVATE JOINT STOCK)

DOCUMENT NO.:
MP-SVG-31ED-08-AE0-001

Rev: 0

PROJECT:
SHIRVAN 6X159 MW GAS TURBINE POWER PLANT
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KHERAD WATER TREATMENT CO.

IRAN POWER PLANT PROJECT MANACEMENT CO.