BST Gen CRR RPT Aip 10003 10003 Permanent CP WR # 003

Comment Resolution Sheet (CRS)
Project: BISAT PHASE II DEVELOPMENT PROJECT
Client: OQ
Contractor: Arabian Industries Projects L.L.C
CP Vendor: Amran CPSS

Document: Permanent Cathodic Protection Design Report for produced water disposal pipeline
Ref. Point in
Comment from OQ Amran response OQ Reply Status
document
TR unit rating shall be 48V/50A as We confirm and document revised
Page 21 of 44
confirmed in TBE accordingly
TR unit rating shall be 48V/50A as We confirm and document revised
Page 21 of 44
confirmed in TBE accordingly
Header cables size from TR unit to AJB
Page 26 of 44 and NDB (positive and negative) shall be Noted and incorporated
70 mm2 because the rating of TR is
48V/50A
7 number of anodes shall be provided
Page 28 of 44 each with 8A rating as per TBE Noted and incorporated
confirmation
Page 30 of 44 Cable size shall be 10 mm2 Noted and incorporated
Page 31 of 44 It shall be for 10 mm2 size Noted and incorporated

Ref. Point in
Comment from OQ Amran response OQ Reply Status
document
Page 34 of 44 It shall be for 10 mm2 size Noted and incorporated
Page 35 of 44 TR unit rating shall be 48V/50A as Noted and incorporated

confirmed in TBE
Header cable size shall be 70 mm2 based

Page 36 of 44 Noted and incorporated
on 50 A rating
Header cable size shall be 70 mm2 based

Page 36 of 44 Noted and incorporated
on 50 A rating
Page 37 of 44 Cable size shall be 10 mm2 Noted and incorporated
Kindly note that based on your comments,

This section shall be revised based on the
Appendix-B the calculation has been revised and
comments mentioned above
updated
CONSTRUCTION AND SERVICE CONTRACT
(CSC) FOR BLOCK 60 & 48
Company Name: OQ EXPLORATION & PRODUCTION LLC
Contract Number: AB/2019-036
Work Package: WATER DISPOSAL PROJECT WP #: WR-003
Contractor Name: ARABIAN INDUSTRIES PROJECTS LLC
Consultant Name -
Vendor Name: AMRAN CATHODIC PROTECTION SYSTEMS & SERVICES
Sub Vendor Name: -
PO Number: WO #: 14-220000733-01
Package Title: CATHODIC PROTECTION SYSTEM BISAT AREA DEVELOPMENT PHASE II

PROJECT
Vendor Document P2988-REP-002

Number (if any)
Document Title: PERMANENT CATHODIC PROTECTION DESIGN REPORT- PRODUCED

WATER DISPOSAL PIPELINE
Document Number: BST-GEN-CRR-RPT-AIP-10003-10003-00 Rev. K-01
Document Status: IFR - Issued for Review Issue Date: 20-06-2022
IFI - Issued for Information
AFC/AFU - Approved for Construction /

Approved for Use
ASB - As Built
For Contractor Use Only
REVIEW CODE AND STATUS
A CONSENT TO PROCEED
B CONSENT TO PROCEED SUBJECT TO COMMENTS
C CONSENT TO PROCEED WITHHELD RESUBMIT
D REVIEW NOT REQUIRED
Date: 20-09-2022 Sign:

Review does not constitute acceptance of design details, calculations, test methods or materials developed or selected by
Vendor/Contractor nor does it relieve Vendor/Contractor from full compliance with contractual or other obligations or responsibilities.
DOC # BST-GEN-CRR-RPT-AIP-10003-10003-00
PERMANENT CATHODIC
PROTECTION DESIGN
OQ EXPLORATION & PRODUCTION
REPORT- 24" CS PIPELINE
LLC FROM PW MANIFOLD TO
INTERMEDIATE STATION
Project : BISAT PHASE II DEVELOPMENT

PROJECT
Purchase order # : 14-220000733-01
ARABIAN INDUSTRIES PROJECTS

LLC
Location : BISAT
PRODUCED WATER DISPOSAL
Structure :
PIPELINE
Amran Doc. # : P2988-REP-003

Originator : Dinesh
Checked by : Arunachalam
Approved by : Gineeth Sebastian
AMRAN CATHODIC PROTECTION
SYSTEMS & SERVICES
Amran Cathodic Protection Systems & Services LLC | PO Box: 919 | PC: 100 | Muscat | Sultanate of Oman
AMRAN CPSS L.L.C OQ EXPLORATION & PRODUCTION
PERMANENT CATHODIC PROTECTION DESIGN ARABIAN INDUSTRIES PROJECTS LLC
REPORT- PRODUCED WATER DISPOSAL PIPELINE CATHODIC PROTECTION SYSTEM - BISAT AREA
AMRAN JOB NO. 2988 DEVELOPMENT PHASE II PROJECT
REVISION RECORD
AMRAN CPSS ARABIAN OQ

DESCRIPTION
REV. DATE
PREPARED REVIEWED APPROVED APPROVED APPROVED
Issued for Review

K 00 23.05.2022 Syam Sankar Arunachalam Gineeth
(IFR)
Issued for Approval

K 01 20.06.2022 Dinesh Arunachalam Gineeth
(IFA)
Rev. K01 Page 2 of 42 BST-GEN-CRR-RPT-AIP-10003-10003-00

P2988-REP-003
TABLE OF CONTENTS
1. PROJECT DETAILS ..................................................................................................... 4

2. SCOPE OF WORK ........................................................................................................ 4
3. SCOPE OF DOCUMENT .............................................................................................. 5
4. DEFINITIONS & ABBREVIATIONS .............................................................................. 5
5. REFERENCE CODES AND STANDARDS ................................................................... 9
5.1. PROJECT SPECIFICATIONS & DRAWINGS .......................................................................... 9
5.2. PROJECT DOCUMENTS .................................................................................................. 10
5.3. INTERNATIONAL STANDARDS ......................................................................................... 11
6. STRUCTURE DETAILS .............................................................................................. 12
7. DESIGN OF PERMANENT CATHODIC PROTECTION SYSTEM .............................. 12
7.1. DESIGN PHILOSOPHY .................................................................................................... 12
7.2. CRITERIA FOR PERMANENT CATHODIC PROTECTION....................................................... 14
7.3. DESIGN BASIS, ASSUMPTIONS AND PARAMETERS .......................................................... 14
7.4. DESIGN CURRENT CALCULATION ................................................................................... 15
7.5. GROUND BED DESIGN ................................................................................................... 21
7.6. RATED VOLTAGE OUTPUT SELECTION FOR CP UNIT....................................................... 23
7.7. SUMMARY – PCP DESIGN.............................................................................................. 28
APPENDIX – A ....................................................................................................................... 29
BILL OF MATERIALS ............................................................................................................ 29
APPENDIX – B ....................................................................................................................... 38
DESIGN CALCULATIONS-PCP ............................................................................................. 38
APPENDIX – C ....................................................................................................................... 41
ATTENUATION PROFILE ALONG PIPELINE ....................................................................... 41

P2988-REP-003
1. PROJECT DETAILS
Client / Company : OQ Exploration & Production LLC
Off plot Contractor : Arabian Industries Projects LLC
Project : BISAT PHASE II DEVELOPMENT PROJECT
Structure : 24” Produced Water Disposal Pipeline
CP Contractor : Amran Cathodic Protection Systems & Services LLC (ACPSS)
Purchase Order : 14-220000733-01
Date of PO : 16th March 2022
Purchase Order Activity : Cathodic Protection (TCP & ICCP)
2. SCOPE OF WORK
The scope of work associated with this project is listed below,
Description of Activity CP Vendor (Amran CPSS) Off Plot Contractor (Arabian)
CP Site Survey & Report √

Site Support (Surveyor, Site
√
transport, PTW requirements)
Design (TCP & ICCP) √
Supply of CP Material Note1 √
Installation of CP Equipment √
Supervision of Installation of CP
√
Equipment
Review of Engineering Documents √
Electrical Isolation (Pipeline
√
extremities and tap offs)
LV Power Cable AC (Input to TR
√
Unit)
All Civil, Mechanical & Electrical
Accessories (Not listed in TCP & √
ICCP Design MTO)
Site Support (PTW, Transport at
Site, Accommodation, Messing, √
HSE support)
Testing & Commissioning of CP
√
System

P2988-REP-003
CIPS / DCVG Survey √

Support for CIPS / DCVG Survey
(Water Browser, Helper and √
Transport)
Final Documentation including
√
MRB
3. SCOPE OF DOCUMENT
Corrosion protection of the external surface of the pipeline shall be provided with high integrity coating systems,
supplemented by cathodic protection.
The intent of this document is to provide the design basis and engineering calculation of permanent cathodic
protection system for buried pipelines which shall include but not limited to the Design philosophy, assumptions
and calculations for pipelines, and bill of materials.
4. DEFINITIONS & ABBREVIATIONS
The following definitions and abbreviations have been used in this document:
TECHNICAL:
TERMINOLOGY DESCRIPTION
Alternating voltages and currents induced to on a structure because of the AC power
AC Exposure
system
Alternating Current Alternating Current is an electrical quantity whose direction changes with time
Ampere Unit of Current.
Anode An electrode, placed in the electrolyte, to apply cathodic protection to the structure
Material placed in a cotton bag to fill the space around the permanent reference
Backfill
electrode of a cathodic protection system.
Cable One conductor or multiple conductors insulated from one another.
Casing A metallic pipe (normally steel) installed to contain a pipe or piping.
Cathode The structure that is to be protected by cathodic protection
Cathodic The destruction of adhesion between a coating and the coated surface caused by
Disbondment products of a cathodic reaction.
The prevention or reduction of corrosion of metal by making the metal the cathode in
Cathodic Protection
a galvanic or electrolytic cell
A liquid, liquefiable or mastic composition that after application to a surface is
Coating
converted into a solid protective, decorative or functional adherent film.

P2988-REP-003
A connection, usually metallic, that provides electrical continuity between structures
Continuity Bond
that can conduct electricity.
The deterioration of metal caused by its electrochemical reaction with its
Corrosion
environment
The potential of a corroding surface in an electrolyte relative to a reference electrode
Corrosion Potential under open-circuit conditions (also known as rest potential, open-circuit potential, or
freely corroding potential)
The associate of two or more circuits or systems in such a way that energy may be
Coupling
transferred from one to another
Criterion Standard for assessment of the effectiveness of a cathodic protection system
Current Density Current flowing into the cathode divided by cathode surface area
Direct Current Current whose direction does not change with time.
Location of the negative cable connection to the protected structure through which
Drain Point
the protective current return to its source
The condition of being electrically separated from other metallic structures or the
Electrical Isolation
environment.
A liquid, or the liquid component in a composite material such as soil, in which
Electrolyte
electric current may flow by ionic charge transfer
Any metallic structure that is not intended as a part of a system under cathodic
Foreign Structure
protection.
A metal that provides sacrificial protection to another metal that is more noble when
Galvanic Anode
electrically coupled in an electrolyte.
One or more anodes installed below the earth’s surface for the purpose of supplying
Ground Bed
cathodic protection.
An electric current supplied by a device employing a power source that is external to

Impressed Current
the electrode system. (An example is direct current for cathodic protection.
A potential substantially free of voltage gradients. Electrical potential measured
Instant Off Potential within 100 milliseconds after the cathodic protection system has ceased operation
and with no current flowing to or from the structure.
Interference Any electrical disturbance on a metallic structure as a result of stray current
An intentional metallic connection, between metallic systems in contact with a
Interference Bond common electrolyte, designed to control electrical current interchange between the
systems
A joint that breaks electrical continuity in a structure, but does not affect the
Insulating Joint
mechanical integrity of the structure
The part of a measured electrode potential attributable to the passage of current

IR Drop
through the resistance between cathode surface and reference electrode
An electric discharge that occurs in the atmosphere between clouds or between

Lightning
clouds and earth
Line Current The direct current flowing on a flowline
Metallic Short Direct or indirect metallic contact between two metallic structures
“ON” Potential Electrical potential measured while cathodic protection system is operating.

P2988-REP-003
The change from the open-circuit potential as a result of current across the
Polarization
electrode/electrolyte interface.
The potential across the structure/electrolyte interface that is the sum of the
Polarized Potential
corrosion potential and the cathodic polarization
The surface to electrolyte potential of a structure measured in Volts, with respect to a
Potential
reference cell, unless specifically stated otherwise.
The structure-to-electrolyte potential measured after application of cathodic
Protected Potential
protection
A device for converting alternating current to direct current. Usually includes a step-
Rectifier down AC transformer, a silicon or selenium stack (rectifying elements), meters, and
other accessories when used for cathodic protection purposes.
An electrode that has a stable potential in one or more electrolytes at a given
Reference
temperature, thus enabling it to be used for the measurement of other electrode
Electrode
potentials
✓ The resistances per unit length of a substance with uniform cross section.
Resistivity ✓ A measure of the ability of an electrolyte (e.g., soil/water) to resist the flow of
electric charge (e.g., CP current)
A condition considered to exist at an accessible part in a circuit between the part and
Shock Hazard ground or other accessible part if the steady-state open-circuit AC voltage is 15V or
more (root mean square - rms)
A conductor of a known electrical resistance through which current flow may be
Shunt determined by measurement of the voltage across the conductor and calculation
using Ohm’s Law.
Structure A metal which has a surface in contact with an electrolyte
Structure to The potential difference between the surface of a buried or submerged metallic
Electrolyte structure and electrolyte that is measured with reference to an electrode in contact
Potential with the electrolyte.
An electrically conductive wire or cable attached to a structure and terminated in a
Test Lead test station. It is used for the measurement of structure-to-electrolyte potentials and
other measurements.
Test Point / Station A small enclosure or housing that is the termination point of one or more test leads
Maximum value of electric current through a body of a person which that person can
Threshold Current
release himself or herself
Transformer
An electrical unit which converts input alternating current to direct current output.
Rectifier
An electromotive force, or a difference in electrode potentials expressed in volts.
Voltage
Also known as a potential.
ABBREVIATIONS:
TERM DEFINITION
3LPP 3-Layer Polypropylene
A Ampere
AC Alternating Current
A/G Above Ground

P2988-REP-003
TERM DEFINITION
AJB Anode Junction Box
ASTM American Society for Testing of Materials
API American Petroleum Institute
B/G Below Ground
BPX Buried Flowline Crossing
BS British Standard
CD Current Density
CP Cathodic Protection
CS Carbon Steel
Cu/CuSO4 Copper/Copper Sulphate
°C Degree Centigrade
DC Direct Current
DEP Design and Engineering Practice
DP Drain Point
EPC Engineering Procurement Construction
GPS Global Positioning System
GRX Graded Road Crossing
HV High Voltage
ICCP Impressed Current Cathodic Protection
IEC International Electro-technical Commission
IF Insulating Flange
IJ Isolation Joint
IS Isolation Spool
ISO International Organization for Standardization
kg Kilogram
km Kilometer
LV Low Voltage
mm Milli Meter
mV Milli-volts
NACE National Association of Corrosion Engineers
NDB Negative Distribution Box

P2988-REP-003
TERM DEFINITION
OD Outer Diameter
OHL Overhead Transmission Line
OHLX Overhead Power Line Crossing
PCP Permanent Cathodic Protection
PE Polyethylene
P/L Pipeline
PSP Pipe to Soil Potential
ROW Right of Way
RP Recommended Practice
SOW Scope of Work
SP Engineering Specification
TR Transformer Rectifier
TRX Tarmac Road Crossing
TS Test facility
U/G Under Ground
V Voltage
5. REFERENCE CODES AND STANDARDS
5.1. PROJECT SPECIFICATIONS & DRAWINGS
DOCUMENT DESCRIPTION
SCOPE OF WORK
BST-GEN-ELE-SOW-OQ-000-00001- Cathodic Protection Scope of Work: Produced Water Carbon Steel

00-U-01 Pipelines
PROJECT SPECIFIC DRAWINGS
BST-12-PPL-MAP-WPO-614-00002- Key Plan - Proposed 24" CS-PERT Lined Water Disposal Main Header
01-U Rev.02 #1 from Bisat PW M/F to Intermediate Station
BST-12-PPL-ALN-WPO-614-00003-
Pipeline Alignment Sheets - Proposed 24" CS-PERT Lined Water
01-U Rev.02 to BST-12-PPL-ALN-
Disposal Main Header #1 from Bisat PW M/F to Intermediate Station
WPO-614-00003-04-U Rev.02
BST-12-PPL-LAY-WPO-614-00001- Pipeline Station Approach Drawing – Proposed 24" CS-PERT Lined
01-U Rev.02 MH #1 and 10” CS-PERT Lined PW Pipeline at Bisat Station
BST-12-PPL-LAY-WPO-614-00002- Pipeline Station Approach Drawing – Proposed 24" CS-PERT Lined
01-U Rev.02 MH #1 and Sub Header #1/ #2 at Intermediate Manifold Station

P2988-REP-003
5.2. PROJECT DOCUMENTS
BST-GEN-CRR-RPT-AIP-10003- Pre-Design Site Survey Report 24" CS pipeline PW manifold to
10001-00 Intermediate station
BST-GEN-CRR-RPT-AIP-10003- Temporary Cathodic Protection Design Report- 24" CS pipeline PW
10002-00 manifold to Intermediate station
BST-GEN-CRR-RPT-AIP-10003- Permanent Cathodic Protection Design Report- 24" CS pipeline PW
10003-00 manifold to Intermediate station
BST-GEN-CRR-RPT-AIP-10003- Commissioning Report for CP system of 24" CS pipeline PW manifold
10004-00 to Intermediate station
BST-GEN-CNS-MOS-AIP-10003- Method Statement for Installation, Testing & Commissioning of CP
10001-00 System
BST-GEN-CRR-DAS-AIP-10003-
Material Data Sheets - Cathodic Protection Equipment
10001-00
BST-GEN-QAC-PLN-AIP-10003-
Inspection & Test Plan for Cathodic Protection System
10004-00
BST-GEN-QAC-PCD-AIP-10003-
Factory Acceptance Test (FAT) Procedure - CP TR unit
10002-00
BST-GEN-CRR-DTL-AIP-10003-
Detail Drawing -Welded Pad Cable Connection & Encapsulation
10001-00
Detail Drawing - Pin Brazing Cable Connection & Encapsulation
10002-00
Installation Details - Cable Trench
10003-00
Detail Drawing - Standard CP Test Post
10004-00
Detail Drawing - CP Marker Plate
10005-00
Detail Drawing - General Purpose Bond Box
10006-00
BST-GEN-CRR-DTL-AIP-10003- Installation Drawing - Potential Monitoring Test Facility with Mg Anode
10007-00 (TP1A)
Installation Drawing - Isolation Spool Test Facility (Type-3)
10008-00
Installation Drawing - Drain Point with & CU (Type-2)
10009-00
Installation Drawing - Foreign Service Test Facility (Type-5)
10010-00
Installation Drawing - OHL Crossing Test Facility (Type-7) -
10011-00
Installation Drawing - Road Crossing Test Facility (Type-6) -
10012-00
Installation Details-Negative Distribution Box
10013-00
Installation Details- Anode Junction Box
10014-00
Installation Details- Anode Ground Bed Installation
10015-00
Installation Details- Anode Ground Bed Head Works
10016-00
Installation Details - Transformer Rectifier (TR) Unit
10017-00
Circuit Diagram for Transformer Rectifier Unit
10018-00

P2988-REP-003
BST-GEN-CRR-DTL-AIP-10003- CP Appurtenance Drawing - 24" CS pipeline PW manifold to
10019-00 Intermediate station
BST-GEN-CRR-GAR-AIP-10003-
General Arrangement Drawing for CP Equipment at RMS-1
10001-00
BST-GEN-CRR-LAY-AIP-10003-
Schematic Layout - Cathodic Protection System
10001-00
5.3. INTERNATIONAL STANDARDS
ASTM Standards
ASTM B843 Standard Specification for Magnesium Alloy Anodes for Cathodic Protection
National Association For Corrosion Engineers (NACE)
The Use of Coupon for Cathodic Protection Monitoring Application

NACE RP0104
NACE SP0169 Control of External Corrosion of U/G or Submerged Metallic Piping System
NACE SP0177 Mitigation of Alternating Current and Lightning Effects on Metallic Piping System
Design, Installation, Operation and Maintenance of Impressed Current Deep Anode

NACE SP0572
Beds
NACE SP0286 Electrical Isolation of Cathodically Protected Flowlines
ISO 15589-1-2015 Cathodic Protection of Pipeline Transportation Systems – On land pipelines
British Standard
BS 7361 Part 1 Cathodic protection Part 1, Code of Practice for Land and Marine Application
Shell Standards
Cathodic Protection Design, Installation, And Commissioning (Amendments &

DEP 30.10.73.10 Gen
Supplements to ISO 15589 1:2003)

P2988-REP-003
6. STRUCTURE DETAILS
TECHNICAL DETAILS
The technical detail of proposed new buried water disposal pipeline can be listed as:
Dia. Wall Max.

Sl. Length Coating
Description in Thickness Operating
No. in km Type
inch in mm temp 0C
24" CS-Pert Lined Produced Water
1. 24” 4.250 11.13 60 3LPP
Disposal Pipeline
7. DESIGN OF PERMANENT CATHODIC PROTECTION SYSTEM
7.1. DESIGN PHILOSOPHY
The design strategy followed for permanent ICCP system for subject pipeline is enumerated below:
• All buried sections of pipeline shall be protected using permanent impressed current CP system.
• Design life for the impressed current cathodic protection system shall be 25 years as per SOW.
• Mixed Metal Oxide (MMO) tubular anodes in coke breeze column shall be used as impressed current anode
for permanent ICCP system.
• Considering the high surface resistivity prevalent in the region, deep well ground beds (borehole type - until
the existing water table) is proposed for the pipeline CP system which shall be remote from the structure to
be protected.
• Remote deep well anode ground beds shall be provided at Produced Water Manifold station to provide
permanent impressed current cathodic protection to the 24” CS pipelines subjected to Produced Water
Manifold station. The requirement of the CP systems has been discussed in the site survey report BST-
GEN-CRR-RPT-AIP-10003-10001-00. The same shall be verified with detailed calculation in the preceding
sections.
• Impressed current anode bed shall be sized as a minimum to discharge the rated current output of the DC
power source.
• Cathodic protection current shall be injected to the anodes through following arrangements: DC power
source→ Anode junction box →Anodes→ Pipeline → Negative Distribution Box →DC power source.

P2988-REP-003
• NDB shall be installed in between the transformer rectifier unit and pipeline. The current drain cable from
the pipeline to transformer rectifier unit shall be routed through negative distribution box.
• Material of construction of AJB, NJB & NDB enclosures shall be SS 316L with a minimum ingress protection
of IP55 and shall be suitable for safe area application.
• Material of construction of bond boxes shall be SS 316L with an ingress protection of IP55 and shall be
suitable for installation in non-classified areas.
• Anode junction box is designed to terminate the anode lead cables with suitable rated shunt for current
measurement.
• The designed active column length is 40 meters considering a spacing 5 meters between anode-to-anode
centres below the water table.
• Potential monitoring test facility shall be provided at every 2 km for proposed pipeline .
• Cable to proposed pipeline connection (monitoring and negative drain connection) shall be achieved by
welded pad / cleats connection. Encapsulation at cable connection location shall be done using two-part
epoxy.
• Cable to existing buried metallic pipeline connection (at P/L crossing locations) shall be achieved by pin
brazing. Encapsulation at cable connection location shall be done using two-part epoxy.
• Test facility shall be provided at metallic foreign pipeline crossing locations identified during site survey.
However, interference and mitigation requirement shall be evaluated and employed during the
commissioning of the system, if required.
• At road crossing locations, CP test station shall be provided on one side of the crossing as minimum.
• Test stations with coupon test facility shall be installed at drain points of the pipeline.
• Test post with bond box for isolation flange & drain point test facility shall be provided at produced water
manifold station of the pipeline to analyse the integrity of the isolation flange and measure the drain point
potential of the pipeline.
• Surge diverter/ spark gap shall be provided across isolation flange as available produced water manifold
Station and intermediate manifold station to protect the isolation flange from the surge AC and lightning
strike on the pipeline.

P2988-REP-003
• DC power sources (TR units) shall be installed at Produced Water Manifold Station. The TR units shall be
oil cooled type suitable for outdoor installation. The cabinet shall have ingress protection of a minimum of
IP66. The TR unit shall be suitable for installation in non-hazardous location and shall be placed
accordingly.
7.2. CRITERIA FOR PERMANENT CATHODIC PROTECTION
The criteria for determining the adequacy of the protection of structure shall be as per clause 3.3. of CP SOW
doc# BST-GEN-ELE-SOW-OQ-000-00001-00-U-01. Adequate cathodic protection for the 24” CS Pert Lined
produced water disposal pipeline as below:
• Impressed current cathodic protection (ICCP) system shall be designed such that instantaneous “OFF”
potentials can be measured. The system shall be designed to achieve minimum structure-to-electrolyte
“Instant OFF” potential of (-) 850 mV with respect to copper-copper sulphate (Cu/CuSO4) reference
electrode.
• ICCP system will be designed in such a way that maximum “Instant OFF” potential shall be restricted to (-)
1200 mV to avoid over protection of DSS structure. The potentials shall be recorded w.r.t. a saturated
copper-copper sulphate (Cu/CuSO4) reference electrode.
• Alternatively, (Ref: NACE RP 0169 clause no 6.2.2.1.3), a minimum of 100 mV of cathodic polarization
measured between the pipeline surface and a stable reference electrode contacting the electrolyte shall be
considered as an adequate protection. The formation or decay of polarization shall be measured to satisfy
this criterion.
7.3. DESIGN BASIS, ASSUMPTIONS AND PARAMETERS
The design parameters for permanent CP system can be listed as under
DESIGN PARAMETER DESIGN VALUE
Water disposal pipeline diameter 24” / 0.6096 m (OD)
Design Life (PCP) system 25 Years
Max Operating Temperature 60 ⁰C
0.010 mA/m2 (Section 3.3 of the CP

Cathodic Protection Current Density at 30 ͦC for 25 years SOW For Bisat Phase II Development
Project – Cathodic Protection Scope
design life for 3LPP Coating
BST-GEN-ELE-SOW-OQ-000-00001-
00-U-01)
25% increase per 10 degree C rise in
temperature above 30°C (Section 3.3 of
Current Density Adjustment with the CP SOW For BISAT PHASE II
Temperature DEVELOPMENT PROJECT – Cathodic
Protection Scope BST-GEN-ELE-SOW-
OQ-000-00001-00-U-01)

P2988-REP-003
DESIGN PARAMETER DESIGN VALUE
Pipeline coating 3 Layer Polypropylene (3LPP)
Specific Coating Resistance (Rc) 30000 ohm-m2
Resistivity of Carbon Steel 1.6 x 10-7 Ω-m
Pipeline natural potential (-) 0.50 V w.r.t. Cu/CuSO4 ref. cell
Minimum protective potential (-) 0.85 V w.r.t. Cu/CuSO4 ref. cell
7.4. DESIGN CURRENT CALCULATION
The following section outlines the design calculations for permanent impressed current cathodic protection for
the Produced Water Manifold Station pipeline 24” CS from Produced Water Manifold Station Intermediate
Manifold Station. The detailed ICCP calculation is attached in Appendix-C.
COATED SURFACE AREA OF PIPELINE
Sa,c = 𝜫 × 𝑫 × 𝑳-------------------------------------------- (1)
= 3.14 x 0.6096 x4250
= 8139.24 m2
CURRENT DENSITY AT OPERATING TEMPERATURE

𝑶 −𝟑𝟎
( 𝑻 )
ICP,T = 𝒊𝒄𝒑,𝟑𝟎 × 𝟏. 𝟐𝟓 𝟏𝟎 --------------------------- (2)
 60 − 30 
 
=0.01 × 1 . 25  10 
= 0.02 mA/m2
CURRENT DEMAND
𝑺𝒂,𝒄 × 𝒊𝒄𝒑 , 𝑻
ICP = ⁄
𝟏𝟎𝟎𝟎 ------------------------------- (3)
= 8139.24 x 0.02 /1000
= 0.16 A
Current demand with 30 % current allowance
= 0.16 x 1.3
= 0.21 A

P2988-REP-003
7.4.1. Attenuation Model
Polarization
Polarization at Drain Point, E0 :  n − 0

Polarization at End of Pipeline, Em : n −m
Polarization at point x along the Pipeline, Ex :  n − x
Considering the maximum observed protection potential limit on pipeline at any point,
Maximum Protection Potential, Emax :  n −  max

0
Minimum Protection Potential, Emin :  n −  min

0
where
0 - Pipeline potential at drain point (V)
m - Pipeline potential at pipe end (V)
x - Pipeline potential at point x (V)
n - Pipeline natural potential (V)

 max
0
- Maximum protected potential (V)
min
0 - Minimum protected potential (V)
Pipeline Linear Resistance
R’
s …………………….(4)
= (Ω/m)
2  r  t
Where
s - Resistivity of Steel (Ωm)
r -Outer Radius of Pipeline (m)

t -Wall thickness of Pipeline (m)
Specific Coating Leakage Conductance
= 1 (S/m2) …………………….(5)
g RC
Where
-Specific Coating Resistance for

i
Polypropylene (30,000 Ω-m²)

P2988-REP-003
Coating Leakage Conductance
G’ = ( g  2    r ) (S/m) …………………….(6)
Where
g -Specific coating leakage conductance

(S/m2)
r -Outer radius of pipeline (m)
Attenuation Constant
 =
R'  G' (1/m)
…………………….(7)
Characteristic Resistance, Z (Ω)
Z = …………………….(8)
R' / G' (Ω)
R' From (4)
G' From (6)
Resistance of the Pipeline Looking from an Open End
Rso = Z coth[L] (Ω) …………………….(9)
Polarization at Point x along the Pipeline, (Ex)
The polarization of pipeline at location ‘x’ from the source, when connected to an anode through a DC power
source, is given by the following expression
Ex = Em cosh[ ( L − x)] (V) …………………………….(12)
Polarization at Drain Point
E
= Em cosh[L] (V) …………………………….(13)
0
Polarization at Mid-Point of the Pipeline
Emd = E m cosh[ ( L / 2)] (V) …………………………….(14)

P2988-REP-003
Polarization at End Point of the Pipeline
Em = E0 / cosh(L) (V) …………………………….(15)
Current Flow at Drain Point
I0 = E0
(A) ……… …………………...(16)
Z coth[L]
Where
Em - Polarization at end of pipeline (V)
Ex - Polarization at point x along the pipeline (V)
E0 - Polarization at drain point (V)
 - Attenuation constant
L - Length of pipeline (m)
Z - Characteristic resistance (Ω)
References
1. Von Baeckmann, V., Schwenk, W., and Prince, W., Handbook of Cathodic Corrosion protection Third
Edition [All Equations]
2. Morgan. J, Cathodic Protection - Second Edition [Cross Reference]
3. NACE CP Level 4 : Course Manual [Cross Reference]
Results & Analysis of the Attenuation Model

The attenuation model indicates the change of potential shift along the pipeline with respect to a potential shift
at the D.C source point or drain point. However, the potentials are shown in the graphs with respect to a
Cu/CuSO4 reference electrode for the convenience of interpreting the model.
The model is based on the assumption that the pipeline and the earth acts as a two-parallel conductor with a
linear resistance component along the pipeline and a shorting resistance across the conductors. The resultant
characteristic resistance and attenuation constant for such system defines the potential attenuation behaviour
along the length of the pipeline. [Refer Von Baeckmann, V., Schwenk, W., and Prince, W Handbook of
Cathodic Corrosion Protection - Third Edition]
This model can only be used as a guideline to determine the capability of a CP station to generate sufficient
potential shift on the pipeline surface, leading to polarization of the pipeline meeting the protection criteria and

P2988-REP-003
has the primary assumption of looking into an infinite resistance on one end which is essential an electrical
isolation.
As per NACE CP4 manual, a net potential shift of 350 mV at any point on the pipeline shall be sufficient to
polarize the pipeline cathodically meeting the criterion above and thus effectively mitigate corrosion.
The maximum and minimum anticipated shifts in potentials are given by the CP criteria under Section 7.2 of
this document. The maximum protection potential criterion for CS pipeline (i.e., a 1200 mV in the electro
negative direction when measured w.r.t. to a portable Cu/CuSO4 reference cell) is impressed on the pipeline
at the drain point, attenuated along the length of the pipeline.
Maximum Protection Potential Shift, Emax =  n −  max

0
= -0.50 – (- 1.2)
= 0.7 V
Minimum Protection Potential Shift, Emin =  n −  min

0
= -0.50 – (-0.850)
= 0.350 V
CP station shall be installed at Produced Water Manifold Station. The attenuation model shall be developed
along these CS pipeline as detailed in Appendix–D
Below section shows the typical attenuation model for 24” diameter pipeline from Produced Water Manifold
Station to Intermediate Manifold Station
Pipeline Linear Resistance, R’ =

s (Ω/m)………………….from (4)
2  r  t
= (1.6 x 10-7) / (2 x π x 0.30504 x 0.0099)
= 8.432 x 10-6 Ω/m

Specific Coating Leakage Conductance,
g
= 1/Rc (S/m2) ………………… from (5)
= 1/30000
= 3.33 x 10-5 S/m2
Coating Leakage Conductance, G’

= (g  2    r ) (S/m) ……………from (6)
(2 x π x 0.30504 x 3.33x 10-5)

=
6.389 x 10-5 S/m
=
Attenuation Constant, 
= R'  G' from (7)
=
√(6.389 E -05) × (8.432 E -06)

P2988-REP-003
= 2.32104 x 10-5 /m
Polarization at end of pipeline due to drain point at one end at which a potential of 1050 mv (500 mV natural
potential + 550 mV of polarization) is applied.
Em = 1050 mV
The attenuation model for the 24” produced water pipeline 4250 meters is calculated with 1 number of CP
station (ICCP ground bed and power source) at produced water manifold station.
The attenuation constant above has been used for the water disposal pipeline since this is represents the
worst condition.
Considering the attenuation calculation and over all current demand, it is understood that, the proposed ground
bed at Produced Water manifold station is sufficient to supply adequate current to the proposed pipeline to
meet the design criteria as mentioned in section 7.2.
The attenuation model shall be developed along proposed water disposal pipeline as detailed in Appendix-C
of this document.
Therefore, the proposed ground bed locations are effectively protecting the entire length of pipeline and
satisfies the ICCP design requirements as per section 7.2 of this document.
The Overall pipe to soil potential profile graph is provided under Appendix-C
CP System – Ground Bed Location, and rating of CP system
Considering the total current requirement for the proposed pipeline is 0.21 A. The proposed CP station shall
be installed at produced water manifold station.
Considering the current requirement for the anticipated future pipeline, the transformer rectifier unit rating shall
be proposed as 48V/50A.
TR Unit Rating
Pipeline ID Proposed Location Chainage (KP)
(Proposed)
24” CS Pipeline from

Produced Water Manifold Produced Water Manifold
0+000 48V / 50A
Station to Intermediate Station
Manifold Station

P2988-REP-003
7.5. GROUND BED DESIGN
General
The design of anode ground bed shall ensure sufficient quantity of anode material and carbonaceous backfill
to meet or exceed the design life time. A utilization factor of 75% is applied over the design to ensure time for
replacement or refurbishment of the system, towards the end of design life, if required. The quantities shall be
calculated on the basis that the maximum CP unit rated current output is impressed for the entire duration of
the design life.
Selection & Design of Active Column
The anode active column and the constituents like dimensionally stable anodes, calcined petroleum coke are
chosen and designed such that the current densities on the anode and that on the active column are within
the limits set forth by manufacturer:
Description Specification
Mixed Metal Oxide Coated Titanium Tubular Anodes

Material
(MMO/Ti)
Anode Length, La 1m
Anode Diameter, da 0.025 m
Maximum Anode Current Density, iA 100 A/m2 for 25 years
Rated Anode Current Output, IA 8 A per anode for 25 years
Anode Coating Consumption Rate, Ct < 4 mg / A-Yr
Tail Cable Single core 16 mm2 Cu / PVDF / HMWPE cable (Kynar)
Nominal Maximum Current Output from

50 A
the DC Power Source, I
Length of Active Column, L 40 m
Diameter of Active Column, D 0.250 m

Current Density on Active Column at
1.592 A/ m2
Peak Load (i.e 50A)
Backfill Material Calcined Petroleum Coke Breeze
Backfill Bulk Density, ρB 1185 Kg/m3
1 Kg/ A-Yr (Refer : T.H. Lewis, Deep Anode Systems,

Backfill Consumption Rate, Ct
NACE)
Utilization Factor, Uf
(The maximum quantity of backfill that 75 %
will be used up, in the design life
period)

P2988-REP-003
Number of Anodes Required

Minimum anode quantity required in the active column for protection of the pipeline is calculated based on the
current output from an individual anode and the maximum peak current deliverable from a DC power source.
It shall be chosen that the maximum current output from the DC power source as 50 A.
To calculate the minimum number of anodes based on the anode’s maximum current density, the following
formula is used,
I
N = d a L a   A ----------------------------- (18)
Where
N = Number of anodes required
I = Rated current output (A)
da= Diameter of anode (m)
La=Anode length (m)
ϒ= Maximum Anode Current Density (A/m2)
N = (50/π x 0.0254 x 1 x 100)………………………………From (18)
= 6.3
≈ 7 No. of Anodes
The calculated total no. of MMO anodes is 7 Nos.
Hence the active column of the deep well bed shall be constructed with a minimum of 7 no’s anodes spaced
5m equidistant from each other along the 40 m depth, backfilled with calcined petroleum coke.
Minimum Quantity of Backfill Required
It is necessary to ensure that the designed coke breeze quantity shall also be sufficient for the minimum rated
current output based on consumption rate and also based on the dimensions of the active column chosen. It
shall be estimated using the following equations.
Based on ground bed dimensions, the minimum quantity of coke breeze required, is given by
d 2 L B
WCB = (kg) …………………..(19)
4
Where
d -Dia of active column (m)

L -Length of active column (m)
ΡB -Backfill Bulk Density (kg/m3)

P2988-REP-003
WCB = (π x (0.25)2 x 40 x1185) / 4 (kg ) …………………..From (19)
= 2326.742 kg
= 2500 kg
However, 2500 kg of calcined petroleum coke shall be considered to account for spillage, diffusion into the
water table and ensure good compaction in the active column. This quantity shall be verified against the
consumption rate.
Based on consumption rate, the minimum quantity of coke required, is given by
I  t  Cr
WCB = (Kg) ………………………..(20)
Uf
Where
I -Max. Current Output of Ground Bed (A)

t -Design Life (y)
Cr -Consumption Rate of Backfill (kg/A-y)
Uf -Utilization Factor (no unit)
WCB = (50x 25 x 1) / 0.75 (kg) ……………………… From (20)
= 1666.667 kg
Hence, the 1666.667 kg of calcined petroleum coke shall be required based upon the consumption rate.
Therefore,2500 kg of calcined petroleum coke shall be considered to be supplied to account for spillage,
diffusion into the water table and ensure good compaction in the active column.
7.6. RATED VOLTAGE OUTPUT SELECTION FOR CP UNIT
The Equivalent Circuit

From the equivalent circuit shown below, for the proposed impressed current cathodic protection system for
pipeline, it can be shown that the total circuit resistance is the sum of Resistance of the Anode to Remote
Earth (RAE), Net Resistance in DC Header Cables (Rc) and the Pipe to Remote Earth Resistance (RP).

P2988-REP-003
+
RC,
- RC,
N
Ground
PL
bed
RP
RAE
Remote Earth
The total resistance of the circuit is given by,

R = RAE+ RDC+ RP (Ω) ----------------------------------------------------------(21)
Generally, the surface of pipeline in contact with Remote Earth is very large yielding a very negligible
resistance. Therefore, the above equation reduces to
R = RAE+ RDC (Ω) ------------------------------------------------------------(22)
Where
R -Total Circuit Resistance (Ω)

RAE -Anode to Earth Resistance (Ω)
R -DC Header Cable Resistance (Ω)
DC
RP -Pipeline to Earth Resistance (Ω)
Anode Ground Bed to Earth Resistance
Vertical remote deep ground bed is proposed to cathodically protect the subject pipeline. The depth of the
borehole shall be fixed at site as per the water table depth during drilling. The active column length and
diameter of the ground bed shall be 40 m and 0.25 m respectively.
The active column length (40 m) shall be drilled from the first water strike observed during drilling, so as to
ensure the active column being completely immersed into the water table at all time. The length of the active
column, in addition to the factors discussed earlier (current density on active column and the backfill quantity
required) is also dependent on the anode to earth resistance. It is advisable to maintain the resistance of active
column, around 1 ohm, during the design stage to ensure effective utilization of power and reduce electrolytic
stress on the anode-electrolyte interface.

P2988-REP-003
The water resistivity for ground bed resistance calculations shall be assumed, contingently, as 10 Ωm, as the
anodes are installed in the water table depth.
Anode ground bed to earth resistance (RAE) for vertical ground bed is determined using Modified Dwight
Equation
𝜌 4𝐿𝐴𝐶
(𝑙𝑛 ( ) − 1) (Ω)
RAE = 2𝜋𝐿𝐴𝐶 𝑑𝐴𝐶
----------------------------------------(23)
Where
RAE -Anode to earth resistance (Ω)
ρ -Soil resistivity (10 Ω-m)
LAC -Length of active column (40 m)
dAC -Dia of active column (0.25 m)

10 4 𝑋 40
RAE = (ln ( ) − 1)
2𝜋 𝑋 40 0.025
RAE = 0.217 Ω
System DC Cable Resistance
• The positive and negative header cable (from DC power source to anode junction box and negative
distribution box) shall be single core 70mm2 XLPE/ PVC cable.
• The average length of positive header cable (from CP DC power source to anode junction box) shall be 100
m approximately.
• Anode tail cables shall be single core 16 mm2 PVDF/HMWPE (Kynar) with max. length of 90 m. Total
number of anode tail cables at anode junction box shall be 7 No.
• The length of negative drain cable from pipeline to negative distribution box shall be approximately 15m.
• The negative cable (from NDB to DC power source) shall be average of 50 m.

P2988-REP-003
Cable Length of Average

Cable core No. of Combined
Description size Each Resistance
specification Cables Resistance (Ω)
(mm2) cable (m) (Ω)
Anode Tail Cable Single core 16 7 90 0.01479
Header Cable 0.0416

from DC power Single core 70 1 100 0.02680
source to AJB
Header Cable
from DC power Single core 70 1 50 0.01340
source to NJB 0.0174
Drain Cable From
Single core 70 1 15 0.00402
24" PL to NDB
RDC = 0.0416+ 0.0174

RDC = 0.0590 Ω
The circuit resistance shall be
R = 0.217 + 0.0590
R = 0.276 Ω
Rated Output Voltage

The rated output voltage should be at least sufficient to pass the design current demand across the circuit
resistance calculated above. Using Ohms Law, the rated output voltage is given by,
V = I  R + Back E.m.f.(V) --------------------------------(24)
Where,
V = Voltage ( V)
I = Rated DC Current Output (A)
R = Circuit Resistance (Ω)
V = ( From 24)
50 X 0.276 + 2
= 15.82 V
An allowance of 2.0 V shall be considered to overcome the back EMF of the CP circuit as an electrochemical
cell formed between the anode and the pipeline. Hence, the minimum rated output voltage of DC power source
shall be 48 V.
The proposed maximum rating of cathodic protection DC power source shall be 48 V / 50 A. The proposed TR
unit rating can cater the current requirement for the 24” CS pert water disposal pipeline and the future pipelines

P2988-REP-003
as mentioned in the SOW. Therefore, the designed TR unit rating is sufficient to achieve the design criteria for
the proposed & future pipeline.
Maximum allowable resistance of DC power source can be calculated as below
Allowable resistance = (Rated Output Voltage – Back EMF) / Rated Output Current
= (48 –2) / 50
= 0.920 Ohm
The combined anode to earth resistance shall be 0.217 ohm and the total circuit resistance shall not exceed
0.920 ohm.
Power Requirement Estimation

Input power requirement for cathodic protection DC power source shall be estimated using the following
formula,
VTR  ITR
P = ------------------------------ (25)
  1000
Where,
𝑉 𝐴
𝜂
×
P = Power requirement for DC unit (W)
V = Rated voltage output of DC unit (V)
A = Rated current output of DC unit (A)
η = Efficiency of DC unit
The efficiency of three phase transformer rectifier unit in converting AC to DC is given by manufacturer
as 75% (min).
Hence, the rated input power required,
48 × 50⁄
P = 0.75 X 1000…………………………….. From (25)
= 3.20 kW

P2988-REP-003
7.7. SUMMARY – PCP DESIGN
PARAMETER VALUE / DESCRIPTION

Impressed Current Cathodic Protection System using
Permanent Cathodic Protection :
Remote Deep Well Anode Ground Bed
Power Supply : Transformer Rectifier Unit
Location of Power Supply and

: Produced Water Manifold Station
Ground Bed
Input Power Required : 3.20 kW
AC Input Supply : 415 V, 3 Φ, 50 Hz
DC Output Power Supply : 48 V / 50 A DC output
Deep Well Ground Bed

Ground Bed Type :
(Cased and installed below water table)
0.25 m diameter x 40 m active column
Ground Bed Dimension :
(Below water table depth)
Anode Selection : MMO / Ti Tubular Anodes installed in a coke backfill
Number of Anodes per Ground

: 7 No.
Bed
Backfill : Calcined Petroleum Coke
Backfill quantity : 2500 kg each Ground bed
Total Allowable Circuit

: 0.90 Ω
Resistance
95/8” CS Casing
Type of GB (In active : 40 m
Casing Column)
95/8” CS Casing
: 40 m
(Active Column

P2988-REP-003
APPENDIX – A
BILL OF MATERIALS

P2988-REP-003
BILL OF MATERIALS FOR 24”CS PRODUCED WATER PIPELINE
ITEM
DESCRIPTION TOTAL QUANTITY UNIT
NO.
Pre-Packaged Magnesium Anode with uPVC Pipe for

Watering
Salient Features:
1. 1. Anode tail cable –1x10mm2 XLPE/PVC tail cable (10m)- 2 No.
Red
2. Dimension -700mm (L)x150mm(D)
3. Net Weight-4.1 Kg
4. 3” PVC pipe of length 3m.
Standard Test Post – Potential Monitoring Test Facility,

Type-1A
Salient features of test post:
2. 1. Material – Galvanized Iron (GI) 4 No.
2. Length- 2250 mm
3. Dia. – 4 inches
Standard Test Post with Bond Box –Isolation Joint & Drain
Point Test Facility, Type-2
1. Material – Galvanized Iron (GI)
2. Length- 2250 mm
3. Salient features of bond box: 1 No.
1. Enclosure – Stainless Steel
2. IP rating – IP55
3. Size: 300 x 300 x 150 (mm)
4. Reed switch and magnet
5. No. of terminals- 8

P2988-REP-003
ITEM
NO.
Standard Test Post – Road crossing test facility, Type-4

4. 1. Material – Galvanized Iron (GI) 1 No.
2. Length- 2250 mm
Standard Test Post with Bond Box –Isolation Joint Test

Facility Type-3
2. Length- 2250 mm
5. Salient features of bond box: 1 No.
6. Size: 300 x 300 x 150 (mm)
7. Reed switch and magnet
8. No. of terminals- 8
1x10 mm2 XLPE/PVC Potential Monitoring Cable for Type-

1A, 2, 3 & 4 & foreign line crossing Test Post
Salient Features of Cable:
1. Conductor– Bare Copper

2. Size – Single Core 10 mm2
6. 3. Insulation – XLPE
4. Overall Sheath – PVC
Black 230 m
Red 170 m

P2988-REP-003
ITEM
NO.
Pad Weld Connection (By EPC Contractor)

7. 1. CS plate 50x50mm (as per drawing) 11 No.
2. M10 threaded studs
Encapsulation Material- Cold Setting Liquid Epoxy.

8. 1. Resin – 4.5 litre 9 Litres
2. Hardener – 4.5 litre
Surge Diverter
9. 1. Model: EXFSKU 2 No.
2. Design current: 100 KA
Miscellaneous Items
1. Cable lugs-
• 70mm2 /M10 – 2 No.
• 10mm2 /M10 – 15 No.
10. 1 Lot
2. Cable ties- 2 packet (small)
3. Silicone sealant – 3 tubes
4. M10 GI nut bolt & washers- 10 No.
5. M6 GI nut bolt & washers for box fixing- 10 Set

P2988-REP-003
BILL OF MATERIALS FOR ICCP SYSTEM OF 24”CS PRODUCED WATER PIPELINE
Item Description Qty

No.
Single Channel Oil Cooled Transformer Rectifier Unit

Salient Features:
1. AC input rating- 415V ± 5%, 3 Phase ,50 Hz + 2%
2. DC output rating- 48V / 50A
11. 3. Degree of Protection- IP66 1 No.

4. Control: Manual Variac
5. Cooling Type: ONAN
6. Inbuilt Interrupter: GPS Synchronize timer
7. Painting – RAL 7035
MMO Tubular Anodes for Impressed Current Cathodic Protection

Salient Features:
12. 1. Anode tail cable - 1x16 mm2 Kynar -Black. 7 No.
2. Dimension: 1000mm length x 25mm diameter
3. Anode rating – 8 A for 25 years
Ground Bed Accessories

1. Centralizer- 7 No.
2. End weight -1 No.
13. 3. Nylon rope – 110 m 1 Lot
4. PVC Glue- 5 No.
5. Big Cable tie – 4 Packet
6. 1” PVC elbow - 6 Nos
uPVC Vent Pipe

Salient Features:
1. Size 1”
14. 2. Perforated uPVC pipe for Active column-40 m 80 m
3. In perforated uPVC pipe-Inactive column-40 m
4. Gas vent application

P2988-REP-003

No.
Anode Junction Box

Salient Features:
1. Enclosure –Stainless Steel 316 L
➢ IP Rating - IP 55 (suitable for safe area)
2. No of circuits – 7 No.
3. shunts Rating: 5A/50mV
15. 1 No.
4. Dimension:300 (H) x 300(W) x150 (D) mm
5. Brass gland for 16 mm2 cable exit: 7 No.
6. Brass gland for 70 mm2 cable entry: 1 No.
7. Stopper Plug – M20s: 1 No
8. Mounting - GI frame
9. Painting – RAL 7035
Negative Distribution Box

➢ Enclosure Material – Stainless Steel 316 L
➢ Enclosure Size – 600(H) x 600(W) x 210 (D)
16. ➢ No of circuits – 4 No. (Including Spare) 1 No
➢ Degree of Protection – Minimum IP 55 (suitable for safe area)
➢ Cable Entry – Bottom through glands
➢ Mounting – GI frame
17. Calcined Petroleum Coke Breeze 2500 kg
Cathodic Protection Power Cable – Black

Salient Features:
1. Conductor – Bare Copper 60 m
18.
2. Size – Single Core 1x70 mm2 Cu/XLPE/PVC
3. Outer sheath –Black
4. Application – Negative header cable
Cathodic Protection Power Cable – Red

19. Salient Features:
110 m
1. Conductor – Bare Copper

P2988-REP-003

No.
2. Size – Single Core 1x70 mm2 Cu/XLPE/PVC

3. Outer sheath – Red
4. Application – Positive header cable
Buried Coupon
1. Enclosure: PVC
2. Exposed metal surface: 75 mm x 75 mm
20. 1 No
3. Material – CS
4. Lead cable: 2 No. of single core 10 mm2 Cu/XLPE/PVC Red cable -
10m long tail cable for each

P2988-REP-003
BILL OF MATERIALS FOR FOREIGN LINE CROSSINGS OF 24”CS PRODUCED WATER PIPELINE
ITEM TOTAL
DESCRIPTION UNIT
NO. QUANTITY
Standard Test Post with Bond Box - Foreign line Crossing

Test Facilities, Type-5
2. Length- 2250 mm
3. Dia. – 4inch
1. 2 No.
Salient features of bond box:
3. Size: 300 x 300 x 150 (mm)
4. No. of terminals -5
1x16 mm2 XLPE/PVC Potential Monitoring Cable for Type-5

Test Post
Salient Features of Cable:

48 m
1. Conductor– Bare Copper
2. Size – Single Core 16 mm2
2. 3. Insulation – XLPE
4. Overall Sheath – PVC
Black 24 m
Red 24 m
Brazing Pins and accessories

3. 1. Material - Brass 2 No.
2. Size- M10

P2988-REP-003
BILL OF MATERIALS FOR FOREIGN LINE CROSSINGS OF 24”CS PRODUCED WATER PIPELINE
ITEM TOTAL
DESCRIPTION UNIT
NO. QUANTITY
Miscellaneous Items
1. Cable lugs-
• 16mm2 /M10 – 6 No
• 10mm2 /M10 – 6 No.
4. 1 Lot
2. Cable ties- 1 packet (small)
3. Silicone sealant – 1 tube
4. M10 GI nut bolt & washers- 10 Set
5. M6 GI nut bolt & washers for box fixing- 10 Set

P2988-REP-003
APPENDIX – B
DESIGN CALCULATIONS-PCP

P2988-REP-003
BISAT PHASE II DEVELOPMENT PROJECT
CATHODIC PROTECTION DESIGN CALCULATION SHEET (PERMANENT CP SYSTEM)
Appendix - C
Project : BISAT PHASE II DEVELOPMENT PROJECT
Company : OQ EXPLORATION & PRODUCTION LLC
Consultant : ARABIAN INDUSTRIES PROJECTS LLC
CP Vendor : AMRAN CATHODIC PROTECTION SYSTEM & SERVICES LLC
Title : PERMANENT CATHODIC PROTECTION DESIGN REPORT - 24" CS PIPELINE PW MANIFOLD TO INTERMEDIATE STATION
CURRENT DEMAND CALCULATION
Current density Current

Diameter Diameter Surface Area Current Density Max Operating Current
Sl. No. Station ID Structure ID/ Line Number External Coating Length (m) at operating Demand with 30
(Inch) (m) (m²) (mA/m²) Temp (Deg C) Demand(A)
temp mA/m²) % allowance (A)
PW M/F TO
24" CS-Pert Lined Produced
1 INTERMEDIATE M/F 3LPP 24 0.6096 4250 8139.24 0.01 60 0.02 0.16 0.21
water disposal pipeline
STATION
Total 0.21
P2988-REP-001
c. Ground Bed Design f. Rated Output Voltage Selection for CP Unit

Appendix - C
+
Project : Bisat Phase II Development Project Description Specification
i.
-
RC,N
Company : OQ Exploration & Production LLC Anode Material
RC,P
Mixed Metal Oxide / Titanium
Off plot Contractor : Arabian Industries Projects LLC Anode Length 1 m
CP Vendor : Amran Cathodic Protection Systems and Services LLC, Sultanate of Oman Anode Diameter
0.0254 m
Ground bed
Title Permanent Cathodic Protection System - Design Calculations Sheet Max. Current Density (γ A ) PL
: 2
100 A/m
Location : PW M/F TO Intermediate M/F Station for 25 years life of anode Total Resistance in Circuit,
Rated Anode Current Output (Ia) 8A per anode
1 Total Current Requirement Anode Coating Consumption Rate < 1 mg / A-yr R = RAE + RDC + RP
2
Tail Cable 1x16 mm KYNAR
Nominal Max. Current Output
50.00 A
a.
Permanent Cathodic Protection System of Transformer Rectifier Unit (I dc ) Remote Earth
Station ID Current Req. (A) Dia. of Active Column (D AC ) 0.2500 m The voltage rating of the TR unit can be determined by considering the
Length of Active Column (L AC ) 40.000 m total resistance that may occur in the circuit, which is contributed by
Current density on Active Column Anode to Earth Resistance (RAE), DC cable resistance (RC = RC,P + RC,N)
1.592 A/Sqm
PW M/F TO Intermediate M/F Station 0.21 at peak load (i.e., 50A) and Pipeline to Remote Earth Resistance (RP)
Backfill Material Calcined Petroleum Coke
Backfill Bulk Density (ρ B ) 1185 Kg/m

3
Total Current 0.21
Backfill Consumption rate, (Cr) 1 Kg/A-yr i. Anode Ground Bed to Earth Resistance
Utilization Factor (U f ) 75%
   4L  
2 Design of System R AE =  Ln    1  Ω
2 L   d  
Total Current Required to cathodically protect the Pipelines Assuming a conservative soil resistivity of 10 Ωm (denoted as ρ above)
ii. Min Number of Anode Required in the Groundbed R AE = 0.217 Ω

a. Icp = 0.210 A N = I dc
d A L A   A
No. ii. System DC Cable Resistance
Combined Resistance (Ω)

Average Length of Cable
Linear Cable Resistance
Average Resistance (Ω)

No. of Parallel Cables
= 6.3 No.
Cable Size (mm )

2
Potential Attenuation Calculations N = 7.0 No.
Description
b. Refer Appendix - B for detailed Calculations.
(Ω/m)
Run
iii. Minimum Quantity of Backfill Required
Based on dimensions of Ground Bed Anode Tail Cable 16 7 90 1.15E-03 0.01479

0.0416
W CB =  D AC
D AC L AC  L BAC  
2 2
B
Kg Header cable from
70 1 100 2.68E-04 0.02680
4 4 TR Unit to AJB
= 2326.742 Kg Header cable from
70 1 50 2.68E-04 0.01340
TR to NDB Unit
0.0174
Based on Consumption rate Drain Cable from
70 1 15 2.68E-04 0.00402
Pipeline 24" PL to NDB
W CB = I dc  t  C r
Kg
U f
= 1666.667 From the Table,
Hence, a minimum of 2500 kg of coke breeze shall be poured down the Hence, R DC = 0.0590 Ω
deep well to ensure sufficient coke breeze quantity.
P2988-REP-002

 d a L
I
a   A 2

 L




Ln



4
d
L 


− 1




>> The combined anode to earth resistance shall be around 0.217 Ω and the total
Appendix - C circuit resistance shall not exceed 0.920 Ω, as calculated earlier
iii. Total Resistance in Circuit

R = RAE + RDC + RP Ω
Since, the Pipeline to Remote Earth resistance is too low (due to the
large surface area of pipe, it can be neglected.
Hence, R = RAE + RDC Ω

= 0.276 Ω
iv. Minimum Rate Output Voltage
V = I dc . R + Back Emf
Assuming 2V for Back Emf, the Rated Output Voltage,

V = 15.82 V
Hence, a CP Unit shall be provided with a DC ouput capacity of 48V /50 A
considering the developing field area and future requirements for
upcoming facilities that may arise.
v. Maximum Allowable Circuit Resistance
R max = (V dc - Back Emf) / I dc Ω

= (48 - 2) / 50 Ω
= 0.920 Ω
vi. Input Power for TR Unit
P = kW
Schematic Sketch of a Typical Deep Well ICCP System
At a contingently assumed efficiency of 75% for a three phase

Transformer Rectifier Unit, the input power required will be,
P = 3.20 kW
Required Input VA
kVA
rating = 4.57
4 Conclusion
>> A CP TR unit capable of delivering a DC ouput of 48 V / 50 A, operating on a

suitable deep well ground bed has been designed for a life of 25 years using
Mixed Metal Oxide coated titanium anodes
>> The ground bed shall be 0.25 m in diameter with a length of 40 m for active
column, installed ensuring the first water strike, on the drilled borehole.
P2988-REP-002
APPENDIX – C
ATTENUATION PROFILE ALONG PIPELINE

P2988-REP-003
PERMANENT CATHODIC PROTECTION DESIGN REPORT- PRODUCED WATER DISPOSAL PIPELINE ARABIAN INDUSTRIES PROJECTS LLC
AMRAN JOB NO. 2988 CATHODIC PROTECTION SYSTEM - BISAT AREA DEVELOPMENT
PHASE II PROJECT

P2988-REP-003

BST Gen CRR RPT Aip 10003 10003 Permanent CP WR # 003

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Comment Resolution Sheet (CRS)

Project: BISAT PHASE II DEVELOPMENT PROJECT

CP Vendor: Amran CPSS

Page 31 of 44 It shall be for 10 mm2 size Noted and incorporated

Page 34 of 44 It shall be for 10 mm2 size Noted and incorporated

Page 35 of 44 TR unit rating shall be 48V/50A as Noted and incorporated

Header cable size shall be 70 mm2 based

Header cable size shall be 70 mm2 based

Page 37 of 44 Cable size shall be 10 mm2 Noted and incorporated

Kindly note that based on your comments,

Company Name: OQ EXPLORATION & PRODUCTION LLC

Contract Number: AB/2019-036

Work Package: WATER DISPOSAL PROJECT WP #: WR-003

Contractor Name: ARABIAN INDUSTRIES PROJECTS LLC

Vendor Name: AMRAN CATHODIC PROTECTION SYSTEMS & SERVICES

Sub Vendor Name: -

Package Title: CATHODIC PROTECTION SYSTEM BISAT AREA DEVELOPMENT PHASE II

Vendor Document P2988-REP-002

Document Title: PERMANENT CATHODIC PROTECTION DESIGN REPORT- PRODUCED

Document Number: BST-GEN-CRR-RPT-AIP-10003-10003-00 Rev. K-01

Document Status: IFR - Issued for Review Issue Date: 20-06-2022

IFI - Issued for Information

AFC/AFU - Approved for Construction /

For Contractor Use Only

REVIEW CODE AND STATUS

B CONSENT TO PROCEED SUBJECT TO COMMENTS

C CONSENT TO PROCEED WITHHELD RESUBMIT

D REVIEW NOT REQUIRED

Date: 20-09-2022 Sign:

Project : BISAT PHASE II DEVELOPMENT

ARABIAN INDUSTRIES PROJECTS

Amran Doc. # : P2988-REP-003

AMRAN CPSS ARABIAN OQ

Issued for Review

Issued for Approval

Rev. K01 Page 2 of 42 BST-GEN-CRR-RPT-AIP-10003-10003-00

1. PROJECT DETAILS ..................................................................................................... 4

Rev. K01 Page 3 of 42 BST-GEN-CRR-RPT-AIP-10003-10003-00

Client / Company : OQ Exploration & Production LLC

Off plot Contractor : Arabian Industries Projects LLC

Project : BISAT PHASE II DEVELOPMENT PROJECT

Structure : 24” Produced Water Disposal Pipeline

CP Contractor : Amran Cathodic Protection Systems & Services LLC (ACPSS)

Purchase Order : 14-220000733-01

Date of PO : 16th March 2022

Purchase Order Activity : Cathodic Protection (TCP & ICCP)

The scope of work associated with this project is listed below,

Description of Activity CP Vendor (Amran CPSS) Off Plot Contractor (Arabian)

CP Site Survey & Report √

Rev. K01 Page 4 of 42 BST-GEN-CRR-RPT-AIP-10003-10003-00

CIPS / DCVG Survey √

4. DEFINITIONS & ABBREVIATIONS

Ampere Unit of Current.

Casing A metallic pipe (normally steel) installed to contain a pipe or piping.

Cathode The structure that is to be protected by cathodic protection

Rev. K01 Page 5 of 42 BST-GEN-CRR-RPT-AIP-10003-10003-00

Criterion Standard for assessment of the effectiveness of a cathodic protection system

An electric current supplied by a device employing a power source that is external to

The part of a measured electrode potential attributable to the passage of current

An electric discharge that occurs in the atmosphere between clouds or between

Line Current The direct current flowing on a flowline

Rev. K01 Page 6 of 42 BST-GEN-CRR-RPT-AIP-10003-10003-00

3LPP 3-Layer Polypropylene