Design, Engineering and Installation Manual FOR Permanent Cathodic Protection System FOR Underground Pipeline

CORROSION MATTERS
DESIGN , ENGINEERING AND INSTALLATION MANUAL

FOR
PERMANENT CATHODIC PROTECTION SYSTEM
FOR
UNDERGROUND PIPELINE.
CORROSION MATTERS
6-3-899/2, 2ND FLOOR , SWATHI PLAZA
RAJBHAVAN ROAD, SOMAJIGAUDA, HYDERABAD – 500082
PHONE NO : +91 40 3240 4595

TELEFAX : +91 40 2341 8786
EMAIL: kbswaroop@corrmatt.com
WEBSITE : www.corrmatt.com
Page 1 of 48
CORROSION MATTERS
COMPANY OVERVIEW
Corrosion Matters , this company has been founded by Corrosion and Electrochemical
Engineers in 2005 to cater to projects, related to corrosion prevention systems
For prevention of corrosion , our team of engineers , are having hands on experience in
handling time bound and critical projects of importance.
The company is actively engaged in Cathodic Protection related comprehensive design
and project management services for projects that are typically , cross country pipelines,
complex plant Underground piping, Onshore and Offshore facilities , City Gas and Water
mains, above ground storage tanks , concrete steel structures etc.
The company has been chosen to foresee and supervise construction projects and key
assets of National and International Importance in Oil and Gas sectors.
The Objective of the company is to provide services to the industry to the minute detail
and innovate user friendly methods of Cathodic Protection Applications which shall help
the industries world over in a long way.
REGARDS,
CORROSION MATTERS
Page 2 of 48
CORROSION MATTERS
CATHODIC PROTECTION SYSTEM FOR U/G PIPING ( CROSS-COUNTRY)
1. SCOPE OF WORK :
The scope of work covers the Design, Engineering, Supply of Materials, Installation, Testing &
Commissioning of Permanent cathodic protection system for external surface of under ground
pipeline including post commissioning surveys such as Coating Conductance Measurements ,CIPL
survey, Pearson detection followed by DCVG [for defect classification] at defect locations evinced.
Also getting specific approval for major activities like
• Soil Resistivity survey & site data generation/collection.
• CP Design & Detailed Engineering
• Field Testing & Commissioning
• Procedures for interference testing & mitigation
• All major installation Procedures
• Coating conductance, CPIL & PEARSON Survey.
• Post Commissioning, Monitoring methodology & frequency formats
Page 3 of 48
CORROSION MATTERS
1.1 SOIL RESISTIVITY SURVEY
Soil resistivity survey should be carried out at at minimum two plots for each proposed CP station
as option for selecting best location for construction. Soil resistivity will be carried out at different
depth and at all anode bed locations.
The locations of anode ground bed plot will be selected based on the land availability to avoid
problems during construction & keeping maintenance in view. However from the resistance
calculations it can be decided type of anode bed.
Land selection for anode ground bed has been taken base on following broad guidelines, however
final decision to be taken at site based on land availability.
1. site for shallow ground bed should have minimum 100 mtr perpendicular distance from
the pipeline.
2. Location shall be remote (anode remoteness requirement to be calculated based on design

current rating with local resistivity & criteria)
3. Accessibility of location and route for laying of anode header cable shall be checked and
marked on plot plan drawing.
4. Anode bed shall not be situated below HT line and near electrical earthing.
5. Lowest resistivity location shall be considered over options available, for better anode
ground bed resistance option.
Page 4 of 48
CORROSION MATTERS
1.2 DESIGN BASIS & CRITERIA
The intent of this section is to propose design data and criteria for the Permanent Cathodic Protection
System.
1.2.1 Cathodic Protection Design Life & Current Density
In accordance with the project specification, the Cathodic Protection system will be designed to have a
desired design life in years.
For Example :
The Pipeline external surface is coated with 3 Layer Polyethylene (3LPE) coating and the current density
considered for the design is as follows:
i) For Polyethylene coated Pipeline (Normal Soil) µA/m2

: 25µ
ii) For Polyethylene coated Pipeline (Salt pan Area) : 125 µA/m2
A safety margin of 1.3 i.e. 30% has been provided for the current calculations over and above the
specified protective current density.
1.2.2 Philosophy of Cathodic Protection System for Permanent CP
The Cathodic protection systems shall be a MMO Lida anodes systems and shall be designed for Deepwell
and Horizontal type anode bed.
1.2.3 Codes & Standards
Latest revision of following standards shall be considered
BS7361-Cathodic Protection-Part 1 Cathodic Protection –code of Practice for Land and Marine
Applications
BS: CP:2008 Protection of Iron & Steel Structures From Corrosion.
NACE RP 0177-2000 Mitigation of alternating current and Lightning Effects on

Metallic structures and corrosion control systems
NACE RP 0286-2002 Electrical Isolation of Cathodically protected pipelines
NACE RP 0169-2002 Control of external corrosion on underground or

submerged metallic piping system.
CP_MANUAL.doc Page 5 of 48
CORROSION MATTERS
NACE TM 0497-2002 Measurement techniques related to criteria for cathodic

protection of underground-submerged metallic piping
system.
NACE Publication No 54276 Cathodic protection monitoring for buried pipelines.
NACE RPO. For Deep well CP
1.2.4 Cathodic Protection Design Criteria for Perma nent CP
Cathodic Protection system shall be designed to meet the following criteria:
1. The pipe to Soil Potential measurements shall be in between (-) 0. 95V “Off ” and (-) 1.1.7V “Off ”
as measured between the pipe surface and a copper – copper sulphate reference electrode.
2. In rare circumstances a minimum polarization shift of (-) 100mV shall indicate adequate levels of
cathodic protection for the pipeline with the written permission from owner.
3. A positive potential swing of >20mV shall be considered as the criteria for presence of an
interaction situation requiring investigation and incorporation of mitigation measures.
CORROSION MATTERS
1.3 Cathodic Protection Stations
In line with the project specifications and design calculations, location and No. of CP Station shall be
proposed as under:-
S.N. CP St’n. Location CP Station No. Chainage (Km) Type Rating
1 (SV#1) CP#1
2 (SV#2) CP#2
3 (SV#3) CP#3
4 (SV#5) CP#4
1.4 DESIGN CALCULATION
The following Calculation shall be used for design the permanent cathodic protection system
1.4.1 Total Cathodic Protection Current Requirement
i. Surface Area
Sa = Π x Dx L
Where :
Sa = Surface area of Pipeline m2
D = Diameter of pipeline m
L = length of pipeline m
ii. Current Requirement

It = Sa x Cd x 1.3/1000 Amps.
Where
It = C.P. current requirement (Amp)
Sa = Surface area of Pipeline m2
Id = C.P. protective current density mA/m2
1.3 = Safety Margin
CORROSION MATTERS
The current requirement calculations shall be tabulated as under:
CP station Area Classification Chainage Dia. Protection span Total Km Surface Protective Current
(Km) (mm) (Km) Area (m2) Current Required
Density (µA) (Amp.)
From TO
CP#1 (SV#
1)
CP#2 (SV#
2)
CP#3 (SV#
3)
CP#4 (SV#
5)
CORROSION MATTERS
1.4.2 Anode Requirement
Current
NA = It /Ia.
Where
NA = Total Anode Weight (Kg.)
It = C.P. current requirement
Ia = Out put current of Anode (4Amps)
Weight
W = It x Ct x L/Uf
Where
W = Total Anode weight (Kg)
Ct = Consumption Rate of anode (1 mg/Amp-year)
It = C.P. current requirement
Uf = Anode utilization factor
Total current Out put current Type of Anode required Anode Number of
requirement as per of individual Anode as per current required as Anode
Location
design (Amps) anode (Amps) (Nos) per Weight proposed
(Nos.) (Nos)
CP#1 (SV#1)
CP#2 (SV#2)
CP#3 (SV#3)
CP#4 (SV#5)
CORROSION MATTERS
1.4.3 Ground bed Resistance calculation
i) Horizontal Grounded Resistance Calculation

The resistance of horizontal anode to electrolyte is calculated by the following formula :
Rs = 0.159Ps [ Ln ( 4L2 + 4L ( S2 + L2 ) 0.5) + S – (S2 + L2)0.5 – 1 ) ]
L DS L L
Where
Rs = Resistance to earth in ohms of the horizontal anode (Ω)
Ps = Soil Resistivity in Ω - m
L = Length of Active Anode in Mtr
D = Diameter of Active Anode in Mtr
S = Twice the depth of Anode (M)
ii) DEEP ANODE BED RESISTANCE CALCULATION
The resistance of deep anode to electrolyte is calculated by the following formula :
Rdb = 0.159 Ps [ Ln ( 8 L / d)-1 ]
Where Rdb = Resistance to earth in ohms of the Deep anode (Ω)
Ps = Soil Resistivity in Ω – m
L = Length of Active Anode in Mtr
D = Diameter of Active Anode in Mtr
iii) INDIVIDUAL ANODE TO BACKFILL RESISTANCE
Rbs = 0.159 P [ Ln ( 8 L / d)-1 ]
where
Rbs = Individual Anode to backfill resistance in Ω
Ps = Back fill Resistivity for calcined petroleum coke breeze ( 50 Ω-cm )
L = Length of Anode in mtr.
d = Diameter of Anode in mtr.
CORROSION MATTERS
TOTAL ANODE TO BACKFILL RESISTANCE
Rtbs = Rbs/N
where
Rtbs = Total Anode to Backfill Resistance in Ω
Rbs = Individual Anode to backfill resistance in Ω
N = Number of Anodes
iv) TOTAL GROUND BED RESISTANCE OF THE BED
Rgb = Rs + Rtbs
Rgb = Total Ground bed resistance
Rs = Resistance of vertical /Horizontal Anode to earth in (Ω)
Rtbs = Total Anode to Backfill Resistance in Ω
v) TOTAL CABLE RESISTANCE
ANODE TAIL CABLE RESISTANCE OF SHALLOW GROUNDBED
Single core copper conductor Armoured cable of 10 sq.mm is selected as Anode Tail Cable as per tender
specification.
Ri = Li x R10
Where
Ri = Individual Anode lead Cable resistance in Ω ( i = 01 to 10 )
Li = Length of Anode cable in meters
R10 = Resistance of 10 sq.mm cable = 1.83 Ω / km
Rta = ( 1/R1 + 1/R2 + 1/R3 ........+R/n)
CORROSION MATTERS
HEADER CABLE RESISTANCE FOR CP SYSTEM
Single core copper conductor cable of 35 sq.mm is selected as Anode and Cathode Header cable .
Rac = R35 ( Lac + L cc )

Where
Rac = Resistance of Header Cable
Lac = Length of Anode Header Cable
Lcc = Length of Cathode Cable
R35 = Resistance of 35 sq.mm cable = 0.529 Ω / km
TOTAL RESISTANCE OFFERED BY ALL CABLES
Rtc = Rta + Rac
Rtc = Total cable resistance
Rta = Total anode tail cable resistance
Rac = Total Header Cable Resistance
vi) TOTAL CIRCUIT RESISTANCE
Rtcr = Rgb + Rtotal
Rtcr = Total circuit resistance in Ω
Rtotal = Total cable resistance in Ω
Rgb = Total Ground bed resistance in Ω
vii) OUTPUT OF SYSTEM
It = current required for CP Station in amps
Rtcr = Total Circuit resistance in Ω
Back Voltage : 2Volts
Additional Voltage to drive the required current (V) = It x Rtcr
Total Output Voltage (Vt) = V +2
CORROSION MATTERS
viii) REMOTE EARTH CALCULATIONS

Following Formulae is used to calculate the distance to remote earth
VE = ρxA/2xπxd
Where
ρ = Resistivity in Ohm- mtr
A = Current in Amps
D = Distance between pipeline & Anodebed in mtr
VE = Voltage at Pipeline
Remote earth voltage shall be less than the Natural PSP i.e. -0.45V
CORROSION MATTERS
1.4 Summary of Design Calculation
CP Average Soil Proposed No. of Anodes Installed Type of Size of Anode bed. Total Total Total out put Remote Distance
St’n. Resistivity (Ω
Ω- Anode Anode Bed Ground Total circuit required earth between
Locati mtr Type No current Active Dia / Width Distance bed cable R’tance Voltage Anode bed to
Rating (7) Amps Volts
on (1) (4) (Amps) (6) Depth Length (mm) (10) between R’tance - R’tance (Rtcr) (Volts) Pipeline
Considered (2) (3) (Amps) (mtr) (mtr) (9) Anode (It) (Vt)
(8) (11) Rab (Ω
Ω) (Rtc) (13) (14) (17) proposed
(5) (15) (16)
(12) (mtr) (1.7)
SV-1
SV-2
SV-3
SV-5
Note: If column (17) is less than pipeline Natural PSP , the distance of remoteness is sufficient.
CORROSION MATTERS
1.5 Length Of Pipeline Protected From Drain Point
i) CROSS SECTION AREA OF PIPELINE
Ap = Π x t x ( D-t ) in m2
where
A = Cross section area of Pipe
D = Diameter of Pipe
T = Thickness of pipe
ii) LINEAR RESISTANCE OF PIPE
Rs = ρs x l / A in Ω / km
where
ρs = Resistivity of steel pipe (2.2 x 10-7) ohm meter
A = Cross section area of pipe
l = Unit length of pipe
iii) COATING LEAKAGE RESISTANCE PER KM FOR 3LPE COATING
Rl = Rp/Sakin Ω per km
where
Rp = Coating resistance in
Sak = Surface area of pipe per Km
iv) ATTENUATION CONSTANT - α

α = ( Rs/Rl )0.5
Where
Rs = Linear Resistance of pipe
Rl = Coating leakage resistance
v) MINIMUM POTENTIAL SHIFT AT END POINT
CP DESIGN / PERM / CORRMATT Page 15 of 48

CORROSION MATTERS
Edp = P/s min - P/s nat in Volts
where
P/s min = Least negative PSP at end point
P/s nat = Natural PSP of pipeline
vi) LENGTH OF PIPELINE PROTECTED FROM DRAIN POINT
Lp = α) x Cosh-1(Edp/ Ed)
(1/α
Summary of current Attenuation calculation
01 Dia (mtr)
02 Thickness (mm)
03 Surface Area of 1 Km Pipe (m2)
04 Resistivity of steel pipe (ohm-m)
05 Coating Resistance of Pipe (ohm/ m2)
06 Linear Resistance of pipeline (ohm/km)
07 Coating Leakage resistance of Pipe (ohm/km)
08 Attenuation constant α
09 Least negative PSP at end point
10 Natural PSP of pipeline
11 Minimum potential shift at end point
12 Max. PSP at drain point
13 Length of pipeline protected from drain point

CORROSION MATTERS
1.6 Sample Design Calculation for CP Station for Span Length from 0 to 28.9 Km
Equation Description Value unit
1.6.1 Sa Surface area 41165 m2
Sa = P x d x l d Dia 0.4534 m
l Length 28900 m
1.6.2 It Total Current requirement 1.33 Amps
It = Sa x Id x 1.3/1000 Sa Surface area 41165 m2
Id Current density 0.025 mA/mt2
1.6.3 W Total Anode Weight 0.062 grams
It Total Current 1.33 Amps
W = I t x Ct x L / U f Ct Consumption Rate 0.001 gm/A-Y
L Life 40 Years
Uf Anode Utilization factor 0.85
1.6.4 Nw No of Anode required by weight 0.25 Nos
W Total Anode Weight 0.062 grams

Nw = W/ Wa
Wa Weight of Anode 0.240 grams
(Thickness of MMO Coating 6gm/m2)

CORROSION MATTERS
1.6.5 Nt No of Anode required by current 0.44 Nos
Nt = It/ Ia It Total current 1.33 Amps
Ia Anode output current 3 Amps
GROUND BED RESISTANCE CALCULATION FOR SHALLOW HORIZONTAL ANODE BED
1.6.6 RS Individual anode to backfill resistance 0.806 Ohms
ohm-
PS Soil Resistivity 36 mtr
Rs = 0.159Ps/L Ln(4L2 + 4L (S2+L2) 0.5)/DS)+( S/L) – (S2+L2)0.5/L –1) N No of Anodes 8 Nos
L Active length of anode 51 mtr
D Active diameter of Pre-packed anode bed 0.4 mtr
S Twice the depth of Anode 6 mtr
1.6.7 Rbs Individual anode to backfill resistance 0.38 Ohms
ohm-
Rbs = 0.159 Pb/L Ln ( 8 L / d)-1  Pb Backfill Resistivity for Calcined Coke 0.5 mtr
L Length of anode 1 mtr
d Diameter of anode 0.025 mtr
1.6.8 Rtbs Total Anode to Backfill Resistance 0.047 Ohms
Rtbs = Rbs/N Rbs Individual anode to backfill resistance 0.38 ohms
N Number of Anodes 8 Nos

CORROSION MATTERS
1.6.9 Rgb = Rs + Rtbs Rgb Total Ground bed Resistance 0.853 Ohms
Rs Resistance of vertical Anode to earth 0.806 Ohms
Rtbs Total Anode to Backfill Resistance 0.047 Ohms
Rta = 1/(1/R1)+(1/R2)……..+1/R6 Rta Resistance of Anode Tail Cable 0.0552 Ohms
Ri = Li x R10
Li Length of Anode cable mtr
R1 & R5 = 8 x 0.001.73 = 0.015ohms
1.6.10
R2 & R6 = 15x0.001.73 = 0.028 ohms
R3 & R7 = 22x0.001.73 = 0.040 ohms
R4 & R8 = 29x0.001.73 = 0.053 ohms R25 Resistance of 10 mm2 cable 0.00115 Ohm/Mtr
1.6.11 Rac Resistance of Header cable 0.14 Ohms
R35 Resistance of 35 mm2 cable 0.00056 Ohm/mtr

Rac = R35 ( Lac + L cc )
Lac Length of Cathode cable 75 mtr
lcc Length of Anode cable 175 mtr
1.6.12 Rtc Total Reisistance offered by All cables 0.143 Ohms
Rtc = Rta + Rac Rac Resistance of Header cable 0.14 Ohms
Rta Resistance of Anode tail cable 0.00342 Ohms
1.6.13 Rtotal Total Circuit Resistance 0.997 Ohms
Rtotal = Rgb + Rtc Rgb Total Ground bed Resistance 0.853 Ohms
Rtc Total Reisistance offered by All cables 0.143 Ohms

CORROSION MATTERS
1.6.14 Vt Total Output Voltage 3.32 Volts
Rtotal Total Circuit Resistance 0.997 Ohms

Vt = (Rtotal x It)+ 2Volts
It Total Current 1.33 Amps
Back Voltage 2 Volts
1.6.15 Voltage rise in earth with respect to remote

Vx earth 0.401 Volts
Vx = I /2 L  Soil Resistivity 36 Ohms
L Distance between P/L and Anode bed 100 Mtr
I Maximum current output 7 Amps
From above electrically remoteness calculations for Anode bed, it can observed that Voltage raise in earth with respect to remote earth at a distance 100 is
less than to pipeline Voltage to earth (ie 0.45V) & Remoteness of anode ground bed can be achieved
1.6.16 Ap Cross section area of Pipe 0.0123 Mtr
D Diameter of Pipe (m) 0.4534 Mtr

Ap = P x t x ( D-t )
t Thickness of pipe 0.0087 Mtr
1.6.17 ohm/K
Rs Linear Resistance of pipeline 0.01.70 m
0.0000
s Resistivity of steel pipe 0022 ohm-mtr
Rs = s x l / Ap
I unit length of pipe 1000 mtr
Ap Cross section area of Pipe 0.0123 mtr

CORROSION MATTERS
1.6.1.7 ohm/K
Rl Coating Leakage Resistance for 3LPE 10.45 m
ohm-
Rl = Rp/Sa
Rp Coating Resistance 15000 mtr2
1435.7
Sa Surface area per Km 1 mtr2
1.6.1.7  attenuation Constant 0.0415
=( Rs/Rl )0.5 Rs Linear Resistance of pipeline 0.01.70 ohm/Km
Rl Coating Leakage Resistance for 3LPE 10.45 ohm/Km
1.6.20 Edp Maximum potential shift at drain point -1.05 V
P/s
Edp =P/s max - P/s nat max Least negative PSP at drain point -1.5 V
P/s
nat Natural PSP of pipeline -0.45 V
1.6.21 Ed Maximum potential shift at end point -0.5 V
P/s
Ed =P/s min - P/s nat min Least negative PSP at end point -0.95 V
P/s
nat Natural PSP of pipeline -0.45 V
1.6.22 Lp Length of P/L protected from drain point 33.12 Km
Edp Maximum potential shift at drain point -1.05 V

Lp=(1/) x Cosh-1(Edp/ Ed)
Ed Maximum potential shift at end point -0.5 V
 attenuation Constant 0.0415

CORROSION MATTERS
1.7 INSTALLATION PROCEDURES
1.7.1 TEST STATION / JUNCTION BOX INSTALLATION
Purpose :
Test stations/ Junction box shall be provided along the pipeline ROW for monitoring the
performance of the Cathodic Protection system
Materials Required :
Shuttering Plates, Reinforcement, Concrete Mix, CableLugs , Ferrules
Detailed Procedure:
• The location of the test stations/junction box shall be marked on row as per
approved design with their connection scheme and other related information on
alignment sheet.
• The test stations/junction box shall be installed with the front of the test station
facing the pipeline.
• The overall dimensions of foundations shall be 600 mm(W) x 700 mm (H) X 500
mm (D).
• Excavate 1m x 1 m x 1 m where the foundation is to cast.
• Place reinforcement properly and take TLP bend and place it properly in the
reinforcement.
• Take MS shuttering and place it in right position.
• Fill annular space with RCC Mix. The mixture shall be constantly rammed for
proper compaction.
• Remove the shuttering after 24 hrs.
• The foundation shall be cured properly or it shall be coated with curing

compound.
• Place the TLP boxes/Junction boxes on the studs of the bend cast in concrete
foundation and tighten the bolts.
• The bolts shall then be distorted by hitting with a heavy hammer to make the
installation vandal/theft proof

CORROSION MATTERS
Precautions:
• All the connections should be checked for proper tightening.
• Cable core ferrules are to be provided at end before final termination
• Door of the TLP/Junction box should face Pipeline
• Cable should be neatly dressed inside the trench and to be terminated inside test
station.
• In case of location, where sacrificial anode is to be installed, the same should be

taken parallel and the anode cable to be terminated at test station.
Documentation:
Inspection Reports shall be furnished as per the report formats attached below:

CORROSION MATTERS
INSPECTION AND TEST PLAN FOR TEST STATION / J.B INSTALLATION
PROJECT
OWNER
CONTRACTOR
CP CONTRACTOR
REFERENCE DOCUMENT
PERSONAL RESPONSIBLE
SR NO ACTIVITY CPC CONTRACTOR OWNER
APPROVAL OF TEST STATION INSTALLATION

1 P W A
PROCEDURE
2 CHECK LOCATION P W RM
CONCRETE FOUNDATION SIZE, RCC MIXTURE,

3 P W RM
REINFORCEMENT & CURING
INSTALLATION TEST POST MOUNTING ABOVE

4 P RM
FONDATION W
5 TERMINATION OF CABLES IN THE TEST STATION P RM

W
LEGEND
A - APPROVAL / ACCEPTANCE; R - REVIEW OF RECORD; RM - RANDOM CHECK
W - WITNESS ALL; P- PERFORM

CORROSION MATTERS
SITE INSPECTION REPORT FOR TEST STATION/

JUNCTION BOX INSTALLATION
PROJECT
OWNER
CONTRACTOR
CP CONTRACTOR
REF. DOC UMENT
Test station Location ( Chainage in Km)
Test Station Type
Distance from Pipeline
Foundation Acceptable /Not Acceptable
Test Station Mounting Acceptable /Not Acceptable
Cable Termination Acceptable /Not Acceptable
Final Restoration Acceptable /Not Acceptable

Notes :
CPC CONTRACTOR OWNER

Name
Signature
Date

CORROSION MATTERS
1.7.2 ANODEBED INSTALLATION
PROCEDURE FOR ANODE BED INSTALLATION
SCOPE
This procedure covers installation of Deep ground bed as per standard drawing & design document.
MATERIALS REQUIRED
Sr.No Material/Tool Make Application/Purpose
01 Crimping Tool Standard For crimping cable with lug
02 Excavation tools & Auggers Standard For Excavation
03 Measuring Tape Standard Measurement
04 Petroleum coke breeze Goa Carbons Backfill material
05 Canister Standard Sheet steed for Backfilling
06 Tubular anode Lida® / SME / Anodes for Anode bed

other
approved
07 Anode Tail cable Netco/Suyog Connection to pipe
08 Cu Sleeves/ Cable Lug/D Standard

clamps/Ferrules, PVC pipe & Warning
mat etc.
09 Electrical Tool Box Standard
10 Casing Pipe for Deep anode bed Standard Casing Pipe for Deep anode bed
11 PVC Shrouding Pipe Standard For Deep anode ground bed
13 PVC Vent Pipe Standard For Deep Well
PROCEDURE FOR DEEP WELL ANODE INSTALLATION

• Locate the Drilling Rig at approved deep well ground bed location.
• Start the drilling of borehole with suitable diameter drilling bit and drill a borehole of
suitable depth as per approved document.
• Lower the casing pipe (3mm) one length at a time and coupling various lengths with couplers
one after the other.
• After lowering MS casing pipe, a PVC shrouding pipe equal to the inactive length of the deep well
ground bed shall be lowered along the casing pipe from the top.
• Mark length equal to the required depth on the tail cables of anodes to avoid excessive lowering.

CORROSION MATTERS
• Tie all MMO anodes with vent pipe and cables to gather, and also install the centralizers for each
anodes and End weight to last anode as per design approval.
• Anodes shall be lowered with suitable nylon rope. Nylon rope shall be binded with end weight.
• Mix the coke breeze with water to form slurry.
• Fill the slurry coke breeze inside the bore well up to the active length and rest backfill with metal
gravel, this is to ensure proper filling of entire borehole.
• Backfilling to be done till overflowing from top of the pit, and than allow it to settle, fill the top of
pit as per approved drawing, with metal gravel after settling time of two-three days.
• Clamp / Tie the anode tail cable and lay up to anode junction box
• All the tail cables and Header cable shall be laid and terminated in anode junction box.
• Prepare Anode pit and cover as per approved drawing.
FOR HORIZONTAL BED INSTALLATION

• Length of the ground bed shall be according to the approved design package.
• Total depth of excavation in horizontal ground bed shall be as per design document.
• Cross section of bottom of the trench should be as per approved design document, as the same is
only considered for anode bed resistance calculation. The shape of excavated trench from top to
bottom need not be precise. Moreover, it shall depend on nature of soil at the site.
• Pour backRill into the trench and tamp it to a level corresponding to 0.150 m from bottom of
trench. Pour sufficient water on coke breeze and mix with wooden plank to prepare slurry.
• Mark the locations of individual canister anodes alongside the trench as spacing indicated in the
approved design package and place the individual anode horizontally within the trench on the
bed of the backfill prepared.
• Anode tail cables of individual anodes should be coiled and kept on ground adjoining the trench.
• Pour backfill into the trench and tamp it to a level corresponding to design requirement. (Take
care while tamping the coke breeze so that the anode connection or cable is not damaged). Again
pore sufficient water on top of the spread up coke breeze all over the anode so that slurry can be
achieved.
• Lay Tail cable & header cables and bring them up to proposed anode junction box location as per
standard drawing.
• PVC sleeve to be provided on all anode tail cables up to entry of anode junction box, for
mechanical protection.

CORROSION MATTERS
• At 1.0 m depth all anode tail cable and anode header cable to be laid as per cable laying
procedure.
• Earth restoration work with proper compaction to be carried out at cable laying and anode bed
location.
• Layout of anode installation in anode bed shall be as detailed out in the drawing showing anode
installation.
PRECAUTIONS
• Lower anode carefully to avoid damage to tail cable, Canister anodes should never be handled by
cables, but rope to be used for the same.
• After lowering clamp/Tie the cable to avoid further slide
• Tail cables and PVC conduits shall be of sufficient length so as to reach Anode Junction Box
without any joint and providing sufficient slack for future maintenance purpose.
• Each shallow anode bed shall contain anodes with canisters positioned in the soil with suitable
backfill at appropriate depth with due regards to type of configuration.
• Keep tail cable lengths sufficient so as to reach anode junction box without any joint and
providing sufficient slack for future maintenance purpose
• All cables are to be appropriately tagged before lowering cables in to trench/well.
• Provide cable core ferrules at end before final termination.
HEALTH, SAFETY & ENVIRONMENT

Hazard Identification and risk assessment will be carried out and Operational Control measures shall be
adopted for Anode Installation Activities.
i. Necessary PPE to be utilized
ii. Only trained personnel to be deployed for this activity.
QUALITY ASSURANCE & QUALITY CONTROL

Quality Assurance shall be maintained by ensuring the systematic implementation of this Procedure and
ensure that necessary quality records are generated as per ITP.

CORROSION MATTERS
INSPECTION AND TEST PLAN FOR DEEPWELL /
SHALLOW HORIZONTAL ANODEBED INSTALLATION
PROJECT
OWNER
CONTRACTOR
CP CONTRACTOR
PERSONAL RESPONSIBLE CPC : SITE ENGINEER / SUPERVISOR
CONTRACTOR/ OWNER : INSPECTOR

CONTRACTO
SR NO ACTIVITY CPC OWNER
R
1 APPROVAL OF DEEP GROUND BED PROCEDURE P R A
2 CHECK LOCATION P
W A
3 CHECK DEPTH P
W R
4 CHECK CASING PIPE LOWERING P
W R
5 CHECK ANODE LOWERING P W RM
6 FILLING OF COKE BREEZE P W R
LEGEND
A - APPROVAL / ACCEPTANCE; R - REVIEW OF RECORD; RM - RANDOM CHECK
W - WITNESS ALL; P- PERFORM

CORROSION MATTERS
SITE INSPECTION REPORT FOR DEEPWELL ANODE INSTALLATION
PROJECT
OWNER
CONTRACTOR
CP CONTRACTOR
REFERENCE DOC.
LOCATION
DISTANCE OF ANODE BED FROM PIPELINE
DIA OF CASING PIPE
LENGTH & DIAMETER OF BORE HOLE
NO OF ANODES IN THE STRING
ANODE RATING
ANODE LOWERING OK / NOT OK
COKE BREEZE FILLING OK / NOT OK

Notes:

Name
Signature
Date

CORROSION MATTERS
1.7.3 PIPE TO CABLE CONNECTION
Pipe To Cable Connection By Thermit Welding
Scope
This procedure covers Thermit Weld for cable connection to pipeline for all type of cables related to
Cathodic Protection System.
Cable to Pipe connection during construction shall be done by Thermit welding method.
Materials Required
Sr.No Material/Tool Make Application/Purpose

01 Crimping Tool Standard For crimping cable with
lug/ferrule
02 Thermit Mould & Sparking Gun Erico, USA Thermit welding & Igniting
03 Cad Weld Powder, CA15 & CA32 Erico, USA Welding
03 Cables Netco Connection to pipe

04 Hammer & Chisel Standard Hammering test for Thermit
& Coating cutting
05 Epoxy Dobefil-60 Doctor Beck For sealing of Cable to pipe

joints
06 Hardner-758 Doctor Beck
07 PVC Funnel Local Coating Repair Filing.
08 M seal / Mastic Mahindra / CPC Sealing for PVC funnel

09 Cu Sleeves Standard For Cable Connections
10 Fine File Local Surface Cleaning
11 Sand Paper Local Surface cleaning
12 Holiday Detector Caltech For coating check
Procedure
• Excavate (wherever pipeline backfilled with soil) a pit over the pipeline to expose the pipeline
top surface at location of Thermit weld where cable to pipe connection is to be carry out as per
design document. Care should be taken not to damage the coating of buried pipeline. Only
manual excavation shall be carried out over pipeline.
• Mark where connection is to be carried out. If there are more than one connection as per design
document, consecutive marking shall be minimum 300 mm apart. Connection location shall be
minimum 300mm apart from other connection and Welding joint, Seam or Circumferential Weld

CORROSION MATTERS
Joint of the pipeline. The location for cable to pipe connection shall be selected such that the pipe
joints and field-coated areas are avoided.
• Cut open the coating on the pipeline with care and without damaging the pipe for a size of
approximately 50 mm x 50 mm (suitable for thermit weld mould).
• Clean the surface of the pipeline to white metal finish using sand paper and cleaning with fine file
as required.
• Depending on the size of cable select the model of cad weld material i.e. CA-15 or CA-32 and
mould.
• Copper sleeve of suitable size shall be double Crimped on the cable (up to 10 sqmm cable).
• Place the mould on the exposed area and pour the cad weld material. Ignite using the gun and
wait for 2 minutes cool down period.The resistance of Cable to pipe at thermite connection point
shall not exceed 0.1Ω
• Test the connection by striking 0.5 Kg hammer directly over the connection. And if connection
fails, the above procedure shall be repeated after waiting time of approx.10min.to cool the
pipeline surface.
• Place a plastic funnel around the exposed area such that about 15mm wide coating remains in
side the plastic funnel. Apply mastic/Mseal around the plastic funnel to prevent leakage of
encapsulation materials.
• Mix proper quantity of epoxy-hardner and keep mixing with wooden rod till it gets heated, Fill up
the conical funnel from the top by pouring mix of Epoxy – Dobofil – 60 and hardener – 758 at
1:10 ratio. 3/4th of the cone to be Rilled with mix and remaining plastic cone to cut after setting of
the hardener.
• Allow the epoxy-hardener to set ensuring every metallic part of joint is completely insulated and
test the insulation level by a holiday detector at 25 KV.
• Cable shall be laid in accordance with approval cable laying drawings. Cable route shall be
carefully measured and cable cut to be required length from test station to pipe. A loop of approx
0.5mtr.of cable shall be kept at both pipe and Test Station end.
Precautions
a. Only Manual excavation to be done without damaging the coating.
b. All cables are to be appropriately tagged.
c. Location of cable to pipe connection shall be minimum 300mm apart from other connection
and from Pipe weld joint, Seam or Circumferential Weld Joint

CORROSION MATTERS
d. Check hardness of encapsulation before holiday test by applying pressure with

thumb/Wooden Stick.
e. Coating repair and holiday test should be completed before backfilling.
f. Maximum 15 grams Ignition powder shall be used for each connection. If one connection
fails, wait of approx 10 min for pipeline cooling and then repeat the procedure for
connection.
Health,Safety & Environment
Hazard Identification and risk assessment will be carried out and Operational Control measures shall be
adopted for Anode Installation Activities.
• Necessary PPE to be utilized
• Only trained personnel to be deployed for this activity.

CORROSION MATTERS
SITE INSPECTION REPORT FOR THERMIT WELD CONNECTION
PROJECT
OWNER
CONTRACTOR
CP CONTRACTOR
REFERENCE DOC.
Test Station Type Chainage
Type of Cable to Pipe Connection Thermit welding

Cable Size Length No. of Pipe to Cable Connection
1C x 6 SQMM Cable
1C x 10 SQMM Cable
1C x 25 SQMM Cable
Resistance of cable to pipe at thermit connection point Acceptable / Not Accebtable
Hammer Test
Holiday Test OK / NOT OK
Pipe to soil potential (Natural) w.r.t. Zinc Reference Half cell
1C x 6 SQMM Cable
1C x 10 SQMM Cable
1C x 25 SQMM Cable
Sealing of exposed area of pipe with Epoxy Sealing material

Signature
Name
Date

CORROSION MATTERS
1.8 PROCEDURE FOR COMMISSIONING OF PCP SYSTEM
Purpose
To describe the procedure for commissioning of Permanent cathodic protection system and provide
adequate quality assurance / control of workmanship and inspection at site.
Scope
This procedure will cover commissioning of the Impressed Current C.P system installed to protect under
ground pipeline from external corrosion.
Equipments
- Soil resistivity meter
- Digital multimeters
- Portable reference electrodes
- Megger
Commissioning Procedure
• On completion of installation of anode beds and other systems as envisaged in the specification,
they shall be individually checked, tested and compared against the agreed specifications and
procedure.
• The CP commissioning shall be carried out with current interrupter provided in the output of the
CPPSM unit to measure CP “ON” & “OFF” potentials.
• Current dissipated by each anode shall be corrected through anode lead junction box.
• Electrical continuity of the entire pipeline shall be verified in conformity with design.
• Input resistance of the pipeline at all the drainage points shall be checked and recorded.
• All current measuring test stations shall be calibrated and recorded.
• Temporary protection facilities provided (if any) which do not form part of permanent CP shall
be disconnected from the sytem & removed unless agreed otherwise.
• The pipeline shall be allowed to depolarize for atleast 72 hours after switching ‘off’ the protection
(if any) of all other pipelines in the common R.O.W.
• Before the pipeline is put on charge by switching ‘on’ CP station, natural structure –to-electrolyte
potential values at all the test stations of the system shall be measured with respect to zinc
reference cell.

CORROSION MATTERS
• CP station shall be energized so as to achieve a maximum pipe soil potential (PSP) as specified at
the test station nearest to the drainage point, and observations on either spread of protected
portion of pipeline under this CP station shall be taken for PSP values pipeline current values
across the cross section of the pipeline shall also be determined at all the intended test stations
influenced by this CP station.
• Another complete set of PSP observations shall be taken after lines have stayed on charge for
24/48 hours. If there are appreciable differences in these observations as compared to those of
earlier set, a third set of observations shall be taken after 72 hrs. Maximum drainage point
protective potentials shall not be allowed to go beyond the maximum PSP values as specified, in
any case.
• The output of CP Station shall then be so adjusted that the sites of occurrence of least negative
protective potentials are increased to (-) 1.00 V. A full set of observations shall again be taken 72
hrs. after the adjustment of potentials and the protection system shall be left in this state of
operation.
• Care shall be exercised to ensure that power supply remains uninterrupted during the period of
commissioning. In case of an interruption, the test in progress shall be repeated after allowing
time for polarization. More sets of observations may be advised to be taken by the
owner/owner’s representative in any of the above-mentioned steps.
• PSP values at each of the test stations of the existing pipelines shall be measured and plotted
where existing pipelines run in parallel to the new pipeline and mutual interference situations
between the pipelines shall be identified and necessary mitigation shall be carried out.
• Interference situations shall also be identified and mitigated by comparing different sets of
readings taken at same test stations at different intervals of time under identical conditions
where positive potential swing exceed 50 MV.
• Final records of testing and commissioning including graphical representation of final structure
to electrolyte potential readings shall be complied with interpretation in consolation with
owner/owner’s representative and submitted.
• If it is found during commissioning that the sites of occurrence of least negative or most negative
protective potentials are less negative than (-) 1.00V even after 72 hrs of operation, then the
drainage point potentials shall be adjusted depending upon anode ground bed currents in
consultation with Owner/Owner’s representative. In any case, the drainage point protective ‘ON’
potential values shall not exceed the PSP values as per specification and the pipe to soil ‘OFF’
potential shall not exceed a value more negative than (-) 1.20 V at any location on the pipeline.
• The current dissipated by the indiviual anodes shall be measured from the anode lead junction
box and corrected for equal dissipation to the extent possible keeping the total ground bed
current same.

CORROSION MATTERS
INSPECTION AND TEST PLAN FOR PCP COMMISSIONING
PROJECT
OWNER
CONTRACTOR
CP CONTRACTOR
REFERENCE DOC
CONTRACTOR / OWNER : INSPECTOR
SR NO ACTIVITY CPC CONTRACTOR OWNER
1 Pre commissioning Tests At Anode Bed And TR Unit S W A
Disconnection Of Sacrificial Anode On Entire Spread And P W RM

2
Allow For Depolarization
After 72 Hrs. Of Depolarization Collect Natural Potentials At P W RM

3
All Test Stations
Energize The Cp Unit And Record The Reading To Find P W RM

4
Attenuation
5 Submission Of Records P W A
LEGEND
A - APPROVAL / ACCEPTANCE W - WITNESS ALL
R - REVIEW OF RECORD P- Performed by
RM - RANDOM CHECK S – Submitted by

CORROSION MATTERS
PRE-COMMISIONING CHECKS REPORT
PROJECT
OWNER
CONTRACTOR
CP CONTRACTOR
REFERENCE DOC.
LOCATION
DATE
SR NO ACTIVITY OBSERVATION
1 Anode Bed Installation Termination Etc. OK/NOT OK
CP unit Installation & Earthing , cable OK/NOT OK

2 termination and tagging etc & No Load
operational checks.
3 CP system cable termination & taging OK/NOT OK
4 CP unit working condition (No load) OK/NOT OK
5 Surge Diverter Installation OK/NOT OK
6 Reference cell Calibration (mv) RE-1
RE-2
REMARKS
Name:
Sign:
Date:

CORROSION MATTERS
INSPECTION REPORT FOR PCP COMMISSIONING (ANODE BED)
PROJECT
OWNER
CONTRACTOR
CP CONTRACTOR
REFERENCE DOC.
Date
CP Station No Location
GROUND BED DETAILS
1.0 Groundbed Configuration & Type
2.0 Groundbed Rating Anode Quantity
3.0 Voltage between Pipe and Anode (Back EMF):
4.0 TR Unit Output Voltage Current
5.0 Total Anode bed Resistance (3 Pin) Ohms
6.0 Total Anode To Cathode Circuit Resistance (DC O/P Volts/Current) Ohms
7.0 Individual Anode current at Anode Junction Box

Potential Across the Current (amps) Potential Across the shunt Current (amps)
Anode No Anode No
shunt (mV) (mV)
A1 A6
A2 A7
A3 A8
A4 A9
A5 A10
REMARKS Total Current:
Name:
Sign:
Date:

CORROSION MATTERS
INSPECTION REPORT FOR PCP COMMISSIONING (CP Unit)
PROJECT
OWNER
CONTRACTOR
CP CONTRACTOR
REFERENCE DOC.
Report.No. Date:
CP Station No: Chainage & Location :
TR Unit Parameters
Hour Meter Reading :
Input Voltage (Volts) DC Input Current (Amp) DC
DC output Voltage (Volts) DC output Current (Amps)
Anode bed Loop Resistance Calculated V/I from above _______________________Ohm
Mode Auto/AVCC/Manual
Coarse Control Switch Fine Control Switch
Pipe to Soil Potential W.r.to Permanent Reference cell (Cu-CuSO4)
Reference 1 (-V) Reference 2 (-V) Reference 3 (-V)
Set PSP in TR unit (-V)
PSP at nearest TS (Drainage) -V
REMARKS
Name:
Sign:
Date:

CORROSION MATTERS
INSPECTION REPORT FOR PCPCOMMISSIONING (PSP Natural PSP)
(Format 1 of 3)
PROJECT VCM PIPELINE PROJECT
OWNER CHEMPLAST SANMAR LIMITED

CONTRACTOR CONTRACTOR INFRASTRUCTURE LIMITED
CP ONTRACTOR CPCRPG LIMITED
REFERENCE DOC. CPC-CONTRACTOR-VCM-DD-001
Report.No. Date:
Readings From _______ km to _______km
Test station PSP (-V) Remarks
Chainage Casing
No Type Natural PSP AC PSP
(Km) PSP
REMARKS :- PSP after 48 hrs of disconnection of sacriRicial anode connections to pipeline.
Name:
Sign:
Date:

CORROSION MATTERS
NSPECTION REPORT
FOR PCPCOMMISSIONING (PSP reading First Set ) Format 2 of 3
PROJECT
OWNER
CONTRACTOR
CP ONTRACTOR
REFERENCE DOC.
Report.No. Date:
CP Unit On : Chainage & Location __________________________
Readings From _______ km to _______km
Test station PSP (-V) Remarks
Chainage Casing
No Type `ON` PSP AC PSP
(Km) PSP
REMARKS : Setting of TR unit to be recorded in TR format with note for commissioning first set of readings
purpose.
Name:
Sign:
Date:

CORROSION MATTERS
INSPECTION REPORT
FOR PCPCOMMISSIONING (PSP reading ) Format 3 of 3
PROJECT
OWNER
CONTRACTOR
CP ONTRACTOR
REFERENCE DOC.
Report.No. CP section (IJ to IJ) From _________ to __________km Date:
Test station PSP Initial (-V) PSP 48 Hrs (-V) PSP After 72 Hrs (-V). Remarks
No Type Chainage Km ON PSP ON PSP ON PSP AC PSP CASING
REMARKS
Name:
Sign:
Date:

CORROSION MATTERS
1.9 POST COMMISSIONING SURVEY
CIPL SURVEY
Purpose
To define the procedure for the conduction of CIPL Survey on the commissioned Pipeline to evaluate the
CP system and to provide adequate quality assurance / control.
Equipment / Accessories Required

• Pipeline locators (if required)
• Data collector-Sincoder along with the reference cell Sticks.
• Current interrupts with synchronized timer circuits and adjustable time settings
• Rodometer
• Flexible cable/wire of required length.
Procedure
• Before commencing the survey, confirm that the cathodic protection system is operating
normally by checking the DC feeders, drain points, insulating joints with commissioning
results.
• Check the cathodic protection commissioning result to identify the area requiring special
attention during the CIPL survey.
• Locate the route of the pipeline using the pipeline locator and provide temporary markers
(Marking powder) on the route to enable the survey to walk-on the route of the pipeline for
carrying out the CIPL survey.
• Install current interrupter with synchronized timer in the DC negative output of the DC
power source (CP System) at the CP station of the section in which the survey is being
carried out.
• Set the interrupter switching cycle at a ratio of 4:1 ON:OFF.
• With the equipment connected and the pipeline located, move along the pipeline carrying the
mobile data collector and Zinc reference cell and measure and store the pipe to soil
potentials.
• Check reference electrodes regularly for its operation.
• Record distance traversed and physical features such as roads, as descriptors to assist
locating specific areas after processing the data.

CORROSION MATTERS
• As each section between TLP connections is completed, real the fine wire for further use and
shift continuous chart records to the next section.
• Transfer the data from the simcorder to a computer for producing the data print outs and
plot of the PSP potential profiles.
• The data collected during the survey shall include
i. Monitoring results of the sectional T/R Units
ii. Data (PSP Values) – ON and Instant OFF
Distance location details as a descriptors.

• After completing the survey based on the above procedure, the readings in numeric and
graphical manner shall be submitted after detailed interpretation.

CORROSION MATTERS
SITE INSPECTION PLAN FOR CIPL SURVEY

PROJECT
OWNER
CONTRACTOR
CP
ONTRACTOR
REFERENCE DOCUMENT
CONTRACTOR/OWNER: INSPECTOR
Verification Records
S.NO ACTIVITY Performed By Verification By
By submission
CPC OWNER
CONTRACTOR by CPC
1 Submission & Obtaining approval of P R A

Procedure
2 R RM
TR Interrupter Setting P
3
Conduction of Survey P W RM
5
Entering of Readings P R RM
5
Entering of Location Description P R RM
6 P R R
Final Report
LEGEND
A - APPROVAL / ACCEPTANCE
R - REVIEW
RM - RANDOM CHECK
W - WITNESS

CORROSION MATTERS
Inspection Report for CIPL Survey
PROJECT
OWNER
CONTRACTOR
CP ONTRACTOR
REF. DOC : CPC-CONTRACTOR-VCM-DD-001 DATE
Interrupter Setting OK / NOT OK
Staring Location , Chainage
Ending Location , Chainage
TRU Section
Conduction of Survey OK / NOT OK
Entering of Datas / Locations OK / NOT OK

Remarks

Signature
Name
Date
**********************

Design, Engineering and Installation Manual FOR Permanent Cathodic Protection System FOR Underground Pipeline

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CORROSION MATTERS

DESIGN , ENGINEERING AND INSTALLATION MANUAL

PHONE NO : +91 40 3240 4595

• Soil Resistivity survey & site data generation/collection.

• CP Design & Detailed Engineering

• Field Testing & Commissioning

• Procedures for interference testing & mitigation

• All major installation Procedures

• Coating conductance, CPIL & PEARSON Survey.

• Post Commissioning, Monitoring methodology & frequency formats

1.1 SOIL RESISTIVITY SURVEY

2. Location shall be remote (anode remoteness requirement to be calculated based on design

1.2 DESIGN BASIS & CRITERIA

1.2.1 Cathodic Protection Design Life & Current Density

i) For Polyethylene coated Pipeline (Normal Soil) µA/m2

1.2.2 Philosophy of Cathodic Protection System for Permanent CP

1.2.3 Codes & Standards

Latest revision of following standards shall be considered

BS: CP:2008 Protection of Iron & Steel Structures From Corrosion.

NACE RP 0177-2000 Mitigation of alternating current and Lightning Effects on

NACE RP 0286-2002 Electrical Isolation of Cathodically protected pipelines

NACE RP 0169-2002 Control of external corrosion on underground or

NACE TM 0497-2002 Measurement techniques related to criteria for cathodic

NACE Publication No 54276 Cathodic protection monitoring for buried pipelines.

NACE RPO. For Deep well CP

1.2.4 Cathodic Protection Design Criteria for Perma nent CP

Cathodic Protection system shall be designed to meet the following criteria:

1.3 Cathodic Protection Stations

S.N. CP St’n. Location CP Station No. Chainage (Km) Type Rating

1.4 DESIGN CALCULATION

1.4.1 Total Cathodic Protection Current Requirement

ii. Current Requirement

The current requirement calculations shall be tabulated as under:

1.4.2 Anode Requirement

It = C.P. current requirement

Ia = Out put current of Anode (4Amps)

Ct = Consumption Rate of anode (1 mg/Amp-year)

It = C.P. current requirement

Uf = Anode utilization factor

1.4.3 Ground bed Resistance calculation

i) Horizontal Grounded Resistance Calculation

Rs = 0.159Ps [ Ln ( 4L2 + 4L ( S2 + L2 ) 0.5) + S – (S2 + L2)0.5 – 1 ) ]

Rs = Resistance to earth in ohms of the horizontal anode (Ω)

L = Length of Active Anode in Mtr

D = Diameter of Active Anode in Mtr

S = Twice the depth of Anode (M)

ii) DEEP ANODE BED RESISTANCE CALCULATION

The resistance of deep anode to electrolyte is calculated by the following formula :

Rdb = 0.159 Ps [ Ln ( 8 L / d)-1 ]

Where Rdb = Resistance to earth in ohms of the Deep anode (Ω)

L = Length of Active Anode in Mtr

D = Diameter of Active Anode in Mtr

iii) INDIVIDUAL ANODE TO BACKFILL RESISTANCE

Rbs = 0.159 P [ Ln ( 8 L / d)-1 ]

Ps = Back fill Resistivity for calcined petroleum coke breeze ( 50 Ω-cm )

L = Length of Anode in mtr.

d = Diameter of Anode in mtr.

TOTAL ANODE TO BACKFILL RESISTANCE

Rtbs = Total Anode to Backfill Resistance in Ω

Rbs = Individual Anode to backfill resistance in Ω

iv) TOTAL GROUND BED RESISTANCE OF THE BED

Rgb = Total Ground bed resistance

Rs = Resistance of vertical /Horizontal Anode to earth in (Ω)