TCM IDENTIFICATION CODE

Job-EC-Type-N°
4239-LZ-VD-AC304046420xx
PORT HARCOURT REFINING COMPANY LIMITED SHEET DOC. CLASS: REV.
(PHRC)

1 / 23 1 00

CLIENT IDENTIFICATION CODE

REHABILITATION OF PORT HARCOURT
REFINERY PROJECT
(Port Harcourt – Nigeria)

SUBCONTRACTOR’S JOB: SUBCONTRACTOR’S DOC. NO.:

JETTY AND ACCESS BRIDGE 2022-BGT-ENG-294

REFURBISHMENT WORKS
SUBCONTRACT NO.: SCOPE OF WORK NO.:
7500104642 4239-LZ-WS-000304

IMPRESSED CURRENT CATHODIC PROTECTION DESIGN REPORT FOR JETTY

CONTRACTOR DOCUMENT CLASS: R

Acceptance Discipline Checker
Date
Status Code Abbreviation Name Signature

Acceptance Status Description:

A- Accepted
CONTRACTOR’s acceptance of this document does in no way
AC- Accepted with Comments
relieve the SUBCONTRACTOR of its contractual obligation
CR-Commented
NA-Not Accepted

filename: 4239-LZ-VD-AC304046420xx-IS00

00 1-June-2023 IFA – Issued for Approval E. Diala E. Nwankwo C. Ugorji

Rev. Date Reason for Issue – Revision Description Prepared Checked Approved

Digital signature

These are TCM main areas of concerns:

1.The anode system is not sized on the anode current capacity but on the conceptually wrong (for a
non-soluble anode) consumption rate;
2.Calculation of the number of anodes per sled is not clear;
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3.Piles resistances calculation (pile to remote and steel armoring resistance estimation) has not been
included therefore the TR suitability cannot be confirmed.
The same observation are reported along the pages of the report.
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Content
1 INTRODUCTION ........................................................................................................ 4

2 DEFINITIONS AND ABBREVIATIONS ............................................................... 5

2.1 Definitions .................................................................................................................... 5

2.2 Abbreviations ............................................................................................................... 6

3 REFERENCE DOCUMENTS .................................................................................... 7

3.1 Nigerian National Regulation ..................................................................................... 7

3.2 Project Reference Documents ................................................................................... 7

3.3 Industry Codes and Standards .................................................................................... 8

4 CATHODIC PROTECTION OVERVIEW – ICCP ............................................... 9

5 CATHODIC PROTECTION DESIGN BASIS ..................................................... 10

5.1 General ........................................................................................................................ 10

5.2 Piles Parameters ......................................................................................................... 10

5.3 Protection Potential Criteria ..................................................................................... 11

5.4 Environment Resistivity ............................................................................................ 11

5.5 Pile Jacketing .............................................................................................................. 12

5.6 Design Current Density ............................................................................................ 12

5.7 Design Life.................................................................................................................. 12

6 CATHODIC PROTECTION REQUIREMENT .................................................. 13

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6.1 ICCPS Anode ............................................................................................................. 13

6.2 CP Transformer Rectifiers ........................................................................................ 14

6.3 CP Junction Boxes ..................................................................................................... 14

6.4 CP Cables .................................................................................................................... 15

6.5 Cable to Pile Connection .......................................................................................... 17

6.6 Cathodic Protection Design Conditions ................................................................. 17

7 Cathodic Protection Calculations ................................................................................ 18

7.1 Coating Breakdown Factor ....................................................................................... 18

7.2 Surface Area ................................................................................................................ 19

7.3 Current Demand ........................................................................................................ 19

7.4 Anode Mass ................................................................................................................ 20

7.5 Circuit Resistance ....................................................................................................... 21

7.6 DC Supply Voltage .................................................................................................... 22

8 DESIGN SUMMARY AND RECOMMENDATIONS ....................................... 22

Appendix 1: CP Calculations for Jetty Piles

Appendix 2: Jetty Pile Layout

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1 INTRODUCTION

This document presents the design review report of the existing impressed current cathodic
protection systems for Refurbishment of Port Harcourt Refinery Company (PHRC) Jetty. This
document is the design basis for the refurbishment of the existing impressed current cathodic
protection systems for all piles in the Jetty area shown in Figure 1 below.

The design review is carried out to ascertain that the refurbishment for the existing ICCPS of
the Jetty piles are in accordance with the findings and recommendations of 4239 LZ-VD-
CD30404642015, Report on Integrity Assessment and Installation of the Cathodic Protection
Systems, ISO 15589-2 and Mineral Oils Safety Regulations.

The design basis for the cathodic protection system for all other isolated structures (such as
berthing, mooring dolphins and protective barriers) shall be presented in another report. All
isolated structures shall be cathodically protected using galvanic anodes.

Figure 1: Location of Access Bridges and Jetties

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2 DEFINITIONS AND ABBREVIATIONS

2.1 Definitions

The following definitions shall be applied to the standard terms used throughout this
document.
COMPANY Port Harcourt Refinery Company.

CONTRACTOR: Tecnimont.

SUBCONTRACTOR Bridgsite Nigeria Limited

Shall: Indicates mandatory requirement

Should: Indicates preferred recommendation

Specific Definitions
Cathodic Protection Process of reducing or preventing corrosion of metal
structures in contact with an electrolyte through provision
of the flow of ionic current passing through the electrolyte
onto the structure surface.
Corrosion Potential Theoretical potential of the surface, in absence of net
(external) electric current flowing to or from the steel
surface.
Current Density Amount of current per unit area of the steel surface, coated
or uncoated, in contact with the electrolyte.
Electrochemical Capacity Total amount of electricity that is produced when a fixed
mass (usually 1 kg) of anode material is consumed
electrochemically.
Remote earth The areas in which the structure-to-electrolyte potential
change is negligible with change in reference electrode
position away from the structure.

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Drain Point Point on the pipeline or structure where the connection of

the negative terminal of the cathodic protection voltage
source is made to conduct [drain] the returning current
from the pipeline to the voltage source.

2.2 Abbreviations
AC Alternating Current
Ag/AgCl Silver/Silver Chloride Reference Electrode
API American Petroleum Institute
ASME American Society of Mechanical Engineers
ASTM American Society for Testing and Materials
BS British Standard
CA Corrosion Allowance
CASHES Community Affairs, Safety, Health, Environment and Security
CFRP Carbon Fiber Reinforced Plastic
CPS Cathodic Protection System
Cu/CuSO4 Copper/Copper Sulphate
DC Direct Current
DED Detailed Engineering Design
GB Groundbed
HDPE High Density Polyethylene
HSCI High Silicon Cast Iron Anodes
ICCPS Impressed Current Cathodic Protection System
ID Inside Diameter
ISO International Organization for Standardization
MMO Mixed Metal Oxide
NACE National Association of Corrosion Engineers

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ND Nominal Diameter
NNPC Nigerian National Petroleum Company Limited
OD Outer Diameter
PHRC Port Harcourt Refinery Company
SCE Saturated Calomel Electrode
SWA Steel Wire Armoured Cable
TP Test Post
TR Transformer Rectifier
WT Wall Thickness

3 REFERENCE DOCUMENTS

3.1 Nigerian National Regulation

Local laws regulating the oil and gas industry shall be strictly adhered to.

Identification Functions Description

Mineral Oil (Safety) Regulations These regulations, in so far as they apply to pipelines, require
1997, as amended. compliance with the IP, API and ASME codes and standards.

Oil Pipelines Act, 1956. CAP. Provides for licenses to be granted for the establishment and
145 (Amended 1965, CAP. 338, maintenance of pipelines incidental and supplementary to
LFN 1990) oilfields and oil mining, and for purposes ancillary to such
pipelines.

3.2 Project Reference Documents

Document Title

S-69-1387-501 Jetty B Cathodic Protection Design Basis

S.69.1387.501 Jetty B Cathodic Protection Material

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D-69-1387-502-A New Jetty B Cathodic Protection Layout

D-69-1314-552-X Jetty B Pile Layout

Cathodic Protection Water Pumping Station and Anodes

D-69-1387-518-D
Location

Report on Integrity Assessment and Installation of the

4239 LZ-VD-CD30404642015
Cathodic Protection Systems

3.3 Industry Codes and Standards

Reference Number Title

Specification for SI Units and Recommendations for

ISO 1000
the Use of their Multiples and of Certain Other Units

ISO 15589-2 Petroleum and Natural Gas Industries – Cathodic

Protection of Pipeline Transportation Systems Part 2

DNVGL RP B401 Cathodic Protection Design

DNV-RP-F103 Cathodic Protection of Submarine Pipelines by

Galvanic Anodes

NACE SP0169 Control of External Corrosion on Underground or

Submerged Metallic Piping System

NACE SP0286 Electrical Isolation of Cathodically Protected

Pipelines

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4 CATHODIC PROTECTION OVERVIEW – ICCP

All the piles of Port Harcourt Refinery Jetty were cathodically protected using impressed
current cathodic protection systems (ICCPS) designed originally for 10 years performance life
as shown in Table 4-1 below:

Table 4-1: Piles and Associate CPS

Pile Location Number of Associated CPS Transformer Rectifier Groundbed

Description Piles Output Rating

39 Section 1 200 A / 10V 20 HSCI Anodes

72
Linkway of Jetty
33 Section 2 200 A / 10V 20 HSCI Anodes

Jetty Tee Junction 31 Tee Junction 200 A / 10V 20 HSCI Anodes

39 Section 3 200 A / 10V 20 HSCI Anodes

59
Linkway to Jetty B
20 Section 4 200 A / 10V 22 HSCI Anodes

Jetty B 52 Jetty B 200 A / 10V 12 HSCI Anodes

Sea Water Pump 100 A / 10V

12 HSCI Anodes
Fire Pump House 31 Station

51 CP 1 100 A / 20V -
Linkway to Jetty A 102
51 CP 2 100 A / 20V -

49 CP 3 100 A / 20V -
Jetty A 98
49 CP 4 100 A / 20V -

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The piles have outlived the 10 years design life of the original impressed current cathodic
protection systems and some of the CP components such cables are either vandalized or not
found. Hence, the existing ICCPS require refurbishment in order to effectively protect the piles.

5 CATHODIC PROTECTION DESIGN BASIS

5.1 General
For the design review, all piles in the jetty shall be cathodically protected using impressed
current cathodic protection systems. The minimum requirement for the upgraded cathodic
protection system shall be in accordance with ISO 15589-2 and with consideration of the
following:

• Pile parameter including total surface area to be protected.

• Protection potential criteria
• Environment Resistivity
• Coating resistance values
• Design current density for each zone (tidal, submerged and buried zones)
• Design life
• Coating breakdown

5.2 Piles Parameters

The Jetty piles are categorized into:

• Linkway of the Jetty (marked as ‘’C’’ in Appendix 2) – 72 piles

• Jetty T-Junction (marked as ‘’B’ in Appendix 2) – 31 Piles (this is junction where the
linkway splits into Linkway to Jetty A and Linkway to Jetty B)
• Linkway to Jetty A Head (marked as ‘E’ in Appendix 2) – 102 piles
• Linkway to Jetty B Head (marked as ‘P’ Appendix 2) – 59 piles
• Jetty A Head (Marked as ‘A’ in Appendix 2) – 98 piles

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• Jetty B Head (Marked as ‘D’ Appendix 2) – 52 Piles

• Fire Pump House, Control Room Jetty and Power House (‘G’ in Appendix 2) – 31
Piles
Based on section 4 of S-69-1387-501, Jetty B Cathodic Design Basis and for conservative
design purpose, outer diameter of 711 mm is adopted for the piles steel marked “G” in
Appendix 2 and outer diameter of 720 mm is adopted for all other piles steel.

5.3 Protection Potential Criteria

In order to ensure adequate CP of the piles, the measured protection potential shall be in
accordance with ISO 15589-2 as extracted and shown in Table 5-1 below:

Table 5-1: Protection Potentials of Piles

Materials Minimum negative potential Maximum negative potential
(V) (V)

Immersed in seawater − 0.80 − 1.10

Buried in sediments − 0.90 − 1.10

The potentials are referenced to an SCE reference electrode, which are equivalent to a
silver/silver chloride reference electrode (Ag/AgCl/seawater) in 30 Ω⋅cm seawater.

However, from the original cathodic protection design, the protection potential criteria were
based on the present pH value of 7.2 at 20" C (referring to sampling), the potential to be
reached in order that the steel would be the site of only metal reduction reaction [ Fe++ (ion) +
2 electrons - Fe (metal)] is -780 mV in relation to the silver chloride half-cell comparison
electrode.

5.4 Environment Resistivity

Based on section 5-3 of S-69-1387-501, Jetty B Cathodic Protection Design Basis, resistivity
range 30 - 200 Ohm.cm was used for the original design. However, for CP design for

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refurbishment of existing ICCPS, 30 Ohm.cm is adopted in accordance with section 7.2.1 of

ISO 15589-2:2012 which is within the range as specified by the original design and also of best
practice for conservative design.

5.5 Pile Jacketing

All piles were original coated with:

• Coal tar epoxy (CTEP) on the upper part of the piles up to the lower level of the water
bottom
• Zinc silicate primer (ZNSIL) on the buried part of the piles.

For refurbishment of Port Harcourt Refinery Jetty, all the piles shall be jacketed with a 3mm
CFRP in accordance with this project requirement. The annulus between the CFRP jacket and
the deteriorated pile shall be filled with concrete.

5.6 Design Current Density

The current density used for the original cathodic protection design for the piles were:

• Tidal zone (coated): 120 mA/m.

• Submerged zone (coated): 80 mA/m.
• Buried zone (nearly base): 50 mA/m.

Considering that CFRP coating has a better performance compared to the original coatings on
the piles, the above current density for the respective zones shall be conservatively adopted and
used for this design review.

5.7 Design Life

The design life of the ICCPS for the piles was 10 years based on original CP design, however
for refurbishment of the existing ICCPS, a design life of 20 years shall be used.

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6 CATHODIC PROTECTION REQUIREMENT

6.1 ICCPS Anode

The anode for the impressed cathodic protection system shall be of alloy with satisfactory
performance under similar field conditions. The anode shall be sized such that sufficient
current is delivered to the piles to maintain the required protection potentials throughout the
design life.

Iron Silicon anode of 38.2 kg were used as groundbed anodes in the original design of the
impressed cathodic protection system of the piles. The Iron Silicon anodes with 4.5 %
chromium had 0.2 kg / A-year consumption rate, 30 A/m2 current density and of 10 years basic
life time.

For this design review, the cathodic protection system is expected to optimally operate for 20
years design life. In view of this, Ruthenium oxide (RuO2) MMO anode which performs better
in chlorinated environment like sea water shall be used as the ICCPS groundbed anodes.

MMO anodes have imperceptibly low wear rates and are often referred to as Dimensionally
Stable Anodes as they do not change geometry over time like the graphite and high silicon cast
iron. MMO anode with a current density in the range of 50 to 100 A / m2, has a consumption
rate that is negligible when compared to Iron Silicon anodes and other anodes. MMO anode
has an exceptional long life, light weight and low cost when compared to other anodes.

In view of the above, the selected anode for ICCPS groundbed shall be Ruthenium oxide
(RuO2) MMO Anode tubes with center connection for cables with the following
characteristics:

• Anode Type: MMO (RuO2) Anodes Titanium substrate

• Anode Length: 1 m
• Anode diameter: 0.025 m

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• Individual Anode net weight: 0.35 kg

• Anode consumption rate: 1 mg/A-yr
• Utilizations factor: 0.90
• Single anode current output: 8 A

The anodes shall be arranged as Anode Sled suitable for sea bottom use. The anode sled shall
be protected using heavy duty, machined fiberglass housing and shall have 120 m length of 1C
x 50 mm2 PDVF (Kynar) / HMWPE anode cable. The MMO anode sled shall be sized to
operate with the existing transformer rectifiers with output rating as shown in Table 4-1 above.

Each of the anode sled shall be built with reinforced concrete end weights to allow for
permanent stay put at the sea bottom for stability and also to minimize the possibility of the
anodes becoming covered with mud or silt as required of section 12.5 of ISO 15589-2:2012.

6.2 CP Transformer Rectifiers

For the refurbishment of the existing ICCPS, the DC supply source shall be the existing
transformer rectifiers as sized in the original CP design with output rating detailed in Table 4-1
above. The transformer rectifiers are as specified in section 9 of S-69-1387-501, Jetty-B
Cathodic Protection Design Basis and section 2 of S.69.1387.501, Jetty-B Cathodic Protection
Material.

All the existing transformer rectifiers were subjected to integrity test as provide in 4239 LZ-VD-
CD30404642015, Report on Integrity Assessment and Installation of the Cathodic Protection
Systems.

6.3 CP Junction Boxes

The cathodic protection junction boxes made from moulded aluminum are for CP cable
connections, potential and current measurement shall be the existing ones as provided in the
original CP design. The junction boxes are explosion proof type suitable for zone 11 area with
IP 66 rating.

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The CP junction boxes comprise of positive junction boxes, negative junction boxes and bond
boxes and are being refurbished to be re-installed for used.

The negative junction boxes and bond boxes may be provided with variable resistor for
balancing of the piles potential as required in accordance with design protection criteria.

6.4 CP Cables
Based on original design, the CP cables were as follows:

• Positive cables

The positive cable connects the positive terminal of the transformer rectifier to ground bed
via positive junction box. The cable is DC single core multiple stranded copper cable. Based
on the original CP design, the specification of positive cable was 1 x 50 mm2 PE/PVC
0.3/0.5 kV grade of red colour in accordance with IEC 277.

For refurbishment of the existing ICCPS, the positive cable shall be 1 x 50 mm2 XLPE/PVC
0.6/1.0 kV grade of red colour conforming to ASTM Specification B-8 and ASTM D-1248.
The assumed total length of the positive cable for CP sizing shall be 170 m. This consist of
the cable length from anode sled to positive junction box and the from positive junction box
to transformer rectifier.

The positive cable length from the anode sled to positive junction box shall be installed in an
anti-theft conduit with in fill concrete mix of ratio 1:2:4 as to be detailed in “cathodic
protection installation details-ICCPS.”

• Negative cables
The negative cable connects the negative terminal of the transformer rectifier to negative
junction box. The cable is DC single core multiple stranded copper cable. Based on the
original CP design, the specification of negative cable was 1 x 50 mm2 PE/PVC 0.3/0.5 kV
grade of black colour in accordance with IEC 277.

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For refurbishment of the existing ICCPS, the negative cable shall be 1 x 50 mm2
XLPE/PVC 0.6/1.0 kV grade of black colour conforming to ASTM Specification B-8 and
ASTM D-1248. The assumed total length of the negative cable for CP sizing shall be 100 m.

• Bond cables
The bond cable connects the negative cable of the negative junction box to piles. The cable
is DC single core multiple stranded copper cable. Based on the original CP design, the
specification of bond cable was 1 x 35 mm2 PE/PVC 0.3/0.5 kV grade of green colour in
accordance with IEC 277.
For refurbishment of the existing ICCPS, the bond cable shall be 1 x 35 mm2 XLPE/PVC
0.6/1.0 kV grade of green colour conforming to ASTM Specification B-8 and ASTM D-
1248. The assumed total length of the bond cable for CP sizing shall be 50 m.
• Test cables

The test cable connects piles to test points. The cable is DC single core multiple stranded
copper cable. Based on the original CP design, the specification of test cable was 1 x 16 mm2
PE/PVC 0.3/0.5 kV grade of red colour in accordance with IEC 277.

For refurbishment of the existing ICCPS, the test cable shall be 1 x 16 mm2 XLPE/PVC
0.6/1.0 kV grade of red colour conforming to ASTM Specification B-8 and ASTM D-1248.
The test cable shall be 10 m length maximum.

• Earth cables

The earth cable connects CP equipment to earth. The cable is DC single core multiple
stranded copper cable. Based on the original CP design, the specification of earth cable was
1 x 16 mm2 PE/PVC 0.3/0.5 kV grade of yellow/green colour in accordance with IEC 277.

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For refurbishment of the existing ICCPS, the earth cable shall be 1 x 16 mm2 XLPE/PVC
0.6/1.0 kV grade of yellow/green colour conforming to ASTM Specification B-8 and ASTM
D-1248. The earth cable shall be 10 m length maximum.

• AC cables

The AC cables connects transformer rectifier to AC power source. The cable is AC four
core multiple stranded copper cable. Based on the original CP design, the specification of
AC cable was 4 x 4 mm2 XLPE/SWA/PVC 1.0 kV grade of black colour in accordance
with IEC 502.

For refurbishment of the existing ICCPS, the AC cable shall be 4 x 4 mm2

HEPR/SWA/PVC 0.6/1.0 kV grade of black colour.

6.5 Cable to Pile Connection

The cable to pile connection shall be by Pin Brazing. The connection of the CP current drain
cable to pile shall be to the lead pile and end pile of each CP section. Checks for cable to pile
continuity and cable to pile resistance shall be carried at end of each cable connection to pile.
The drain cable after connection to each pile shall be completely embedded in CFRP pile
jacketing.

6.6 Cathodic Protection Design Conditions

For the purpose of the review of the existing cathodic protection systems of Jetty piles, the
following conditions are considered for design calculations:

− The deteriorated piles are to be jacketed with CFRP in accordance with this project
requirement.
− The piles sea water environment is zoned into tidal, submerged and buried and current
density of 120 mA/m2, 800 mA/m2 and 50 mA/m2 are adopted in line with original CP
design.

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IMPRESSED CURRENT CATHODIC Job-EC-Type-N°

PROTECTION DESIGN REPORT 4239-LZ-VD-AC30404642014

SUBCONTRACTOR’S DOC. No. FOR JETTY SHEET DOC. CLASS: REV.

2022-BGT-ENG-xxx
18/23 1 00

− Mixed Metal Oxide anode with utilization factor of 0.9 is selected in accordance with
Section 8.4 of ISO 15589-2: 2012 for a design life of twenty (20) years. The MMO anodes
shall be arranged as anode sled suitable for sea water use in line with section 7.1 above.
− The piles are steel with specific resistivity assumed to be 18 x 10-6 Ohm.m as applicable in
the industry. The pile steel outer diameter are taken to be 711 mm and 720 mm in line with
section 5.2 above .
−
− Design factor of 1.25 to take care of risk factors such as possible coating gaps during
coating, coating damage during construction, non-uniform current distribution on piles,
based on section 6.1.5 of DNVGL-RP-F103: 2016.
− Based on section 7.2 of ISO 15589-2: 2012, the maximum protection potential for the
piles shall be 1100 mV wrt Ag/AgCl Reference Electrode.
− The adjoining cables for the cathodic protection systems are assumed to have the
parameters and characteristic provided in section 6.4 above.

7 Cathodic Protection Calculations

7.1 Coating Breakdown Factor

The current demand of the jacketed pile increases with time as the CFRP deteriorates (this
conservatively assumed as CFRP used can last over 50 years in aggressive environment; also
CFRP jacket used is impermeable). Enough cathodic protection capacity should be provided to
maintain protection overtime as the CFRP breakdown.

Breakdown factors shall be applied to calculate the bare metal surface areas of the CFRP
jacketed piles for mean conditions and at the end of the design life respectively.

Mean and final coating breakdown factors shall be calculated in accordance with Equation (1)
and Equation (2) of ISO 15589-2: 2012 as follows:

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𝑓𝑐𝑚 = 𝑓𝑖 + (0.5 × ∆𝑓 × 𝑡𝑑𝑙 ) (1)

𝑓𝑐𝑓 = 𝑓𝑖 + (∆𝑓 × 𝑡𝑑𝑙 ) (2)

where,

fi is the initial CFRP breakdown factor at the start of pipeline operation.

Δf is the average yearly increase in the CFRP breakdown factor;

tdl is the design life time expressed in years.

7.2 Surface Area

For each pile section, the surface areas to receive CP shall be calculated separately where
conditions cause different current requirements using the equation below.

𝑆𝐴 = 𝜋 × 𝐷𝑜 × 𝐿 (3)

where,

Do = Pile Outer Diameter (m)

L = Pile Length within specific sea water zone (m)

7.3 Current Demand

The current required for protection of the piles are:
− Mean Current Demand
The mean current demand, Icm is calculated using equation 4 below in accordance with
section 6.2.1 of DNVGL-RP-F103: 2016

𝐼𝑐𝑚 = 𝑆𝐴 × 𝑓𝑐𝑚 × 𝑖𝑐 × 𝑘 (4)

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SUBCONTRACTOR’S DOC. No. FOR JETTY SHEET DOC. CLASS: REV.

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− Final Current Demand

The final current demand, Icf is calculated using equation 5 below in accordance with
section 6.2.1 of DNVGL-RP-F103: 2016

𝐼𝑐𝑓 = 𝑆𝐴 × 𝑓𝑐𝑓 × 𝑖𝑐 × 𝑘 (5)

where,

ic = is the current density, selected for mean and final conditions (A/m2)
k = Design factor (1.25), based on section 6.1.5 of DNVGL-RP-F103: 2016

7.4 Anode Mass

The total anode mass required is calculated using equation 6 below:

𝑡𝑑𝑙
𝑀𝐴 = 𝐼𝑐𝑓 × 𝑄 × (6)
𝑈𝑓

where, Minimum required anode mass calculation is necessary

for sacrificial anodes and soluble/semisoluble
impressed current anodes. Dimensionally stable
Q = Anode consumption rate (kg/A-yr)
anodes are sized basing on anode current capacity
Uf = Utilization factor (manufacturer data) and anode resistance.

From the total anode mass above, the number of anode required based anode weight is
calculated using:

𝑁𝑎𝑤 = 𝑀𝐴 /𝑚𝑎 (7)

where,

ma = Individual Anode net weight

Also, the required number of anode based on current requirement is calculated using equation 8
below:
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𝑁𝑎𝑖 = 𝐼𝑐𝑓 /𝐼𝑎 (8)

7.5 Circuit Resistance

Allowable circuit resistance for the cathodic protection system is calculated using equation 9
below:

𝑅𝑇 = (𝑈𝑠 − 𝑉𝑏 )/𝐼𝑐𝑓 (9)

where,

Us = DC Voltage Source Capacity (V)

Vb = Back Voltage (V), 2V
Basically, the allowable circuit resistance, RT is made of contributory resistance from groundbed
(Ra), adjoining cables (Rc) and pile (Rp).

𝑅𝑇 = 𝑅𝑎 + 𝑅𝑐 + 𝑅𝑝 (10)

The allowable groundbed resistance is ≤ 70 % of RT in accordance with section 9.3.1 of ISO

15589-1:2015 and the remaining is the resistance of the adjoining and pile put together.

Effective pile resistance is calculated using equation 11 below:

𝐸𝐷
𝑅𝑒𝑝 = 𝑎𝑏𝑠𝑜𝑙𝑢𝑡𝑒 ( ) (11)
𝐼𝑐𝑚
This is not considering the pile armoring resistance and
newly applied pile jacketing specific resistance.
where,

ED = Pile Maximum Protection Potential wrt Ag/AgCl Reference Electrode (V)

The resistance of each of the cables is calculated by multiplying the per unit resistance of the
cable with the cable length.

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The single anode groundbed resistance in sea water is calculated in accordance with equation
A.9 of ISO 15589-2: 2012 as shown in equation 12 below:

𝜌 𝐿
𝑅𝑎 = [𝐿𝑛 (4 𝑎⁄𝑟𝑎 ) − 1] (12)
2𝜋𝐿𝑎

where, What about the resistance of a full anode sled?

ρ = Sea Water Resistivity (Ohm-m)

La = Anode Length (m)

Da = Anode Diameter (m)
S = Anode Area (m2)

7.6 DC Supply Voltage

The voltage rating for the DC supply source, TR is calculated using the equation 13 below:

𝑉𝑠 = (𝐼𝑐𝑓 × 𝑅𝑇 ) + 𝑉𝑏 (13)

8 DESIGN SUMMARY AND RECOMMENDATIONS

a. Based on the design calculations as shown in Appendix 1, anode sled with one (1)
MMO anode will serve, however considering the piles status, the saliferous
environment and contingency for optimal performance of the system, anode sled with
five (5) MMO anodes connected in parallel is selected for all the groundbeds of the
impressed current cathodic protection system for the Jetty Piles.

b. The existing transformer rectifiers with output rating of 200 A / 10 V dc, 200 A/ 10 V
dc and 100 A / 10 V dc of the respective cathodic protection system meet the
requirement for the DC supply based on the design calculations of Appendix 1. Hence,

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the existing transformer rectifier of each of the ICCPS shall be used as the DC source
for respective system.

c. The MMO anode sled shall have output rating of up to 200 A or 100 A current capacity
as provided in Appendix 1 with performance service life of a minimum of 20 years.

d. The MMO anode sled installation shall be as to be detailed in "Cathodic Protection

Installation Details - ICCPS".

e. The current drain cable shall be connected or attached to the lead and end pile of each
CP section by Pin Brazing with drain cables completely embedded in pile CFRP jacket.

f. The positive cable from the anode sled to positive junction box shall be installed in an
anti-theft conduit with in fill concrete mix of ratio 1:2:4 as shall be detailed in “cathodic
protection installation details-ICCPS”

g. The cathodic protection equipment and materials required for the installation of the
Jetty Piles ICCPS shall be as indicated in “Cathodic Protection MTO – ICCPS”

h. The CP design for the refurbishment of the existing ICCPS are of comparative
advantage to the origin CP design in terms of :

• Cost
The cost for the purchase, installation and handling of CP materials such as
groundbed anodes has been reduced by using five(5) numbers of MMO anodes
(0.35kg) as one unit of anode sled as against the use of up to twenty two (22)
numbers of Iron Silicon anodes(38.2kg) of the original CP design.
• Performance
With this design, five (5) numbers of MMO anodes (0.35kg) per anode sled as
groundbed a design life of 20 years is achieved at very low consumption rate as
against the twenty-two (22) numbers of Iron Silicon anodes(38.2kg) used as

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 A CLIENT IDENTIFICATION
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SUBCONTRACTOR’S DOC. No. FOR JETTY SHEET DOC. CLASS: REV.

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groundbed to achieve a design life of 10 years at a higher consumption rate in the

original CP design

Appendix 1: CP Calculations for Jetty Piles

Appendix 2: Jetty Pile Layout

General comments:
Considerations of mooring piles CP is missing.

Comments on Appendix 1:
Each proposed anode sled is composed by 5 anodes so, the total current capacity of a sled is 5 x 8A = 40A. This is in
contrast with note 3 of appendix 1 that states a sled current capacity of 200A.

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