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OFFSHORE

DESIGN SECTION
MUMBAI REGION
FORMAT NO :
ODS/SOF/004

FUNCTIONAL SPECIFICATION FOR


CATHODIC PROTECTION SYSTEM OF
OFFSHORE STRUCTURE

WELL PLATFORM
PROJECT

VOL NO III
REV NO 1
SPEC NO FS 4001
SHEET NO 1OF 1

FUNCTIONA L SPECIFICATION
FOR
CATHODIC PROTECTION SYSTEM
OF
OFFSHORE STRUCTURES

OIL AND NATURAL GAS CORPORATION LTD


INDIA

PREPARED
BY

REVISED
BY

ISSUED AS

TOTAL
PAGE

APPROVED BY

DATE

REV NO

OFFSHORE
DESIGN SECTION
MUMBAI REGION

FUNCTIONAL SPECIFICATION FOR


CATHODIC PROTECTION SYSTEM OF
OFFSHORE STRUCTURE

FORMAT NO :
ODS/SOF/004

1.

WELL PLATFORM
PROJECT

VOL NO III
REV NO 1
SPEC NO FS 4001
SHEET NO 2OF 2

SCOPE
This specification defines the minimum requirements for the material selection,
design, manufacture, supply and installation of a sacrificial type cathodic
protection system with monitoring facilities (wherever required). It includes all
submerged offshore structures like platform jackets, clamp-on structures on
existing platforms, flare or bridge supports, tripods, SPM including PLEM and
other appurtenances permanently attached to the structure etc.

1.1

SCOPE OF SUPPLY
The scope of supply through this specification includes:

Sacrificial type Anode materials for cathodic protection.


Reference electrodes & monitoring anodes.
Monitoring panel including all control & monitoring instruments / devices.
Cables required along with cable glands and lugs, junction boxes, filling
compound, conduits etc.

2.0

CODES & STANDARDS


Design and installation of the cathodic protection system shall be in accordance
with good marine practice in corrosion protection and compliance with the latest
revisions of following Codes & Standards:
Det Norske Veritas:

DNV RP B 401, DNV RP B 403

National Association of Corrosion Engineers: NACE RP 0176-94,


NACE RP 0492-92
American Petroleum Institute:

API RP 5L

American Society for Testing and Materials: ASTM A36


National Electrical Code:

NEC

National Electrical Manufacturers Association: NEMA

OFFSHORE
DESIGN SECTION
MUMBAI REGION
FORMAT NO :
ODS/SOF/004

FUNCTIONAL SPECIFICATION FOR


CATHODIC PROTECTION SYSTEM OF
OFFSHORE STRUCTURE

WELL PLATFORM
PROJECT

VOL NO III
REV NO 1
SPEC NO FS 4001
SHEET NO 3OF 3

Any other international standard or code may be used in lieu of the above with
prior approval of the Company.
1.0

TECHNICAL REQUIREMENTS
3.1 General
Cathodic protection system shall be made up of anodes with a configuration and
anodic material composition suitable for use in seawater. All raw materials
finished products and components of the CP system and monitoring assemblies
specified herein shall be new and unused, of current manufacture, of highest
grade and free from all defects and imperfections that could adversely affect the
performance of the system.

3.2

Design Criteria:
The cathodic protection system for the Jacket structure shall be designed in
accordance with DNV RPB 4011993 and the requirements of this
Specification.
For C.P.system design following current density and driving potential
shall be considered.

CD in sea water (initial)


:130ma/m2

CD in sea water (average)


: 107.65ma/m2

CD in sea mud
: 43.05ma/m2

Driving potentials (initial and near end life) : 250 mV

Driving potential (mid life)


:150mV
3.2.1

Design Life

: as per data sheet

3.2.2

Cathodic Protection method: sacrificial anodes

3.2.3
Surface Areas
:
The estimated surface area of the structure in seawater and mud shall be
indicated in the attached CP system data sheet.
a)
The system shall be adequately designed to protect all bare external steel
surface of the structure along with its various components submerged in
sea water / sea mud.
The contractor shall, however, prepare a comprehensive list covering all other
structural members/assemblies exposed to seawater and sea mud along with

OFFSHORE
DESIGN SECTION
MUMBAI REGION
FORMAT NO :
ODS/SOF/004

FUNCTIONAL SPECIFICATION FOR


CATHODIC PROTECTION SYSTEM OF
OFFSHORE STRUCTURE

WELL PLATFORM
PROJECT

VOL NO III
REV NO 1
SPEC NO FS 4001
SHEET NO 4OF 4

their individual surface area calculation and total surface area calculation and
submit it to Company, along with jacket drawings, for review and approval.
Anode requirements shall be based on the above details. The following factors
shall also be taken into consideration-

3.2.4

a)
b)

Jacket structure area shall be considered upto splash zone only


Riser protector area shall be considered upto chart datum only.

c)

Pile surface areas are to be calculated taking into account apparent


batter. Piles from mud line upto a depth of 30 meters shall be
considered. Internal surface area is not required to be considered.

Well casing & Tubing


Wherever applicable a current drain of 5A shall be included for each well for
protection of buried portion of well casing and tubing. In addition surface area
of casing, conductor guide and conductor tubing in seawater shall be included in
total surface area of the structures. Proper electrical contacts shall be ensured
between conductor and the jacket structure.

3.2.5 Interference
Suitable arrangement to prevent interference in cathodic protection system on
bridge-connected structures shall be made by the vendor.
3.2.6 Clamp-on structures:
Vendor shall calculate the exact surface area based on structural drawings and
furnish details on the same. While calculating the surface area all the
components exposed to seawater shall be considered for cathodic protection. In
case of conductors, conductor guide support framings, clamps including
stiffeners, stubs, anode clamps, only external surface area shall be considered.
While in case of conductor guides, conical plates, both external and internal
surface area shall be considered. In addition to the above, contingency specially
for fasteners and other fixtures of clamps shall be included in total surface area.
4.0

Anode Material
Anodes shall be GALVALUM-III or Equivalent (Al-Zn-In) alloy suitable for
protection of steel in submerged marine environment. They shall not have any

OFFSHORE
DESIGN SECTION
MUMBAI REGION
FORMAT NO :
ODS/SOF/004

FUNCTIONAL SPECIFICATION FOR


CATHODIC PROTECTION SYSTEM OF
OFFSHORE STRUCTURE

WELL PLATFORM
PROJECT

VOL NO III
REV NO 1
SPEC NO FS 4001
SHEET NO 5OF 5

mercury content. The potential of the sacrificial alloy material shall be (-) 1.08V
or more negative referred to a silver/silver chloride reference electrode. The
Electro-chemical efficiency of anode material shall be minimum 2500 AH/Kg
after four (4) days of operation as per DNV RP B 401.

5.0

Testing and Inspection

5.1

Anode Composition analysis


Anode composition analysis shall be undertaken by methods agreed upon in
advance. Two samples from each melt shall be taken for chemical analysis. The
samples shall be taken in the beginning and at the end of casting from the
pouring string. Checking of closed circuit potential and practical mass
consumption shall be done for each 15 ton produced anodes. The test samples
may be separately casted or cut directly from an anode. Ampere-hour capacity
test shall be carried out be weight loss method only.

5.2

After casting, the inspection of the anodes shall be done to ensure that:

5.2.1 AH capacity of anodes shall not be less than the figures considered for design
i.e. no negative tolerance shall be permitted.
5.2.2 Closed circuit potential shall be within (+) 10 mV and (-) 50mV of the
guaranteed value. For example, for design value of (-) 1.08 volts, anodes having
closed circuit potential less negative than (-) 1.07 Volts shall be rejected.
5.2.3 The anodes shall have minimum net weight (Gross weight minus core weight)
within a tolerance of + 2.0% to 1.0%. However, overall negative tolerance
shall be 0% to ensure that is no short fall in total alloy weight.
5.2.4 Dimensions shall be within tolerance limits indicated in the approved drawings.
No negative tolerance shall be allowed in standoff dimensions.
5.2.5 At least one anode per delivery or at least 0.5 percent of the anodes shall be
subjected to destructive testing to check that the casting is to an acceptable
standard, each anode shall be cut at 3 of the most relevant locations. The cut
surface shall generally be free from visible pores and slag/dross inclusions. The

OFFSHORE
DESIGN SECTION
MUMBAI REGION
FORMAT NO :
ODS/SOF/004

FUNCTIONAL SPECIFICATION FOR


CATHODIC PROTECTION SYSTEM OF
OFFSHORE STRUCTURE

WELL PLATFORM
PROJECT

VOL NO III
REV NO 1
SPEC NO FS 4001
SHEET NO 6OF 6

lack of bond or void between anode core and anode material shall not exceed
5%.
As an alternate to a destructive testing, a non-destructive testing by radiography
may be used to check for lack of bond or slag/dross inclusions if so permitted by
the Company or its authorized representative.
5.2.6 Anode to steel insert shall be checked for electrical continuity. The resistance
between the connector and the body of the anode shall not exceed 0.005 ohm.

5.3

The anodes shall be free from mechanical defects like cracks, shrinkages,
excessive flash, surface projections, laminations, cold laps, surface slag etc. as
consistent with good casting practice. Criteria for accepting these shall be as per
NACE RP 0492-92.
All the above Inspection / tests shall be witnessed by Company or its authorized
representative.
All anodes shall be delivered with material certificate from the Vendor stating
batch identification number and chemical analysis.

5.4

All work, materials, and equipments shall be subjected to inspection by


Company at all reasonable times However inspection by the Company shall not
relieve the Vendor of his responsibility under terms of contract.

5.5

The monitoring system shall be inspected after completion of fabrication and


prior to load out. These checks shall include:
a)
b)
c)

6.0

Polarity checks on all monitored anodes.


Insulation and continuity test of all cables.
Calibration tests shall subsequently be carried out on all instrumentation and
reference electrodes.
Anode Dimensions And Physical Characteristics
Anode shall be standoff type. The steel core of the anode and stub pipes or
brackets provided for mounting the anode on the platform structure shall
conform to ASTM-A36 (for structural shapes) and API-5L Gr. B Seamless (for
pipes) or equivalent.

6.1

The core shall consist of nominal 4 inch schedule 80 seamless steel pipe or
equivalent structural shape. Anode material shall surround the core.

OFFSHORE
DESIGN SECTION
MUMBAI REGION
FORMAT NO :
ODS/SOF/004

FUNCTIONAL SPECIFICATION FOR


CATHODIC PROTECTION SYSTEM OF
OFFSHORE STRUCTURE

WELL PLATFORM
PROJECT

VOL NO III
REV NO 1
SPEC NO FS 4001
SHEET NO 7OF 7

6.2

Stand off-legs shall be 18` long from core and 12` clear, of nominal 4 inch
schedule 80-pipe size. Distance between the two legs shall be less than the
anode length. The free ends of the legs shall be welded to the gusset plates
superimposing member.

6.3

Anodes shall be of bracelet-segmented type for clamp-on structures.

6.4

Monitored Anodes
The monitored anodes shall be identical to those supplied for the structural
protection system and have the same physical characteristics but suitably
modified so that current outputs can be electrically measured at the monitoring
panel. The anodic material of the monitoring anodes shall be electrically
insulated for those parts of the anode core to be welded to the structure with an
insulation resistance, When dry, of not less than one mega ohm reducing when
wet, to not less than one thousand ohms. Prefabricated isolating joints with
suitable mechanical properties shall be utilized.

7.0

Anode distribution:
Anode distribution on the structural members of jackets shall be based on
advanced computer modelling techniques such as Boundary Element Method
(BEM). The contractor shall submit all relevant details of the techniques used/
procedures adopted, datasheets, results, drawings etc, for Companys review
and approval during detailed engineering and prior to commencement of the
installation of anodes over the structural members.
Anode locations shall ensure early polarization of structures to provide adequate
protection at node welds. Anode for SBM chains and piles shall be mounted on
SBM whereas those for PLEM piles shall be put on PLEM itself. Anode to be
installed on PLEM shall be suitable for saline mud.
Clamp-on structures:
Anode distribution for clamp-on structures shall be based on the results of
survey carried out by successful bidder. Anodes shall be located on the existing
jacket horizontal and vertical structural members near to Row-1 and/ or new
structural members such as conductor guide support framings in a manner to

OFFSHORE
DESIGN SECTION
MUMBAI REGION
FORMAT NO :
ODS/SOF/004

FUNCTIONAL SPECIFICATION FOR


CATHODIC PROTECTION SYSTEM OF
OFFSHORE STRUCTURE

WELL PLATFORM
PROJECT

VOL NO III
REV NO 1
SPEC NO FS 4001
SHEET NO 8OF 8

achieve uniform current distribution and maximum efficiency of the cathodic


protection system.
Anodes shall be located on the structural members in direct proportion to the
protected surface area distribution.
Anode distribution shall ensure that the interference effects with already
existing standoff anodes or adjacent anodes being installed, is minimum.

8.0

Monitoring System

8.1

General
Monitoring system shall be required only for the cathodic protection of process
platform jackets and shall be designed to provide the following as minimum
requirements:
a) The measurement of the effectiveness of the cathodic protection system as
judged by potential measurements.
b) The performance of the sacrificial anodes as judged by measurements of
current output of monitored anodes
c) The system should include monitored anodes and reference electrodes
electrically connected to a monitoring panel located in platform switchgear
room.
d) The electrodes shall be located in areas where the potential is expected to be
least negative.
e) All equipment and items associated with the monitoring system shall
comply with the relevant specifications and requirements stated elsewhere in
the Contract documents.
Cathodic protection system for unmanned well platforms, clamp-on structures,
Flare tripod, SBM, PLEM shall be unmonitored.

8.2

Monitoring panel
The monitoring panel shall be located in the switchgear room or other suitable
location in safe area. The panel shall be of sheet steel (14 SWG) construction
with an enclosure protection equivalent of IP-51 or NEMA-12. The monitoring
panel as a minimum shall contain the following;
a)

Selector Switches

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DESIGN SECTION
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FORMAT NO :
ODS/SOF/004

b)
c)
d)
e)
f)
g)
h)

9
9.1

FUNCTIONAL SPECIFICATION FOR


CATHODIC PROTECTION SYSTEM OF
OFFSHORE STRUCTURE

WELL PLATFORM
PROJECT

VOL NO III
REV NO 1
SPEC NO FS 4001
SHEET NO 9OF 9

Voltmeter-Panel
Ammeter
Meter calibration
Mimic diagram - showing the positioning of all reference electrodes and
monitored anodes marked distinctly on it.
Recording unit provisions
Electric Power Supply:
Painting in accordance to Spec no 2005

Service after installation


The vendor shall provide necessary test equipments, material and services of a
corrosion specialist and carryout performance tests at the site after jacket
installation and verify that required protection level has been achieved.

9.2.1 The contractor shall carry out CP survey to ascertain the effectiveness of the
cathodic protection system provided for the jacket structure. The survey shall be
carried out after 60 days of the launching of jacket (and before 180 days
maximum) to ensure that the structures are sufficiently polarized.
9.2.2 During detailed engineering, the contractor shall develop and submit procedure
for carrying out CP survey, for Companys approval. However, the survey
procedure shall comply with the requirements of DNV standard RP B-403. If
the survey results show that the protection level is not sufficient on any one or
more than one location of the jacket member, the contractor shall provide
additional new anodes on all deficient locations so as to raise the protection
potential to required level and cost of all these shall be borne by the contractor.
The basis of redesign/redistribution and all relevant back-up documents, as
required by the Company, shall be made available by the contractor for review
and approval
10.0

Warranty:
Vendor shall have final and total responsibility for the design and performance
of all equipments supplied and guarantee the equipment / anode for their design
life. Vendor shall warrant the equipments furnished by him and their
performance in accordance with this specification and `General SpecificationDefinition.(Spec No. 1050)

OFFSHORE
DESIGN SECTION
MUMBAI REGION
FORMAT NO :
ODS/SOF/004

11

FUNCTIONAL SPECIFICATION FOR


CATHODIC PROTECTION SYSTEM OF
OFFSHORE STRUCTURE

WELL PLATFORM
PROJECT

VOL NO III
REV NO 1
SPEC NO FS 4001
SHEET NO 10OF 10

Vendor Data Requirements


Vendor shall furnish the following information relative to the anodes

11.1
11.2

Dimensional drawings of sacrificial anodes, monitored anodes and reference


anodes and supporting parts or accessories along with separate as well as
assembled drawings for their supporting parts and other accessories
Guaranteed minimum electrochemical value in ampere-hour per kg

11.3
11.3

Net, gross, and buoyant weight of anodes.


Minimum closed-circuit potential in volts.

11.5
11.6
11.7

Recommended means of anode support.


Anode alloying compositions (% age by weight and volume)
Testing method of anodes and details of the test procedure. The test shall
establish the guaranteed minimum electro-chemical value of the anode material
and its potential w.r.t. Ag/AgCl reference electrode under site conditions.
Analytical information regarding the location of reference electrode (which has
to be located in least negative potential area.).
Calculation of anode quantity and weight based on current and weight basis for
the designated design life
Cable type /specification along with routine and type test certificates.
Type test certificate for monitoring panel (IP-51)
Routine and type certificates for cable glands, junction boxes, pull boxes etc.
Vendor shall confirm and provide guarantee for the design life (minimum) for
reference anodes with necessary back up calculation and other relevant data.

11.8
11.9
11.10
11.11
11.12
11.13

12.0

Vendor Pre - qualification:


Vendor Pre-qualification will be as per the requirements stated elsewhere in the
bid document

13.0

PACKING AND TRANSPORATION:


The offered equipment along with their accessories shall be shipped to site
packed in wooden crates. They shall be wrapped with polythene sheets, before
being placed in the crates to prevent damage to finish. Crates shall have skid
bottom for handling.

OFFSHORE
DESIGN SECTION
MUMBAI REGION

FUNCTIONAL SPECIFICATION FOR


CATHODIC PROTECTION SYSTEM OF
OFFSHORE STRUCTURE

FORMAT NO :
ODS/SOF/004

VOL NO III
REV NO 1
SPEC NO FS 4001

WELL PLATFORM
PROJECT

SHEET NO 11OF 11

DATA SHEET FOR CP SYSTEM


1.0

DESIGN INPUTS

1.1
1.2

Design life
Seawater temperature

:Specified
life
:23 to 40 C

1.3

Details of Area to be protected

:
* M
:
* M
:as per scope of work(not
applicable for process platform
jackets)
(Contractor shall furnish necessary jacket drawing)
Current drain per well
:
5A

COMPONENT DETAILS:

2.1

Details of Sacrificial Anodes

Anode Output
Anode Potential
Performance characteristics and test
procedure
Anode Material & Composition in
percentage

2.2

Details of Reference electrodes:

2.3

Dimensional details
Material Composition in percentage
Percent purity
Electrode Potential
Weight of complete electrode
Details of Monitored Anodes:
-

Platform

Steel surface area in sea water


Steel surface area below mud line
Number of wells on the platform

2.0

of

:
:
:

* AH/kg
* mV
*

*
Not Required
:
:
:
:
:

Dimensional details
:
Anodes to be identical to sacrificial anodes :
(Vendor to furnish the differences if any)

Not Required

OFFSHORE
DESIGN SECTION
MUMBAI REGION

FUNCTIONAL SPECIFICATION FOR


CATHODIC PROTECTION SYSTEM OF
OFFSHORE STRUCTURE

FORMAT NO :
ODS/SOF/004

2.4

Detailed of Monitoring Panel:


-

2.5

Make & Type


Construction
Applicable Standard
Cross Section Area & Overall Diameter

Make & Type


Size
Material
Details of Thickness & Thread
Details of Accessories

SPEC NO FS 4001
SHEET NO 12OF 12

:
:
:
:
:
:
Not Required
:
:
:
:

Conduits
-

2.7

Basic component
Size
Mounting details & fixing arrangements
Enclosure
Weight & overall dimensions
Electrical power requirement at
24V DC (Nominal)

REV NO 1

Not Required

Cables:
-

2.6

WELL PLATFORM
PROJECT

VOL NO III

Not Required
:
:
:
:
:

Junction Boxes:

Not Required

Make & Type


Constructional details
Enclosure Protection
Weight & Overall Dimensions
Details of filling compound

:
:
:
:
:

:
Details of entry
(conduit entry from seaside, armoured cable with double compression
nickel/chromium plated brass cable gland on platform side.)

Note: Vendor shall furnish data marked (*) thus along with bids.