Pipeline Cathodic Protection Design - Compress PDF

Project n° - Unit Doc. type Code Serial n° Rev.
Page
8474L 082 CN 3533 101 0 2 / 15
VIETNAM OIL AND GAS CORPORATION ( PETROVIETNAM )

DUNG QUAT REFINERY (DQR) PROJECT
PIPELINE CP DESIGN
TABLE OF CONTENTS
1.0 INTRODUCTION ........................................................................................................................................................3
2.0 SUMMARY OF RESULTS .........................................................................................................................................4
3.0 DESIGN PARAMETERS............................................................................................................................................6
4.0 METHOD OF ANALYSIS ..........................................................................................................................................8
5.0 CONCLUSION...........................................................................................................................................................14
6.0 REFERENCES ...........................................................................................................................................................15
APPENDIX A COMPUTER PRINTOUTS

ANODE SIZING CALCULATIONS
8474L-082-CN-3533-101-0.doc
Project n° - Unit Doc. type Code Serial n° Rev. Page
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PIPELINE CP DESIGN
1.0 INTRODUCTION
This calculation note presents the offshore pipeline external corrosion protection design for the two of 30-inch crude
oil carbon steel insulated pipeline from the Pipeline End Manifold (PLEM) system located on the seabed below the
Single Point Mooring (SPM) buoy to the landfall (up to KP 3.960) as part of the Dung Quat Refinery Project.
The scope of work includes:
i. Determining the type of anti-corrosion coating required for pipeline against external corrosion throughout its
design life.
ii. Design of aluminium sacrificial bracelet anodes required for the pipeline against external corrosion for the
design life of 20 years.
1.1 ABBREVIATIONS
CP - Cathodic Protection
CPR - Crack Propensity Ratio
ID - Inside Diameter
KP - Kilometre Point
OD - Outer Diameter
3LPP - 3 Layer Polypropylene
Thk. - Thickness
yrs - years
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PIPELINE CP DESIGN
2.0 SUMMARY OF RESULTS
2.1 EXTERNAL ANTI-CORROSION COATING
The selected external anti-corrosion coating system for the 30-inch pipeline from the Pipeline End Manifold (PLEM)
system to the landfall is presented in Table 2.1.1.
Table 2.1.1 External Anti-Corrosion Coating System
Section Type of Anti-Corrosion Coating
KP 0.0-3.200 2.5 mm thick 3LPP
2.2 CATHODIC PROTECTION
The pipeline cathodic protection requirements for the 30-inch pipeline from the Pipeline End Manifold (PLEM)
system to the landfall are presented in Table 2.2.1.
Table 2.2.1 Cathodic Protection Requirements for Pipeline
KP 0.0 - KP 1.390 - KP 2.000 - KP 2.610 -

Description Unit
KP 1.390 KP 2.000 KP 2.610 KP 3.200
Anode Type - I (Submerged) II (Submerged) II (Buried) III (Buried)

Anode Inside
mm 832.6 (Note 4)
Diameter
Anode Outside
mm 942.60 982.60 1042.60
Diameter
Anode
mm 60.0 80.0 110.0
Thickness
Anode Length mm 361.41 369.62 433.37
Net Weight /
kg 140.0 200.0 340.0
Pair (Note 1)
Spacing
- 12 8 9
(Pipe Joint)
Total Anode
Quantity (for 2 set 20 10 14 12
lines)
Total Net
kg 2800.0 2000.0 2800.0 4080.0
Weight
Crack
Propensity - 1.13 0.46 0.20
Ratio (Note 2)
Anode
- Aluminium-Indium Alloy Bracelet (Half-Shell Type)
Material
Notes:
1. One (1) pair of anode is made up of two (2) pieces of half-shell bracelet anode.
2. Crack Propensity Ratio (CPR) is a measure of the ratio of anodes length, diameter and thickness. A CPR
value of less than 5 will ensure a lesser probability for the occurrence of cracks in the anodes.
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PIPELINE CP DESIGN
3. Vendor shall propose steel core dimensions and shall include in their calculations.
4. Positive tolerance on OD of pipe (3mm) and 0.1mm thick coating inside the anode has been considered in
anode ID calculation.
2.3 INSULATION JOINTS
Monolithic insulation joints have been considered at the following location.
• One each at the shore line on 30-inch pipelines between onshore and offshore pipeline section.
• One each on the 30-inch onshore pipeline at the transition of above ground to below ground at pig
launcher/receiver station.
This report addresses only design of Cathodic Protection System of offshore pipelines. Cathodic Protection design
for onshore pipelines will be carried out by others.
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PIPELINE CP DESIGN
3.0 DESIGN PARAMETERS
3.1 DESIGN DATA
Unless otherwise stated, the design data are as per Crude Oil Pipeline Design Basis [Ref. 1] and the requirements of
DNV RP B401 [Ref. 3]
Table 3.1.1 Design Parameters for Cathodic Protection Design
KP0.000– KP 1.390 – KP 2.000 – KP 2.610 –

Description Unit
KP1.390 KP 2.000 KP 2.610 KP 3.200
Pipeline Data
Pipeline OD mm 762.0
Pipeline Wall Thickness mm 15.9
Segment Length m 1390 610 610 590
Corrosion Coating Type - 3LPP
Corrosion Coating Thk. mm 2.5
Insulation Thickness (HDPU) mm 23.0
Insulation Density kg/m3 180.0
Outer Case Thickness (HDPE) mm 8.2
Outer Case Density kg/m3 940
Concrete Coating Thk. mm 60.0 80.0 80.0 110.0
Design Life yrs 20 (Note 8)
Anode Data
Anode Thickness (Note 2) mm 55.0 75.0 75.0 105.0
Bracelet Gap Width mm 100.0
Density of Anode kg/m3 2730
Closed Circuit Potential V -1.05 (w.r.t Ag/Ag/Cl)
Driving Potential Difference volts 0.25 0.15
Anode Design Temperature (Note 3) °C 32
Anode Current Capacity (Note 4) Ahr/kg 2176.0
Anode Material Type - Aluminium-Indium Alloy

2
Initial mA/m 157.0 27.0
Current Density
Mean mA/m2 77.0 27.0
at 25oC (Note 5)
Final mA/m2 97.0 27.0
Coating Initial % 1.00

Breakdown Mean % 5.00
Factor (Note 6) Final % 7.00
Anode Utilization Factor - 0.80
Surrounding Resistivity
Resistivity (Note 7) Ohm-m 0.21 (Seawater) 1.00 (Soil)
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PIPELINE CP DESIGN
Notes:
1. The anode shall be designed to employ the factory limitations for producing the anode.
2. Selected anode thickness is 5mm lower than the corresponding concrete coating thickness.
3. The design temperature is taken as maximum seabed temperature.

4. Anode electrochemical efficiency shall be determined by the following formula as recommended by DNV
RP B401:
Efficiency = 2500 – 27 [Anode Temperature (°C) – 20] Ahr/kg

Assuming anode efficiency is 2500 Ahr/kg at 20°C.
5. The current density has been increased by 1 mA/m2 for each 1oC that outside steel temperature exceeds
25oC.
6. The coating breakdown factors due to ageing of coating during design time are calculated in accordance
with DNV RP B401. Since coating break down factor due to damage is very small, those are ignored.
7. As per DNV RP B401, soil resistivity has been considered five times of seawater density (for sandy soil).
8. Though the pipeline mechanical design life is 60 years, pipeline cathodic protection is designed to 20 years
in accordance with the requirement 8474L-000-JSD-1600-008 [Ref. 5]
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PIPELINE CP DESIGN
4.0 METHOD OF ANALYSIS
4.1 ANTI-CORROSION COATING SELECTION CRITERIA
The selection of the external coating system for the pipeline has been made taking into considerations cost, fit for
purpose, project specification requirements [Ref. 1] and at the same time satisfying the following criteria:
Maximum pipeline operating temperature
Coating impact resistance
Cathodic disbonding
Concrete coating suitability (for concrete coated pipe)
Field joint coating material and its compatibility with the proposed coating
Field experience
4.2 CATHODIC PROTECTION ANALYSIS
The external corrosion coating provides passive protection to the pipeline against corrosive actions of seawater.
However, this may still be subjected to breakdown due to harsh environment, incorrect pipe handling and others,
exposing the surface of the pipe to corrosion. An active protection mechanism, in the form of anodes, shall be
provided to supplement the FBE coatings as a corrosion protection measure. The provision of anodes is discussed in
the following section.
The cathodic protection (CP) analysis is performed to determine the dimensions and quantity of sacrificial bracelet
anode required to protect the pipeline against external corrosion throughout its design life.
The following sections describe the methodology and governing equations for the CP design. Aluminum based
material have been selected for the anode.
Calculations have been performed using TPGM’s in-house computer program ‘Anode-B401 Version 3’ [Ref. 4].
This program calculates the number of anode for cathodic protection in accordance with the requirements of DNV
RP B401 [Ref. 3].
4.2.2 CALCULATION OF REQUIRED NUMBER OF ANODES
Calculation of the number of anodes shall satisfy four criteria:

a) The number of anodes required to initially polarize the pipeline.
b) The number of anodes required to provide the maintenance current throughout the life of the design.
c) The number of anodes required to provide adequate protection on the final day of the design life.
d) Maximum allowable anode spacing.
4.2.2.1 Total Surface Area of Pipeline (Ac)
Ac = π x D x Ltot (Eq. 4.2.2.1.1)
Where,
D = Pipeline outside diameter

Ltot = Pipeline segment length
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PIPELINE CP DESIGN
4.2.2.2 Anode Inside Diameter (Dia)
Dia = D + 2 tC (Eq. 4.2.2.2.1)
Where,
D = Pipeline outside diameter

tC = Pipe corrosion coating thickness
4.2.2.3 Anode Outside Diameter (Doa)
Doa = Dia + 2 ta (Eq. 4.2.2.3.1)
Where,
Dia = Anode inside diameter

ta = Anode thickness
4.2.2.4 Anode Length (La)
Required anode length based on the weight and diameter of the anode specified in design,
La = Ma (Eq. 4.2.2.4.1)
b/2
Da π Dia t a + t a2 − 2b t a cos sin− 1
Dia /2
Where,
Ma = Assumed mass of each anode (net)

b = Side gap width of anode
Da = Anode material density
4.2.2.5 Anode Surface Area at Initial Life (Aai)
With the defined dimensions, anode surface area at the start of design life, Aai can be found by:
D oa −1 b/2
Aai = π DoaLa – 2 La × 2 sin × (Eq. 4.2.2.5.1)
2 D oa /2 180
Where,
Doa = Anode outside diameter

La = Anode length
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PIPELINE CP DESIGN
4.2.2.6 Anode Surface Area at End of Life (Aaf)
With the defined dimensions, anode surface area at the end of design life, Aaf can be found by:
D ia + 2t a (1 − u ) b/2 π
A af = π[Dia + 2t a (1 − u)]L a − 2L a . 2 sin −1 .
2 D ia + 2t a (1 − u) 180
2
(Eq. 4.2.2.6.1)
Where,

U = Anode utilization factor
La = Anode length
4.2.2.7 Anodes Required To Initially Polarize The Pipeline
E
Initial anode current output = (Eq. 4.2.2.7.1)
0.315x
A ai
Where,
E = Potential difference between anode and the linepipe protection

ρ = Resistivity of surrounding
Aai = Anode surface area at initial of life
4.2.2.8 Anodes Required To Protect The Pipeline At The End Of Life
E
Final anode current output = (Eq. 4.2.2.8.1)
0.315X ρ
A af
Where,
E = Potential differences between anode and the linepipe protection

ρ = Resistivity of surrounding
Aaf = Anode surface area at end of life
4.2.2.9 Total Number of Anodes Required To Polarize The Pipeline
i ci × A c × fci
Number of anodes (N) = (Eq. 4.2.2.9.1)
Iai × 1000
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PIPELINE CP DESIGN
Where,
ici = Initial current density; Current required to polarize an unprotected pipeline located on sea
bottom
Ac = Total surface area of pipeline segment
fci = Initial coating breakdown factor
Iai = Initial anode current output
4.2.2.10 Anodes Required To Provide The Maintenance Current
icm × A c × fcm × t f × 8760

ε ×1000 ×u×Ma
Where,
icm = Maintenance current density; The current density required maintaining

protection on the pipeline.
Ac = Surface area
tf = Design life
fcm = Mean coating breakdown factor
ε = Anode electrochemical capacity
u = Utilization factor
Ma = Assumed mass of each anode (net)
4.2.2.11 Anodes Required To Protect The Pipeline At The End Of Life
i cf × A c × fcf
Iaf × 1000
Where,
icf = Final current density. The current density required maintaining protection on the
pipeline under end of life operating conditions.
Ac = Surface area
fcf = Final coating breakdown factor
Iaf = Initial current output per anode
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PIPELINE CP DESIGN
4.2.3 ANODES SPACING
The anodes shall be evenly spaced along the pipeline. For pipelines with inlet product temperatures in excess of
45°C, closer spacing of the anodes until the product has cooled to less than 45°C is acceptable. The spacing shall not
exceed the minimum allowable spacing. The anode spacing, Sm (in meters) can be found by:
L tot
Sm = (Eq. 4.2.3.1)
Max (Nmean , N final )
Where,

Nmean = Number of anodes to meet mean current demand
Nfinal = Number of anodes at final design life
The number of spacing in pipe joints is given by:
Sm
S jo int s = (Eq. 4.2.3.2)
SLL
Where,
Sm = Anode spacing
SLL = Standard linepipe length per joint
The recommended anode spacing, SR, is the calculated number of spacing in pipe joint, Sjoints rounded down to an
integer.
To obtain the recommended anode quantity, NR, the following equation is used:
L tot
NR = (Eq. 4.2.3.3)
SLL × S R
Where,

SLL = Standard linepipe length per joint
SR = Recommended anode spacing
The recommended anode quantity is rounded up to the next integer to get a whole number.
8474L-082-CN-3533-101-0.doc
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PIPELINE CP DESIGN
4.2.4 CRACK PROPENSITY RATIO (CPR)
Crack Propensity Ratio (CPR) is used to adjust the ratio of anode length, diameter and thickness so that the anode
will be manufactured with lesser probability of cracks. It is advised to design anode of which CPR value is 5 or less.
π x L a x D ia
CPR = 3
(Eq. 4.2.3.4)
5 x ta
Where,
La = Anode length
Dia = Anode inner diameter
4.2.5 COATING BREAKDOWN FACTORS
The coating breakdown factor specified the amount of damage that is expected to occur to the pipeline’s corrosion
coating at various stages of the pipeline’s life. The breakdown factor is determined by the type of coating, predicted
operating temperature of the pipeline, whether the pipeline is concrete coated and an estimation of the amount of
physical damage that will occur to the pipeline.
4.2.6 ANODE ELECTROCHEMICAL EFFICIENCY
The performance of a sacrificial anode material is dependent on its actual chemical composition. At increased
temperatures, the self-corrosion of the anodes is greater and therefore their efficiency decreases. In practice, the
theoretical capacity of sacrificial anodes is not fully available for cathodic protection. Refer to Section 6.6 of DNV
RP B401 [Ref. 3] for further details.
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PIPELINE CP DESIGN
5.0 CONCLUSION
The selection of external anti-corrosion coating system is made in view of the following criteria:
• Subsea Pipeline
The 3LPP coating is selected for the subsea section of this concrete coated 30-inch pipeline.
The requirements of sacrificial bracelet anode are determined to satisfy the following criteria:
i) The number of anodes required to initially polarize the pipeline.
ii) The number of anodes required to provide the maintenance current throughout the design life of the pipeline.
iii) The number of anodes required to re-polarize the pipeline if such layers are partly and periodically damaged
at final of design life.
i) The maximum allowable anode spacing.
ii) Ease of installation.
As a conclusion, the pipeline external corrosion protection design consists of passive corrosion protection system
via the coating of the pipeline and active corrosion protection in form of cathodic protection system, as presented
in Table 2.2.1, can sufficiently protect the pipeline for the design life of 20 years.
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PIPELINE CP DESIGN
6.0 REFERENCES
1. Crude Oil Pipeline Design Basis

Doc. No.: 8474L-082-JSD-3500-001
2. Concrete Coating Thickness

Doc. No.: 8474L-082-CN-3531-002
3. DNV RP B401
Cathodic Protection Design (1993)
4. Technical User Manual and Validation Report

ANODE-B401 Computer Program for Cathodic Protection of Submarine Pipeline
Doc. No.: PL/TM/VR/07
5. Internal and External Cathodic Protection.

Doc. No.: 8474L-000-JSD-1600-008
8474L-082-CN-3533-101-0.doc
8474L 082 CN 3533 101 0 A

PIPELINE CP DESIGN
APPENDIX A
COMPUTER PRINTOUTS
ANODE SIZING CALCULATIONS
8474L-082-CN-3533-101-0.doc
E-ANODE
Version 3.0 (04/03/2005)
1 PIPELINE CATHODIC PROTECTION REQUIREMENT

2 PROJECT : DUNG QUAT REFINERY PROJECT
3 LINE : 30" PIPE (60mm THK CONCRETE COATING) KP 0.000-1.390(On the seabed)
4 BASIS OF DESIGN : The calculation is as per DnV-RP-B401(1993) with spacing requirement.
5
7 DESCRIPTIONS SYMBOLS DATA UNIT

8 INPUT:
9 Pipeline Outside Diameter D 762.00 mm
10 Pipeline Wall Thickness d 15.9 mm
11 Pipeline Segment Length Ltot 1390.00 m
12 Corrosion Coating Thickness + Insulation Thickness tc 33.7 mm
13 Resistivity of Linepipe Material ρMe 2.00E-07 Ohm-m
14 Anode Thickness ta 55.00 mm
15 Anode Material Aluminium-Indium Alloy
3
16 Anode Material Density Da 2730.00 kg/m
17 Assumed Anode Mass (Net) Ma 140.00 kg
18 Resistivity of Surrounding ρ 0.21 Ohm-m
19 Side Gap Width of Anode b 100.00 mm
20 Potential Difference Between Anode And Linepipe E = Eco - Eao 0.25 volts
21 Standard Linepipe Length per Joint SLL 12.20 m
22 Design Life tf 20 Years
23
2
24 Current Density : Initial ici 157.00 mA/m
o 2
25 Mean At 32 C icm 77.00 mA/m
o 2
26 Final At 32 C icf 97.00 mA/m
27
28 Coating Breakdown Factor : Initial fci 0.01

29 Mean fcm 0.05
30 Final fcf 0.07
31
32
33 Anode Electrochemical Efficiency ε 2176.00 A-hr/kg

34 Anode Utilization Factor u 0.80
35
36 OUTPUT:
37 Surface Area of Pipeline Segment Ac 3327.51 m2
38 Anode Inside Diameter Dia 829.40 mm
39 Anode Outside Diameter Doa 939.40 mm
40 Anode Length (Based on Net Mass) La 361.41 mm
2
41 Anode Surface Area at Initial of Life Aai 0.9942 m
42 Anode Surface Area at End of Life Aaf 0.8942 m2
43 Initial Current Output per Anode Iai 3.77 Amps
44 Final Current Output per Anode Iaf 3.57 Amps
45 Initial Current Demand Ici 5.22 Amps
46 Mean Current Demand Icm 12.81 Amps
47 Final Current Demand Icf 22.59 Amps
48 Maximum Allowable Anode Spacing s 12.00 joints
49
50 Number of Anodes Required (N) Calculated Anode Spacing (S) Recommended Anode
51 Initial Maintenance Final (m) Joints Spacing (Joints) Quantity (Nos.)
52
53 1.39 9.21 6.32 150.93 12.37 12.00 10

54
55 CRACK PROPENSITY RATIO, CPR = 1.13 < 5 OK

56
57 REMARKS:
E-ANODE
Version 3.0 (04/03/2005)

3 LINE : 30" PIPE (80mm THK CONCRETE COATING) KP 1.390-2.000(On the seabed)
5

8 INPUT:
3
23
2
o 2
o 2
27

29 Mean fcm 0.05
30 Final fcf 0.07
31
32

35
36 OUTPUT:
2
49
52
53 0.59 2.83 2.73 215.62 17.67 17.00 3

54

56
57 REMARKS: RECOMMENDED ANODE SPACING HAS EXCEEDED THE ALLOWABLE ANODE SPACING
E-ANODE
Version 3.0 (04/03/2005)

3 LINE : 30" PIPE (80mm THK CONCRETE COATING) KP 2.000-2.610(Buried in seabed)
5

8 INPUT:
3
23
2
o 2
o 2
27

29 Mean fcm 0.05
30 Final fcf 0.07
31
32

35
36 OUTPUT:
2
49
52
53 0.80 0.99 6.03 101.16 8.29 8.00 7

54

56
57 REMARKS:
E-ANODE
Version 3.0 (04/03/2005)

3 LINE : 30" PIPE (110mm THK CONCRETE COATING) KP 2.610-3.200(Buried in seabed)
5

8 INPUT:
3
23
2
o 2
o 2
27

29 Mean fcm 0.05
30 Final fcf 0.07
31
32

35
36 OUTPUT:
2
49
52
53 0.69 0.56 5.35 110.36 9.05 9.00 6

54

56
57 REMARKS:

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Project n° - Unit Doc. type Code Serial n° Rev.

VIETNAM OIL AND GAS CORPORATION ( PETROVIETNAM )

1.0 INTRODUCTION ........................................................................................................................................................3

2.0 SUMMARY OF RESULTS .........................................................................................................................................4

3.0 DESIGN PARAMETERS............................................................................................................................................6

4.0 METHOD OF ANALYSIS ..........................................................................................................................................8

6.0 REFERENCES ...........................................................................................................................................................15

APPENDIX A COMPUTER PRINTOUTS

VIETNAM OIL AND GAS CORPORATION ( PETROVIETNAM )

The scope of work includes:

VIETNAM OIL AND GAS CORPORATION ( PETROVIETNAM )

2.0 SUMMARY OF RESULTS

2.1 EXTERNAL ANTI-CORROSION COATING

Section Type of Anti-Corrosion Coating

KP 0.0-3.200 2.5 mm thick 3LPP

2.2 CATHODIC PROTECTION

KP 0.0 - KP 1.390 - KP 2.000 - KP 2.610 -

Anode Type - I (Submerged) II (Submerged) II (Buried) III (Buried)

VIETNAM OIL AND GAS CORPORATION ( PETROVIETNAM )

2.3 INSULATION JOINTS

Monolithic insulation joints have been considered at the following location.

VIETNAM OIL AND GAS CORPORATION ( PETROVIETNAM )

3.0 DESIGN PARAMETERS

3.1 DESIGN DATA

Table 3.1.1 Design Parameters for Cathodic Protection Design

KP0.000– KP 1.390 – KP 2.000 – KP 2.610 –

Driving Potential Difference volts 0.25 0.15

Anode Design Temperature (Note 3) °C 32

Anode Current Capacity (Note 4) Ahr/kg 2176.0

Anode Material Type - Aluminium-Indium Alloy

Coating Initial % 1.00

VIETNAM OIL AND GAS CORPORATION ( PETROVIETNAM )

3. The design temperature is taken as maximum seabed temperature.

Efficiency = 2500 – 27 [Anode Temperature (°C) – 20] Ahr/kg

VIETNAM OIL AND GAS CORPORATION ( PETROVIETNAM )

4.0 METHOD OF ANALYSIS

4.1 ANTI-CORROSION COATING SELECTION CRITERIA

4.2 CATHODIC PROTECTION ANALYSIS

4.2.2 CALCULATION OF REQUIRED NUMBER OF ANODES

Calculation of the number of anodes shall satisfy four criteria:

4.2.2.1 Total Surface Area of Pipeline (Ac)

Ac = π x D x Ltot (Eq. 4.2.2.1.1)

D = Pipeline outside diameter

VIETNAM OIL AND GAS CORPORATION ( PETROVIETNAM )

4.2.2.2 Anode Inside Diameter (Dia)

Dia = D + 2 tC (Eq. 4.2.2.2.1)

D = Pipeline outside diameter

4.2.2.3 Anode Outside Diameter (Doa)

Doa = Dia + 2 ta (Eq. 4.2.2.3.1)

Dia = Anode inside diameter

4.2.2.4 Anode Length (La)

Ma = Assumed mass of each anode (net)

4.2.2.5 Anode Surface Area at Initial Life (Aai)

Doa = Anode outside diameter

VIETNAM OIL AND GAS CORPORATION ( PETROVIETNAM )

4.2.2.6 Anode Surface Area at End of Life (Aaf)

Dia = Anode inside diameter

4.2.2.7 Anodes Required To Initially Polarize The Pipeline

E = Potential difference between anode and the linepipe protection

4.2.2.8 Anodes Required To Protect The Pipeline At The End Of Life

E = Potential differences between anode and the linepipe protection

4.2.2.9 Total Number of Anodes Required To Polarize The Pipeline