Sacrificial Anode Sizing Calculation

Modec International LLC - Bijupera & Salema Field Development

Seawater Filters - MAJ-3115A/B/C
Tank Surface Area
Tank Diameter D 132 inches
Side Shell Height H 60 inches
Shell Area Ac = PI*D*H/144 173 ft²
Head Area (two heads) Ad = 2*1.14*D^2/144 276 ft²
Interior Surface Area Ac + Ad 449 ft²
Contingency for Clips, etc. 5%
Total As 471 ft²
Total (metric) As 44 m²
Exposed Surface Area
Percent Coverage of Coating C 65% percent
Exposed Area Ae = As * C 15.3 m²
Current Demand
Current Density J 130 mA/m²
Current Demand I = Ae * J 1992 mA
Anode Quantity
Installation Life L 8760 hours
Protection Capacity Ah = I/1000 * L 17451 Ah
Anode Material Capacity K 2500 Ah/kg
Anode Utilization Factor U 0.85
Total Mass of Anode Material Reqd Mt = Ah / K 8.2 kg
Mass of Single Anode Ms 10.0 kg
Min Surface Area of Anode Aa 0.2 m²
Current Capacity of Anode Ic 11303 mA/m²
Anode Current Ia = Aa * Ic 2261 mA
Number of Anodes N = Mt / Ms 1 each

Notes:
1 Galvalum III has a capacity of 2500 Ah/kg.
2 3 month replacement cycle minimum.
3 Guessing that a 3" OD x 30" LG Anode weighs 10 kg.

REV DESCRIPTION BY DATE

- Preliminary DNS ###
1 Modified J DNS ###
Compare to Current Demand to ensure Anode Quantity
Linear Interpolation of Current Density Given 860-15100mA/m2 from 5-35 degrees C
Seawater Current Density - Galvalum III
Temp ºC mA/m² Temp ºF
5 860 41
6 1335 43
7 1809 45 Current Capacity vs. Temperature
8 2284 46 20000
9 2759 48
10 3233 50
11 3708 52
12 4183 54
13 4657 55 15000
14 5132 57

Current Capacity mA/m²

15 5607 59
16 6081 61
17 6556 63
18 7031 64 10000
19 7505 66
20 7980 68
21 8455 70
22 8929 72
5000
23 9404 73
24 9879 75
25 10353 77
26 10828 79
27 11303 81 0
28 11777 82 0 5 10 15 20 25 30 35
29 12252 84
30 12727 86 Temperature ºC
31 13201 88
32 13676 90
33 14151 91
34 14625 93
35 15100 95
Sacrificial anode system:
If a sacrificial system is chosen, the weight of material required to provide the protection current for the protected lifetime of the
structure is calculated from a knowledge of the current demand and also the specific electrochemical properties of the anode
alloys. Once the total weight has been calculated, then the optimum weight is known.

The MASS of sacrificial anode alloy required will be given by:

            Y x 8760 x A x C
W =  _________________
              1000 x Z x U

where:
           Y= Design life (years) 
           A= Surface area (m²)
           C = Current density (mA/m²) 
           U= Anode utilization factor 
           Z= Capacity of material (Amp Hrs/Kg)

The capacity of an anode alloy is a measure of the quantity of electricity, which the material will give as useable protection
current per unit weight of alloy corroded in unit time.

The utilization factor is a measure of the proportion of the anode, which can be expected to deliver adequate current at the end of
the systems lifetime and is related to the reduced cross section and length of an almost fully consumed anode. For most long
offshore platform anodes, this is 0.9 and for more complex shapes, e.g. bracelet, 0.85 or even lower is used.

The calculated weight of anode alloy cannot be installed all in one piece but must be distributed over the structure in the form of
smaller anodes to ensure uniform distribution of current. In order to select the best size and shape of anode, the total current
demand of the structure both at the beginning and an end of its life must be considered.

The anode must deliver adequate current to polarise the structure and build up Cathodic chalks, but also must be capable of
delivering the required mean current for the structure when 90% consumed. Moreover, the system as a whole must have
adequate excess current demand over that originally catered for in the design so as to ensure that the system is not limited by the
current output characteristics of the anodes.