Rumaila Project

RUMAILA PROJECT
Document
0430WD-N-WM-CP00-ML-REP-0001 Rev B01
Number:
Document
CATHODIC PROTECTION DESIGN REPORT
Title:
CPS 1-5 SOURCE WATER TRUNKLINES REPLACEMENT PRE-
Project Title:
FEED
Tag No’s
(if applicable)
Contractor: Wood
Contractor
Rev
Document No:
Digitally signed by Julia Digitally signed by Digitally signed by

Peter Peter
Julia Tan Tan
Date: 2023.03.10
Peter Woodland Peter Woodland
Woodland Date: 2023.03.10
13:16:06 Z Woodland Date: 2023.03.10
10:36:35 Z 10:37:09 Z
B01 Approved for Use 10-Mar-2023 JT PW/CCU PW
A01 Issued for Review 17-Nov-2022 JT PW PW
Rev. Revision Description Date Originated Reviewed Approved

CPS 1-5 Source Water Trunklines Replacement Pre-FEED
Cathodic Protection Design Report
Change Log
Rev Section Change Description
A01 All First issue
B01 All Reference list fully updated
Project description text updated
Pipeline route map references updated
Pipeline lengths updated
CP calculations fully updated
CPS buried piping segments added
MTO updated
Document Holds
Hold Brief Description of HOLD Location of HOLD
No.
1
2
3
4
0430WD-N-WM-CP00-ML-REP-0001 Rev B01 Page 2 of 33

Table of Contents
1 Executive Summary ....................................................................................... 8
2 Introduction .................................................................................................... 9
2.1 Project Description ................................................................................................... 9
2.2 Process Schematic ................................................................................................. 10
3 Preliminary Pipeline Routing ....................................................................... 11
3.1 General ................................................................................................................... 11
3.2 Route Maps ............................................................................................................ 11
3.3 Routing – Pre-FEED phase .................................................................................... 11
4 Material Selection and Corrosion Control .................................................. 12
4.1 External Corrosion .................................................................................................. 12
4.1.1 Protective Coatings ........................................................................................................... 12
4.1.2 Cathodic Protection ........................................................................................................... 12
4.1.3 CP System Options ........................................................................................................... 12
4.1.4 Independent ICCP ............................................................................................................. 14
4.1.5 Design Parameters and Assumptions ............................................................................... 16
5 ICCP System Design .................................................................................... 18
5.1 General ................................................................................................................... 18
5.2 Soil Resistivity ........................................................................................................ 18
5.3 Existing CP Installations ......................................................................................... 18
5.3.1 Surface Area and Design Current Demand ...................................................................... 18
5.3.2 Design Protected Potential................................................................................................ 20
5.3.3 Pipeline Attenuation Calculations...................................................................................... 20
5.3.4 Design Life ........................................................................................................................ 22
5.4 ICCP Groundbed Configurations ............................................................................ 22
5.4.1 Semi-deepwell Groundbed Resistance Calculation .......................................................... 22
5.5 Temporary Protection ............................................................................................. 24
5.6 CP Ancillaries ......................................................................................................... 25
5.6.1 Test Facilities .................................................................................................................... 25
5.6.2 Cable-to-Pipe Connections ............................................................................................... 26
5.6.3 Anode and Cathode Distribution Boxes ............................................................................ 26
5.6.4 Road Crossings ................................................................................................................. 26
5.6.5 Pipeline Crossings ............................................................................................................ 27
5.6.6 AC Mitigation ..................................................................................................................... 27
5.6.7 Electrical Isolation ............................................................................................................. 27
5.6.8 Transformer Rectifier Unit (TRU) Rated Output................................................................ 27
5.6.9 CPS Piping Underground Sections ................................................................................... 29
5.6.10 Anchor Blocks ................................................................................................................... 30
5.6.11 Protection Levels and Over-Protection ............................................................................. 30
5.6.12 Onshore Coating Integrity Assessment ............................................................................ 31
6 Preliminary ICCP MTO ................................................................................. 32

Acronyms and Abbreviations
Acronym / Abbreviation Description

3LPE 3-Layer Polyethylene
AC Alternating Current
ASTM American Society for Testing and Materials
CA Corrosion Allowance
CBF Coating Breakdown Factor
CD Current Density
CIP(S) Close Interval Potential (Survey)
CP Cathodic Protection
CPS Cluster Pumping Station
CU/CUSO4 Copper/Copper Sulphate (Reference electrode)
DC Direct Current
DCVG Direct Current Voltage Gradient
FBE Fusion Bonded Epoxy
FEED Front End Engineering Design
FJC Field Joint Coating
FM Field Manifold
GACP Galvanic Anode Cathodic Protection
GIS Geographic Information Systems
GPS Global Positioning System
HMWPE High Molecular Weight Polyethylene
HV High Voltage
ICCP Impressed Current Cathodic Protection
ID Inside Diameter
IJTP Isolation Joint Test Post
JB Junction Box
MAWT Minimum Allowable Wall Thickness
MIJ Monolithic Isolation Joint
MMO Mixed Metal Oxide
MTO Material Take Off
NACE National Association of Corrosion Engineers
NORSOK Norwegian Standards
NPS Nominal Pipe size
OD Outside Diameter
(O)HV (Overhead) High Voltage

Acronym / Abbreviation Description

ORA Operational Risk Assessment
OVP Over Voltage Protection
PCR Polarisation Cell Replacement
PVC Polyvinyl Chloride
ROO Rumaila Operating Organization
ROW Right of Way
SA Surface Area
SCADA Supervisory Control and Data Acquisition
STP Standard Test Post
TCP Temporary Cathodic Protection
TP Test Post
TRU Transformer Rectifier Unit
VPN Vickers Pyramid Number
WI Water Injection
WT Wall Thickness
XLPE Cross Linked Polyethylene
XTP Crossing Test Post

References Summary
Ref Document Number Description
1. 0000RO-N-WM-CP00-OP-SOR-0002 STATEMENT OF REQUIREMENTS:
(9-Sep-22) REPLACEMENT OF TRUNKLINES FROM CPS1-
5 STATIONS TO MISHRIF FIELD MANIFOLDS
(FM1 TO FM10)
2. 0430WD-N-WM-CP00-EM-BOD-0001 CPS 1 - 5 Source Water Trunklines Replacement
Pre-FEED Basis of Design
3. 0430WD-N-WM-CP00-PL-LST-0001 CPS 1 - 5 Source Water Trunklines Replacement
Pre-FEED Pipeline Crossing Schedule
4. 0430WD-N-WM-CP00-PR-REP-0003 CPS 1 - 5 Source Water Trunklines Replacement
Pre-FEED Flow Assurance Report
5. 0430WD-N-WM-CP00-PI-MTO-0001 CPS 1 - 5 Source Water Trunklines Replacement
Pre-FEED Piping Preliminary MTO
6. 0430WD-N-WM-CP01-PL-DAG-0001- CPS 1 - 5 Source Water Trunklines Replacement
001 Pre-FEED CPS1 to FM5 Pipeline Routing
Drawing
Drawing
Drawing
Drawing
001 Pre-FEED CPS4 TO FM6 Pipeline Routing
Drawing
Drawing
Drawing
Drawing
Drawing
Drawing
16. BS EN 12954 Cathodic Protection of Buried or immersed
Metallic Structures – General Principles and
Application for Pipelines

Ref Document Number Description

17. BS EN ISO 15589-1 Petroleum, petrochemical and natural gas
industries – Cathodic protection of pipeline
systems Part 1: On-land pipelines
18. ASME B31.4 Pipeline Transportation System for Liquids and
Slurries.
19. 0000RP-C-G0-G000-PL-SPC-0012 SPECIFICATION FOR PIPELINE EXTERNAL
POLYURETHANE COATING OF BURIED
INDUCTION BENDS AND OTHER PIPE
SPECIALS
20. ISO 21809-1 Petroleum and natural gas industries — External
coatings for buried or submerged pipelines used
in pipeline transportation systems — Part 1:
Polyolefin coatings (3-layer PE and 3-layer PP)
21. 0000RP-C-G0-G000-PL-SPC-0014 SPECIFICATION FOR PIPELINE 3-LAYER
POLYETHYLENE EXTERNAL COATING FOR
LINE PIPE
22. ISO 21809-3 Petroleum and natural gas industries — External
coatings for buried or submerged pipelines used
in pipeline transportation systems — Part 3: Field
joint coatings
23. 0000RP-C-G0-G000-PL-SPC-0015 Specification for Pipeline External Field Joint
Coating
24. NACE SP0169 Control of External Corrosion on Underground or
Submerged Metallic Pipeline Systems
25. NACE SP0286 The Electrical Isolation of Cathodically Protected
Pipelines
26. NORSOK M501 Surface preparation and protective coating
27. NORSOK M503 Cathodic Protection
28. ORA: WF-CPS-006/007 ORA & Emerging Risk Notification: Low Wall
Thickness - WT piping in #1500 service at CPS
29. 102391FG-N-FL-CP00-PI-REP-0001 CTRK001 - GEOTECHNICAL INTERPRETATIVE
REPORT CPS-SW TRUNKLINE REPLACEMENT
- PHASE-1
30. 102391FG-N-FL-CP00-PI-REP-0002 CTRK002 - GEOTECHNICAL INTERPRETATIVE
REPORT CPS-SW TRUNKLINE REPLACEMENT
– PHASE 2

1 Executive Summary
For buried steel pipelines, protective coatings, of whatever material or extent, are the primary barrier to
corrosion; with temporary GACP and permanent ICCP providing backup protection to the pipeline at
points where the coating is imperfect (i.e. at holidays) or becomes damaged. This is particularly
important in saline and/or high chloride soil environments.
The replacement trunklines will nominally be provided with 3-Layer Polyethylene (3LPE) external
coating (note that at Basra Railway and MOD Canal Crossing, the recommendation is to use a
Polyurethane coating), an internal FBE coating and permanent ICCP systems installed at each CPS
using semi-deepwell vertical groundbeds.
Each groundbed will consist of six (6) vertically installed MMO anodes on a single string in a borehole
20 metres deep, with an active length of approximately 12 metres. This configuration will be refined as
necessary during later Detail Design. Based on a pessimistic groundbed site soil resistivity of 2,500
Ωcm, groundbed and circuit resistance is calculated to be 1.72 ohms.
Given the high chloride and sulphate content and attendant low resistivity along the trunkline corridors,
temporary GACP is considered necessary to protect the trunklines for a maximum two-year period prior
to energizing a permanent ICCP system.
In accordance with ISO 15589-1 [Ref 17] the design current density for an onshore pipeline with this
coating type for the required system life of 25 years is conservatively taken as 0.2 mA/m2 and for a 2-
year life TCP system is taken as 0.02 mA/m2. This specification factors Coating Breakdown Factor
(CBF) into a single, overall current density figure and is the baseline for this project.
Temporary CP and test facilities will be provided in accordance with ISO 15589-1.

2 Introduction
2.1 Project Description
In the Rumaila fields, source water is injected via Cluster Pumping Stations into two different reservoirs:
Mishrif and Main Pay. At each CPS station, injection water is routed from the CPS high pressure pumps
to Main Pay and Mishrif water injection manifolds. Main Pay manifolds are located within the CPS fence
line and Mishrif manifolds are in the field, outside the CPS. Mishrif manifolds are connected to the CPS
via a trunkline. Water is distributed from the manifolds via flowlines to reinjection wells for enhanced oil
recovery. Refer to Figure 2.1 for CPS WI pump schematic.
Each CPS station has Four (4) fixed speed source water injection pumps which take suction from a
common supply header and discharge to Main Pay and Mishrif manifolds. In CPS1 to CPS4, two (2) of
four (4) CPS pumps are dedicated to Main Pay manifold and other two (2) pumps discharge are
connected both Main Pay and Mishrif manifolds. In CPS5, only one (1) pump is dedicated to Main Pay
manifold and remaining three (3) CPS pumps are connected to both Main Pay and Mishrif manifolds.
Mishrif production plays a critical role in maintaining field production and in time, with the decline of the
Main Pay reservoir, will become the principle producing reservoir. Analysis of operating data has
confirmed high pressure drop in the trunklines which needs to be debottlenecked for increase flow to
mantain arrival pressure at the field manifolds. The replacement trunklines should therefore not just be
a like-for-like replacement. The selected sizes need to debottleneck current and future injection
requirements.
The existing trunklines supply high pressure water in the range of 165 - 200 bar (with design pressure
of 233 barg) from the CPS pumps to the Mishrif field manifolds. They also suffer from corrosion/ erosion
problems. Inspections carried out at CPS1 and CPS2 have identified wall thickness reduction below the
MAWT. There is also uncertainty over the specification of the pipeline material used in the construction
of the trunklines; many have been built to #900 rather than 1500#. These trunklines have been identified
as having a high risk of catastrophic failure with consequential risk of fatalities to personnel close to the
rupture point. The failure of these lines will also lead to a significant loss of injection capabilities and
consequently substantial production losses. An Emerging Risk Notification has been raised with an
ORA in place as a short-term safeguard to continue the operation of these sections of pipes [Ref. 28].
Thus, replacement trunklines are required to eliminate the risk of fatalities to personnel, reduce the
water injection losses, achieve wells target injection rates, and improve the integrity of the pipeline.
The scope of the study is limited to the replacement of the trunklines only. Existing CPS facilities, Main
Pay manifolds, Mishrif manifolds, flowlines and injection wells are all excluded from the scope; if
mentioned it is only to provide a complete description of the process. Ten source water trunklines are
to be replaced in two orders of priority. The priority order is based on the severity of corrosion in existing
trunklines.

Table 2.1: Source Water Trunklines to be Replaced

No. Priority CPS facility Field Manifold
1 CPS1 FM7
2 CPS2 FM9
3 1 CPS3 FM10
4 CPS4 FM8
5 CPS5 FM4
6 CPS1 FM5
7 CPS4 FM6
8 2 CPS5 FM1
9 CPS5 FM2
10 CPS5 FM3
2.2 Process Schematic

Refer to Figure 2.1 for typical process schematic.
Figure 2.1: Process Schematic

The scope of this project is limited to the replacement of the trunklines only, including provision of
connections for temporary pigging. The existing piping within both the CPS facility and the Field
Manifold facility are excluded from this scope. Any debottlenecking, modifications or upgrades required
within these facilities are to be executed via separate projects.
Replacement pipeline material shall be carbon steel with internal Fusion Bonded Epoxy (FBE) lining.
All buried sections shall have external 3LPE coating to mitigate external corrosion.

3 Preliminary Pipeline Routing

3.1 General
The replacement trunklines shall be buried, as implemented for other recent high pressure source
water/produced water trunkline projects. At this stage of the project, routing has been developed based
on GIS Data, and topographical survey capture in routing maps [Ref 6 and Refs 7 to 15 inclusive]. A
reconnaissance of the proposed pipeline routes shall be performed during the next phase of the project
to confirm there is adequate space to construct the new trunkline parallel to the existing one whilst still
in operation; and that there are no changes to the conditions recorded at the moment (i.e, new pipelines,
OHL, etc).
3.2 Route Maps
Route maps have been developed for all ten trunklines. All routes have been reviewed by ROO Land
Management Team. Wood incorporated all comments prior to issue. Preliminary routes are loaded in
GIS. The table below shows the route map document numbers.
Table 3.1: Preliminary Route Map Information
Trunkline Route Map Document number
CPS1-FM5 0430WD-N-WM-CP01-PL-DAG-0001-001
3.3 Routing – Pre-FEED phase

 CPS1-FM7 and CPS4-FM8 trunkline routes cross both the Basra Canal and Basra railway [Ref
7 and 11]. According to the BOD [Ref 2], railway and canal crossings will not be cased, instead
being provided with a polyurethane coating to ensure pipeline integrity. For CP design
purposes, such crossings are thus considered to be uncased;
 There are integrity issues with existing trunklines and an assessment of the risk of installing
replacement trunklines alongside the existing trunklines is necessary to confirm if 10m
separation is adequate. From a CP perspective, each new trunkline will be treated as an
independent entity and once final separation and existence or otherwise of operational CP on
the existing line is assessed, interference mitigation measures will be considered. For
preliminary design purposes, no such interference is assumed;
 Confirm construction method for crossing high pressure water injection lines and gas lines
e.g. open cut vs trenchless. Each such crossing will need to be assess with regards to
separation, existing CP and possible interference effects. See Section 5.6.5. For preliminary
design purposes, an assumed number of pipeline crossings is taken for each trunkline and
provision of a bonding/interference testing box is made for these. No other mitigation
provision is currently considered.

4 Material Selection and Corrosion Control
4.1 External Corrosion

4.1.1 Protective Coatings
4.1.1.1 General
For buried steel pipelines, protective coatings, of whatever material or extent, are the primary barrier to
corrosion; with temporary GACP and permanent ICCP providing backup protection to the pipeline at
points where the coating is imperfect (i.e. at holidays) or becomes damaged. This is particularly
important in saline and/or high chloride soil environments
The current state of pipeline coating technology cannot guarantee a pinhole defect free coating. CP is
provided to protect the pipeline from external corrosion damage at these points. As coatings age, they
become less effective and where this occurs and/or the coating is physically damaged, CP will take
over a greater portion of the protection against corrosion.
4.1.1.2 Onshore Pipelines
In principle, the main onshore pipeline will nominally be provided with the following external coating
regime, or similar:
 3-Layer Polyethylene (3LPE)
Note that HDD sections beneath the railway and canal will be provided with a polyurethane coating in
accordance with 0000RP-C-G0-G000-PL-SPC-0012 [Ref 19].
All factory applied coatings shall be supplied, applied and factory-tested in accordance with 0000RP-
C-G0-G000-PL-SPC-0014 [Ref 21] and ISO 21809-1 [Ref 20].
Whilst not directly impacting provision of CP to the pipeline external surfaces, it should be noted that all
source water pipelines under this scope also have an internal FBE lining to provide additional protection
against the highly corrosive source water.
4.1.1.3 Field Joint Coating
Field Joint Coating (FJC) shall be required to be fully compatible with the proposed coating and pipeline
construction methodology in accordance with 0000RP-C-G0-G000-PL-SPC-0015 [Ref 23] and ISO
21809-3 [Ref 22].
4.1.2 Cathodic Protection
Application of Cathodic Protection to onshore buried pipelines is a standard practice, given that pin-
hole defect free coatings are currently viewed as technologically impossible to achieve and that coatings
degrade with time. Correctly applied ICCP is a proven supplement to points of weakness in carbon steel
pipeline coating systems in a variety of environments.
For onshore pipelines and other infrastructure in direct contact with soil, even where the soil resistivity
may be considerably higher that the nominally quoted ‘slightly corrosive’ range, CP is applied to ensure
and maintain integrity to meet legislative, health and safety, containment and environmental
requirements.
4.1.3 CP System Options
4.1.3.1 GACP
A galvanic (sacrificial) anode cathodic protection (GACP) system uses a more electro-negative metal
and, due to the potential difference, provides a current to a steel pipeline or structure to which it is
electrically connected, thereby depressing its natural potential to a point whereby corrosion is
essentially no longer able to occur. During this process the more reactive material is consumed, thus
‘sacrificing’ itself to protect the parent metal.

Such a system requires no external power source but is reliant upon a low environmental resistivity and
has a limited and finite current capability and throwing power (the distance protective current can be
spread).
As noted above, GACP systems have the benefit of being totally independent and they are not reliant
upon an external power supply. However, once designed, their capacity and output is fixed; and this
will naturally decrease with increasing age, as anodes deplete and coatings breakdown. In addition,
should site circumstances change, a GACP system’s output and/or longevity cannot be increased
without retrofitting additional anodes.
A large current demand and/or long system life necessitates a large volume and weight of anode
material, which can become impractical to install. GACP systems therefore tend to be used on short
onshore pipelines, locations where a suitably reliable mains power supply is unavailable, small subsea
structures, very large structures where anode weight can be easily distributed or offshore pipelines and
flowlines.
For this project, ICCP has been stipulated [Ref 1, 2] and GACP is therefore considered only for provision
of temporary protection during construction, not for permanent CP. Magnesium alloy anodes are
specified for temporary CP prior to energising of the permanent ICCP system and will be utilised for this
project. Packaged Zinc anodes or Zinc Ribbon will be used for stray current dissipation or as earthing
electrodes.
4.1.3.2 ICCP
An impressed current cathodic protection system (ICCP) achieves the same ultimate result as GACP
but uses a generally inert anode material that is driven by an external DC supply (often a transformer
rectifier), thereby ‘impressing’ a current upon the parent metal. Such a system can be effectively used
in a much higher soil resistivity and can be designed to provide a large current output that is adjustable
and/or controllable and, with a much larger driving voltage, greater throwing power.
ICCP systems can be designed to cater for high current demands and/or long system life requirements
for onshore installations and can be automatically controlled to cater for changing soil/groundbed
conditions, such as water table level and deterioration of pipeline coating integrity with time. This makes
such systems very flexible and able to cater for changing circumstances. However, ICCP systems rely
on a constantly available external power supply and if, for whatever reason, that fails, CP is entirely lost
(albeit a well-coated pipeline, particularly onshore, may take several days to depolarise).
Individual ICCP anodes can provide a much higher current output and, for a given current output, are
much lighter than equivalent GACP anodes.
Even when utilising standard construction materials, there is a risk of overprotection with ICCP that
could result in dis-bonding of the pipeline coating and, dependent on the overall system output, a
likelihood of interference on other adjacent structures or pipelines.
Pipelines with ICCP systems installed can be fitted with fixed reference electrodes to monitor potentials.
These can be used to maintain a fixed minimum protection potential that will be adjusted as soil
conditions change and/or the pipeline coating deteriorates.
In accordance with the Statement of Requirements [Ref 1], ICCP is the selected permanent CP system
for this project.
Although the replacement trunklines will be laid approximately parallel to and close to the existing
trunklines, each will be treated as a separate, independent entity with respect to provision of ICCP, on
the premise that any existing CP system(s) will be de-energised. This will need to be confirmed during
Detail Design.

4.1.4 Independent ICCP

It will be necessary to provide independent ICCP systems to provide protection to the various trunklines
connecting the CPS to their associated FM. Given the locality and relative positions of the CPS
locations, it is realistically viable to place TRUs rated for the same capacity as hubs for distribution of
current to various arms of the network.
ICCP groundbed options that have been considered for this project include:
 Horizontal – horizontal anodes
 Horizontal – vertical anode array
 Semi-deepwell
 Deepwell
 Wire anode
The choice of installation configuration is entirely reliant on the available space, environmental (soil)
resistivity, lie-of-the land, power supply and accessibility for groundbeds, TRU and test facilities and
availability of suitable equipment and machinery.
It is understood that the water table is high, meaning that any anode installation, particularly deepwell,
will need to be pumped out during installation to prevent trench/borehole collapse. A vertical groundbed
would need to be installed in metallic casings, which would form a part of the groundbed and corrode
with time. These factors will have both time and cost implications but remain valid as options.
4.1.4.1 Horizontal groundbed – horizontal anodes
A horizontal groundbed, with multiple horizontally-aligned anodes, is nominally the easiest, simplest
and cheapest form of remote groundbed to design and install, as it relies on a simple trench within
which groundbed materials (anodes and backfill) are installed. However, such a groundbed needs to
be a minimum distance of 100-150 metres from the pipeline(s) it is to protect (‘remote’) and, dependent
on soil resistivity, its length may need to be considerable in order to achieve a workable circuit
resistance. However, the congestion around the CPS sites and the number of pipelines running in
parallel corridors preclude this solution. A horizontal groundbed, with multiple horizontally-aligned
anodes is thus not considered any further for this application.
4.1.4.2 Horizontal Groundbed – vertical anode array
An alternative horizontal groundbed, with multiple vertically-aligned anodes, is an option where soil
resistivity is high and there is insufficient space to fit a standard long, horizontal groundbed. Use of
increasing numbers of vertical anodes in parallel can reduce the groundbed resistance, but with the
penalty of needing multiple shallow vertical boreholes in which to install the anodes. However, such a
groundbed also needs to be a minimum distance of 100-150 metres from the pipeline it is to protect
(‘remote’) and, dependent on soil resistivity, its length may still need to be considerable in order to
achieve a workable circuit resistance.
However, the congestion around the CPS sites and the number of pipelines running in parallel corridors
preclude this solution. A horizontal groundbed, with multiple vertically-aligned anodes is thus not
considered any further for this application.
4.1.4.3 Deepwell Groundbed
A deepwell installation requires a footprint only large enough to fit the appropriate drilling rig and header
facilities and is thus ideal in restricted spaces. The additional benefit is that, depending on depth and
location, it is not always necessary to be as physically remote as horizontal groundbeds, as the
separation can be achieved vertically as well as horizontally.
A vertical installation also allows anodes to be placed well below the lowest level of the pipeline, thus
permitting current to spread through a congested area without other pipelines or utilities blocking the
current path.

In areas with soft soil or high water table it is essential that the borehole be cased to prevent collapse
and, dependent on total depth, this would usually be with a metallic casing deeper down and non-
metallic casing closer to the surface. It is possible to utilise drilling rigs that can install and recover
casings during installation, but in areas with a high water table such as for this project, leaving the
casing in place is a better option because it becomes part of the groundbed and eventually corrodes
away.
Anode strings, or individual anodes (sometimes bare, sometimes themselves cased), are lowered into
the borehole and the borehole is backfilled with coke breeze (either poured or liquefied and pumped)
as each anode is installed.
Such groundbeds can be conveniently designated as ‘Semi-deep’ or ‘Deep’.
4.1.4.4 Semi-deep
If the resistivity profile indicates that a ‘shallow’ vertical installation will achieve the required circuit
resistance, then a semi-deep installation can be used; thus avoiding the specialist equipment necessary
for a deeper borehole. This can be for a single anode at, say 4-metre depth, and up to 10 anodes in a
30-metre deep borehole.
With the high water table and available site soil resistivity data, the resistivity profile permits the use of
a 20-30 metre deep borehole; placing the anodes well below pipeline invert level and thus enabling a
good spread of current to the selected portion of the flowline network.
Given the CPS and trunkline network configuration, semi-deepwell groundbeds up to 30 metres deep
are viable for independent provision of ICCP, dependent on actual site soil resistivity profile.
4.1.4.5 Deep
Dependent on the location and geology, a deepwell installation can be upwards of 100-200 metres
deep, with multiple anodes in the lower, active portion and a considerable upper inactive length with no
anodes. Boreholes to this depth permit the groundbed to be placed geographically closer to the
pipeline(s) to be protected, since they are already remote as a result of their depth and they can
distribute current for considerable distances.
The downside is that an extensive drilling operation and attendant specialist equipment is required and
for this application is unlikely to be necessary. Given the relatively short pipeline lengths and resultant
low current demand; coupled with low resistivity, an extensive ‘deepwell’ installation will not be
considered further for this application.
4.1.4.6 Wire anode
Continuous wire anodes are run closely alongside the pipeline(s) to be protected and therefore need
no additional space; and can generally be fitted after pipeline installation but prior to back filling. This
combination of operations would not necessarily be carried out in a single day. Wire anodes can provide
an extremely even and easily controllable current output (and thus pipeline potential), in a very local
area; thus minimising interference risk and over-protection of CP-sensitive pipeline materials.
Wire anodes are particularly useful in congested areas, where they can be conveniently positioned
between parallel pipelines in order to provide even current distribution to both without risk of shielding.
Wire anodes are thus ideal for pipelines where low, even current is required and/or where minute control
of protective potential is required.
Given that this project will incorporate individual flowlines from each CPS, wire anodes will not be
considered further for this project.
4.1.4.7 Selected ICCP Groundbed Solution
Given the CPS and trunkline network configuration, semi-deepwell groundbeds are selected for
provision of ICCP for this application.

Full design of cathodic protection systems will require a ground survey to determine soil resistivity vs
depth.
4.1.5 Design Parameters and Assumptions
4.1.5.1 General
Design parameters used in the cathodic protection design have been extracted from the Statement of
Requirements [Ref 1] unless stated otherwise and are reproduced herein for information.
The CP system for the onshore pipelines shall consist of multiple ICCP installations, with supplementary
packaged Magnesium anodes for temporary protection during construction and prior to energisation of
the ICCP systems.
The design code requirement for cathodic protection of the trunklines is ISO 15589-1 [Ref 17].
4.1.5.2 Design Life
In accordance with the BOD [Ref 2]., the design life of the system is 25 years.
4.1.5.3 Pipeline Design Data
Materials selection and internal corrosion analysis is still ongoing although individual trunkline diameters
have been confirmed as being 24” NPS and wall thickness is confirmed as 30.96mm with a nominal
3mm CA .
For each pipeline the nominal WT, excluding corrosion allowance, is assumed for attenuation purposes.
4.1.5.4 Temperature Data
The maximum operating temperature is taken to be 60°C.
4.1.5.5 Soil Resistivity
Sample soil resistivity data is available from basic surveys conducted by FUGRO and reported in
Geotechnical Interpretative Reports [Ref 29, 30]. Two electrical resistivity tests were performed using
the 4 pin Wenner vertical electrical sounding method and the apparent resistivities were between 0.4
Ωm to 0.9 Ωm, which corresponds to severely corrosive soils. This is in line with the significant sulphate
and chloride contents also reported.
Mean pH value is 8.3, meaning that the soils are classified as moderately alkaline.
Based on this data and the fact that the Rumaila field has a high water table; for preliminary design
purposes, an assumed pessimistic maximum groundbed resistivity value of 2,500 Ωcm is assumed for
CP design purposes. This will need to be confirmed by a dedicated soil resistivity survey.
4.1.5.6 Burial Status
All flowlines within the scope will be totally buried for their entire length, rising above ground only at
each end, where each will be electrically isolated using Monolithic Isolation Joints (MIJ).
4.1.5.7 Crossings
The preliminary routing of the trunklines between CPS and FM locations has highlighted that there are
a variety of crossings of roads, canals and railways. As routings become finalised during Detail Design,
all potential crossings and any required adverse potential mitigation and/or cross-bonding will need to
be taken into consideration.
Crossings have been identified and tabulated based on trunkline routing maps [Ref 6 and Refs 7 to 15
inclusive] and the Pipeline Crossing Schedule [Ref 3] and for this preliminary Pre-FEED design, an
initial allowance for additional testposts, bonding boxes, cabling and zinc anodes for possible mitigation
purposes has been made.

4.1.5.8 Assumptions
The following assumptions have been made in processing the initial CP calculations:
1) Resistivity data is limited and the lack of definitive location-specific data makes confirmation of
a specific groundbed configuration difficult; but for preliminary design purposes a maximum
2500 Ωcm is pessimistically assumed. This will be refined during later Detail Design once
resistivity data becomes available or a full resistivity survey has been conducted. Vertical semi
deep groundbeds have been selected as the optimal solution for this application on the premise
that ROO has approved drilling contractors;
2) It is assumed that access to plant power supply can be made available at all locations and
TRUs for that location will be configured to utilise the available voltage and frequency. It is
further assumed that in the first instance a domestic single phase 220-240VAC supply can be
accessed. An assessment of available power supplies at each CPS will need to be made before
TRU input supply can be confirmed;
3) Given the anticipated high chloride content soil, allowance will be made for a magnesium
anode-based Temporary CP (TCP) system to provide protection during pipe laying operations
and prior to energization of the permanent ICCP system;
4) Onshore pipeline coating is taken as a minimum of 3mm factory-applied 3LPE, with
polyurethane being selected for railway and canal crossings;
5) Current density for onshore buried pipelines has been conservatively taken as 0.2 mA/m²
following ISO 15589-1 [Ref 17] recommendation;
6) A monolithic isolation joint (MIJ) will be fitted at each pipeline soil entry/exit point, between
which the onshore ICCP system will provide protection;
7) The average pipe joint length is taken as 12.2m.

5 ICCP System Design

5.1 General
The trunklines to be provided with permanent cathodic protection are shown in Table 2.1, above.
The baseline design uses the applicable design standards and codes in conjunction with gathered site
data, which in this case is very limited. In essence, five factors must be considered at this stage:
 Soil resistivity
 Existing CP installations
 Surface area and design current demand
 Design protective potential and attenuation along the pipeline
 Design Life
5.2 Soil Resistivity

Sample soil resistivity data is available from basic surveys conducted by FUGRO and reported in
Geotechnical Interpretative Reports [Ref 29, 30]. See Section 4.1.5.5 above.
Based on this data and the fact that the Rumaila field has a high water table; for preliminary design
purposes, an assumed pessimistic maximum groundbed resistivity value of 2,500 Ωcm is assumed for
CP design purposes.
5.3 Existing CP Installations
Consideration will need to be given to the presence of other local pipeline CP systems during future
Detail Design with regards to existing CP system(s) fitted, groundbed location(s) and configuration(s),
proximity, possible sharing of facilities, possible interference effects and possible requirement for cross
bonding.
This is of particular importance when replacement trunklines are to be laid in parallel to existing
trunklines assumed to have operating CP systems. For Pre-FEED design purposes, each new trunkline
will be considered as an entirely separate entity.
5.3.1 Surface Area and Design Current Demand
The pipeline will be externally coated with 3LPE. Surface area is calculated for the entire buried section
of each trunkline between isolation joints, to be fitted at each CPS and FM.
In accordance with ISO 15589-1 [Ref 17] the design current density for an onshore pipeline with this
coating type for the required system life of 25 years is conservatively taken as 0.2 mA/m2 and for a 2-
year life TCP system is taken as 0.02 mA/m2.
This specification factors Coating Breakdown Factor (CBF) into a single, overall current density figure
and is the baseline for this project.
Current requirement calculations for each section of pipeline are shown in Table 5.1 and Table 5.2,
overleaf, for both permanent and temporary CP systems.

Table 5.1: Source Water Trunkline Surface Area and ICCP Current Demand
(1) (2) (3) (4) (5) (6) (7)
Priority CPS FM OD OD WT Length SA Coating CD Current
2 2
(") (m) (mm) (m) (m ) (mA/m ) (A)
2 CPS1 FM5 24 0.6096 27.96 4258 8970.0 3LPE 0.2 1.97
1 CPS1 FM7 24 0.6096 27.96 3832 8072.6 3LPE 0.2 1.78
1 CPS1 FM7 24 0.6096 27.96 560 1179.7 PU 0.3 0.39
1 CPS2 FM9 24 0.6096 27.96 1781 3751.9 3LPE 0.2 0.83
1 CPS3 FM10 24 0.6096 27.96 2279 4801.0 3LPE 0.2 1.06
2 CPS4 FM6 24 0.6096 27.96 1192 2511.1 3LPE 0.2 0.55
1 CPS4 FM8 24 0.6096 27.96 3755 7910.4 3LPE 0.2 1.74
1 CPS4 FM8 24 0.6096 27.96 550 1158.6 PU 0.3 0.38
2 CPS5 FM1 24 0.6096 27.96 4267 8989.0 3LPE 0.2 1.98
2 CPS5 FM2 24 0.6096 27.96 5053 10644.8 3LPE 0.2 2.34
2 CPS5 FM3 24 0.6096 27.96 4034 8498.1 3LPE 0.2 1.87
1 CPS5 FM4 24 0.6096 27.96 5898 12424.9 3LPE 0.2 2.73
(1)
OD values confirmed
(2)
Quoted WT of 30.96mm less 3mm CA
(3) Quantities in accordance with pipelines MTO [Ref 5] (without any margin/contingency). These lengths do not
include the piping from pig trap areas to/from CPS/FM, which is above‐ground piping (ASME B31.3)
(4)
All surface areas include 10% contingency
(5)
Bulk trunkline coating is 3LPE, HDD crossings have PU coating
(6)
Most conservative CD quoted for 3LPE in ISO 15589‐1
(7)
Includes 10% allowance
Table 5.2: Source Water Trunkline Surface Area and Temporary GACP Current Demand
(1) (2) (3) (4) (5) (10) (11)
Priority CPS FM OD OD WT Length SA Coating CD Current
2 2
(") (m) (mm) (m) (m ) (mA/m ) (mA)
2 CPS1 FM5 24 0.6096 27.96 4258 8970.0 3LPE 0.02 197.34
1 CPS1 FM7 24 0.6096 27.96 3832 8072.6 3LPE 0.02 177.60
1 CPS1 FM7 24 0.6096 27.96 560 1179.7 PU 0.03 38.93
1 CPS2 FM9 24 0.6096 27.96 1781 3751.9 3LPE 0.02 82.54
1 CPS3 FM10 24 0.6096 27.96 2279 4801.0 3LPE 0.02 105.62
2 CPS4 FM6 24 0.6096 27.96 1192 2511.1 3LPE 0.02 55.24
1 CPS4 FM8 24 0.6096 27.96 3755 7910.4 3LPE 0.02 174.03
1 CPS4 FM8 24 0.6096 27.96 550 1158.6 PU 0.03 38.23
2 CPS5 FM1 24 0.6096 27.96 4267 8989.0 3LPE 0.02 197.76
2 CPS5 FM2 24 0.6096 27.96 5053 10644.8 3LPE 0.02 234.19
2 CPS5 FM3 24 0.6096 27.96 4034 8498.1 3LPE 0.02 186.96
1 CPS5 FM4 24 0.6096 27.96 5898 12424.9 3LPE 0.02 273.35
(1)
OD values confirmed
(2)
(4)
(5)
(10)
Conservative CD for TCP quoted for 3LPE in ISO 15589‐1
(11)

5.3.2 Design Protected Potential

In accordance with industry norms requirements, a design protected potential that is at least as negative
as -0.85 V vs. Cu/CuSO4 reference electrode is normally considered for buried onshore piping. In
accordance with ISO 15589-1 [Ref 17], a minimum protected potential of -0.95 V vs. Cu/CuSO4 shall
be taken for piping whose internal temperature exceeds 60°C and this more onerous criterion shall be
selected for this application due to previous corrosion history. These criteria are industry standards
utilised to determine the effectiveness of the cathodic protection systems and the level of protection
achieved.
The design protection potential shall be considered as the polarised potential to which the buried
flowlines are raised due to the CP system. It should be noted that the operating energised potential
would be somewhat more negative than the operating polarised potential, due to the intrinsic error
associated with the measurement of the energised potential across the circuit, which always includes a
volt drop error due to the flow of system current around the measuring circuit. In practical terms, the
energised potential is commonly described as the ‘on’ potential, while the polarised potential is closely
approximated as the ‘instantaneous off’ potential.
Practical assessment of the polarised potential would be achieved by the measurement of
‘instantaneous off’ potentials, using the system’s permanent reference electrodes if such were to be
fitted or, as in this application, using a portable reference electrode; and polarisation coupons (technical
details of which are to be provided in project CP Materials Specification) buried alongside the buried
pipelines and with synchronised interruption of the CP system current.
To this end, the transformer rectifiers shall be fitted with GPS time-synchronous current interrupting
facilities (to permit all TRUs within the development to be simultaneously switched on and off according
to a pre-set cycle).
5.3.3 Pipeline Attenuation Calculations
The attenuation calculations in this section are carried out for the buried segment of samples of the
smallest of the Rumaila trunklines, ignoring any corrosion allowance as a worst case scenario.
The attenuation of cathodic protection potentials along a pipeline is calculated using the project-
relevant pipeline design parameters and their relation to the specified pipeline coating type. Standard
formulae are applied to these parameters to approximate the attenuation model along the pipeline
according to the locations and quantities of current sources (e.g. ICCP groundbeds or GACP anode
groups). Table 5-3, below, lists typical coating conductance in milli-Siemens per metre squared
(mS/m2), resistance in Ohm metres squared (Ωm2) and generic ‘quality’ values:
Table 5-3: Coating Conductance/Resistance Values
Typical coating Typical coating
conductance resistance
mS/m 2 m
2
Quality
5 200,000 Super
10 100,000 Very high quality
100 10,000 Excellent
200 5,000 Good
500 2,000 fair
For the proposed 3LPE coating, a pessimistic coating resistance value of 100,000 Ωm2 is assumed for
‘start-of-life’ and 10,000 Ωm2 for ‘end-of-life’ will be used, as this provides considerable contingency.
Figure 5.1 on the following page details the calculation for a finite length of trunkline for this project and
these calculations show that:
 For the smallest diameter, basic WT 24” trunkline, (less assumed 3mm WT loss as corrosion
allowance) the maximum distance current will spread from a single groundbed is approximately
39.8km

Pipeline Attenuation
The attenuation of current and cathodic protection potentials along a pipeline is estimated using the specified and indicated pipeline
design parameters and their relation to the specified pipeline coating type. Standard formulae are applied to these parameters to
approximate the attenuation model along the pipeline according to the locations and quantities of current drain points.
For a finite length pipeline:

Ex = Emcosh( [L-x])
Where:
Ex = polarization along the pipeline a distance x metres from the drain point (V)
Em = polarization at the end of the pipeline, a distance L from the drain point (V)
 = attenuation constant (m-1)
L = pipeline length - from drain point to end of the pipeline (m)
Therefore, at the drain point:

EO = Emcosh( L) Since EO = Em
Where: cosh( L)
EO = polarization at drain point (V) then Ex = EO cosh( [L-x])
cosh( L)
Attenuation constant is defined by the follow ing terms: (per ISO 15589-1: 2015)
 = Sqrt(RL/RT)
Where: And:
RL = r O/( Ds) RT = RI/( D)
Where:
rO = pipe steel resistivity (Ohm.m) D = pipeline diameter (m)
RI = coating insulation resistance (Ohm.m²) s = pipeline w all thickness (m)
Considering the 24 Inch pipeline:

24 Inch
D = 0.6096 m
s = 27.96 mm 3mm CA su 0.02796 m
Based on typical values for line pipe steel resistivity:

rO = 0.00000018 Ohm.m
and on typical figures for the assumed coating type on application

RI = 100000 Ohm.m2 3LPE
To provide a contingency for end-of-life conditions, a substantial reduction in coating resistance is assumed, such that:
RI = 10000 Ohm.m2
Therefore for the 24 Inch pipeline(s):

RL = 3.36112E-06 Ohm.m-1
RT = 5,220.94 Ohm.m
and :
 = 2.53728E-05 m-1
Considering the specified limits of potential along the pipeline; minimum -0.95 V vs. Cu/CuSO4, maximum -1.200 V vs. Cu/CuSO4,
and assuming a natural potential of -0.500 V vs. Cu/CuSO4, minimum and maximum allow able degrees of polarization are
d
E t i d = 0.45 V
MIN
EMAX = 0.70 V
Attenuation must be sufficiently low w hereby the maximum polarization is not exceeded at the drain point w hile at least the
minimum polarization is achieved at the end of the pipeline.
So: And:
Em = EMIN EO = EMAX
= 0.45 V = 0.70 V
Therefore for the 24 Inch pipeline(s):

L = 39827.8 m etres
Figure 5.1: Attenuation for 24inch Flowline

Note that to provide for a worst-case attenuation situation, the pipeline WT is taken to be exclusive of
any corrosion allowance to cater for minimum end-of-life WT. No specific allowance for current drain to
earth or foreign structures has been included in the calculations.
An ICCP TRU could thus be placed at either end of any given trunkline to provide an adequate current
distribution to the entire pipeline length, with an anode configuration to suit. TRUs will thus be placed
at selected CPS locations.
5.3.4 Design Life
The required system design life, in accordance with Ref 2, is 25 years.
ICCP groundbeds, of whatever configuration, can readily be designed for this duration and provided
that all buried connections are carefully sealed during installation there should be no issue with
underground components.
TRUs are to be located at relevant CPS sites and will thus be in secured locations, whereby the required
design life is not an issue. However, it should be noted that other above-ground facilities such as test
posts, JBs, etc. may suffer damage due to building works, collision, vandalism, etc.
5.4 ICCP Groundbed Configurations

Various possible groundbed configurations have been discussed in Section 4.1.4, above; and the
selected choice of groundbed type is a semi-deepwell vertical groundbed.
5.4.1 Semi-deepwell Groundbed Resistance Calculation
Each groundbed will consist of six (6) vertically installed MMO anodes on a single string in a borehole
20 metres deep, with an active length of approximately 12 metres. This configuration will be refined as
necessary during later Detail Design.
Based on a pessimistic groundbed site soil resistivity of 2,500 Ωcm, groundbed and circuit resistance
is calculated as shown in Figure 5.2, overleaf:

SEMI-DEEPWELL VERTICAL GROUNDBED DESIGN
532014 Rumaila North CO99 Source Water pipelines

Semi-deepwell
Groundbed Design Data
Design Soil Resistivity 2,500 .cm

Groundbed Diameter 200 mm
Total Borehole Depth 20 m
Active Groundbed Length 12 m
Anode Diameter (Tubular) 25 mm

Anode Length (1.0m MMO anode) 1,000 mm
Anode Current Output at Maximum CD 5.4 A
Individual Anode Current Capacity Required 2.5 A
Total Number Of Anodes 6
Backfill Resistivity 50 .cm

3
Bulk Backfill Density 1187 kg/m
Consumption Rate Of Backfill 0.5 kg/A.yr
Length Of Anode Cable 100 m

Resistance Of Anode Cable 1.15 /km (16mm²)
Length Of Cathode Cable 100 m
Resistance Of Cathode Cable 0.688 /km (25mm²)
Calculation Results
Groundbed Design Current Output 15.0 A

Calculated Groundbed Current Output 15.0 A OK
Maximum Groundbed Current Output 32.4 A
Design Capacity vs Maximum Output 46.3 %
Total Design Resistance Of Groundbed 1.72 
Minimum Voltage Required To Drive Groundbed 31.0 V
Weight Of Backfill 448 kg

Life Of Backfill 28 Years
Current Density, Backfill To Soil Interface 1.99 A/m²
Length Of Coke Column For Attenuation Calculations 1.00 m
Internal Resistance Of Coke Column Above Anode 15.92 
Resistance To Earth Of Coke Column Above Anode 10.70 
Ratio Coke Internal Resistance:External Resistance 1.49
Attenuation Over Coke Column Above Anode 1.84
Figure 5.2: Semi-deep Vertical Groundbed Resistance

5.5 Temporary Protection

Given the high chloride and sulphate content and attendant low resistivity along the trunkline corridors,
temporary GACP is considered necessary to protect the trunklines for a maximum two-year period prior
to energizing a permanent ICCP system; as shown in the calculations in Figure 5.3, below. The longest
line has been taken to provide a representative calculation and the requirement per line is shown in
Table 5.4, overleaf.
Formula for Installed Anode Resistance Derived From Dwight :
Anode Resistance ( ) :
If : 2,500 = Electrolyte Resistivity ( cm)

48.0 = Installed Anode Length (cm)
7.5 = Anode Effective Radius (cm)
4.1 = Anode Weight (kg)
2,500 4 48.0
R = . ln - 1
2  48.0 7.5
= 8.29 . 2.24
= 18.590 
Operating Current Output per Anode, I (a) :

E (a) - E (str.)
I (a) =
R
Where : I (a) = Individual Anode Current Output (mA)

E (a) = Open Circuit Potential (-ve mV) of Magnesium (w.r.t. Cu\CuSO4)
E (str.) = Polarised Structure Potential (-ve mV) (w.r.t. Cu\CuSO4)
If : 1750 = Open Circuit Potential (-ve mV) of Magnesium (w.r.t. Cu\CuSO4)

950 = Polarised Structure Potential (-ve mV) (w.r.t. Cu\CuSO4)
1750 - 950
I (a) =
18.590
= 43.03 mA
Anode Life :
Y . 8766 . I
W =
1000 . C . U
Where : W = Weight of Magnesium Required to Achieve Design Life (kg)

Y = Design Life (years)
I = Current Requirement (mA)
U = Anode Utilisation Factor
C = Anode capacity (Ah/kg)
If :
2.00 = Design Life (years - temporary system)
170.0 = Current Requirement (mA)
0.50 = Anode Utilisation Factor (from manufacturers tables)
1230 = Anode capacity (Ah/kg) (from manufacturers tables)
2.0 . 8766 . 170.0

W =
1000 . 0.5 . 1230.0
= 4.846 kg
Therefore;
Minimum No. of Anodes required to Satisfy Mass Requirements

4.846243902
=
4.1
= 2 ea.
Minimum No. of Anodes required to Satisfy Current Requirements

170
=
43.03489498
= 5 ea.
Figure 5.3: Baseline Temporary GACP Calculation

Table 5.4: Temporary GACP Requirements

(1) (3) (5) (10) (11) (12)
Priority CPS FM OD Length Coating CD Current Mags
2
(") (m) (mA/m ) (mA)
2 CPS1 FM5 24 4258 3LPE 0.02 197.34 5
1 CPS1 FM7 24 3832 3LPE 0.02 177.60 5
1 CPS1 FM7 24 560 PU 0.03 38.93 1
1 CPS2 FM9 24 1781 3LPE 0.02 82.54 2
1 CPS3 FM10 24 2279 3LPE 0.02 105.62 3
2 CPS4 FM6 24 1192 3LPE 0.02 55.24 2
1 CPS4 FM8 24 3755 3LPE 0.02 174.03 5
1 CPS4 FM8 24 550 PU 0.03 38.23 1
2 CPS5 FM1 24 4267 3LPE 0.02 197.76 5
2 CPS5 FM2 24 5053 3LPE 0.02 234.19 6
2 CPS5 FM3 24 4034 3LPE 0.02 186.96 5
1 CPS5 FM4 24 5898 3LPE 0.02 273.35 7
47
(1)
OD values confirmed
(5)
(10)
Conservative CD for TCP quoted for 3LPE in ISO 15589‐1
(11)
(12)
4.1kg Mg anodes to provide 2 years TCP
5.6 CP Ancillaries
5.6.1 Test Facilities
ISO 15589-1 2015 [Ref 17] and other generic cathodic protection specifications, stipulate that test
stations shall be fitted at the following locations and frequency as a minimum:
 Every 1.0 km for pipe-to-soil potential monitoring
 At all cased crossings (none anticipated for this scope)
 At all isolation joints
 At all HV and foreign pipeline crossings
All test stations will be fitted with a permanent reference electrode, a polarization coupon and one or
more magnesium anodes for temporary protection, as applicable.
Crossings have been identified and tabulated based on trunkline routing maps [Ref 6 and Refs 7 to 15
inclusive] and the Pipeline Crossing Schedule [Ref 3].
Pipeline bonding/interference testing boxes have been assigned for each identified crossings corridor,
or as test posts for individual pipelines if so listed.

Table 5-5: Minimum Test Station and Magnesium SACP Requirements

(1) (12)
Priority CPS FM OD Mags Road Canal Pipe Current Pipe Bond/
Rail Xgs XTP IJTP STP Total TP (13)
(") Xgs Xgs XTP Span Int Box
2 CPS1 FM5 24 5 6 0 0 12 2 21 3 1 39 9
1 CPS1 FM7 24 5 1 0 0 2 2 2 3 1 10 8
1 CPS1 FM7 24 1 0 1 1 4 0 0 0 0 4 0
1 CPS2 FM9 24 2 2 0 0 4 2 1 2 1 10 2
1 CPS3 FM10 24 3 2 0 0 4 2 6 2 1 15 2
2 CPS4 FM6 24 2 9 0 0 18 2 6 1 1 28 2
1 CPS4 FM8 24 5 4 0 0 8 2 10 3 1 24 2
1 CPS4 FM8 24 1 0 1 1 4 0 0 0 0 4 0
2 CPS5 FM1 24 5 3 0 0 6 2 8 3 1 20 3
2 CPS5 FM2 24 6 6 0 0 12 2 20 4 1 39 6
2 CPS5 FM3 24 5 2 0 0 4 2 9 3 1 19 3
1 CPS5 FM4 24 7 3 0 0 6 2 11 4 1 24 16
47 38 2 2 84 20 94 28 10 236 53
(1)
OD values confirmed
(12)
4.1kg Mg anodes to provide 2 years TCP
XTP Crossing Test Post (1 each side of road/rail/canal)
IJTP Isolation Joint Test Post
Pipe XTP Individual pipe crossing
STP Standard Test Post
Current Span Current Span Test Post
(13)
6‐way resistor bonding/interference testing Junction Box at pipeline corridor crossings
Mag anodes will be fitted at appropriately spaced TP of any designation
Note that during Detailed Design, once all routes and crossings are confirmed, actual quantities can be
rationalised by multi-purposing test facilities where possible.
5.6.2 Cable-to-Pipe Connections

Pin brazing is the most efficient and effective means of making cable connections to structures and
pipelines and this is currently the favoured option for CP operations. In addition, pin brazing is approved
for usage on live pipelines. Pin braze procedure shall be qualified by testing to ensure that it does not
create a hard spot that fails the sour service limit of 248-250 VPN.
All CP cable connections to pressurised systems for this project would be made via this method and
will be done above-ground wherever possible.
5.6.3 Anode and Cathode Distribution Boxes
In order to facilitate distribution and allow full monitoring, all anode and cathode cables shall be routed
through suitably-rated and protected steel junction boxes; each mounted on a suitable frames.
Designation and fittings will be determined during Detail Design.
5.6.4 Road Crossings
All road crossings shall have one test point fitted at least on the side most remote from the closest
groundbed location, otherwise on both sides.
As a base case for preliminary design, it is assumed that all crossings will be trenchless and uncased;
because this prevents any possible CP current spread issues.

5.6.5 Pipeline Crossings

Test facilities shall be installed at locations where COMPANY-owned or foreign metallic services cross
the trunkline routes. To mitigate possible interference, bonding is a preferable procedure and facilities
for this will be provided at all identified Pipeline Crossings, including resistors where determined
necessary. The ultimate requirement for bonding should be decided by the responsible CP engineer
during the commissioning stage.
It is considered that mitigation of interference at crossings using sacrificial anodes is acceptable if
circumstances dictate and it is sometimes the only option if either party involved does not permit
bonding.
During the installation stage of this project test cables shall thus be fitted at all such crossings to allow
monitoring, but no mitigation measures will be installed until after completion of the permanent CP
installation and initial commissioning has been carried out.
A listing of all currently identified crossings [Ref 3] has been cross-referenced in compiling the
preliminary test facility requirements.
5.6.6 AC Mitigation
Monitoring facilities shall be installed at all Overhead High Voltage (OHV) crossing points and at the
start and end of parallelisms where the operating voltage has been identified as being in excess of
20kV.
At locations with a voltage in excess of 50kV, mitigation may ultimately prove necessary, with the
possible later requirement to fit earthing strips and/or Polarisation Cell Replacements (PCRs) after initial
commissioning has been conducted.
Note:
A full AC interference survey is recommended to validate assumptions made within this report. No
allowance for AC mitigation is currently allowed for in this preliminary design.
5.6.7 Electrical Isolation
Monolithic Isolation Joints (MIJ) shall be installed at each end of each trunkline, at each
aboveground/underground transition, which lies within or beyond the pig trap section at each CPS.
Between trunkline tie-in point and pig trap area, piping runs above ground on sleepers. All above-ground
pipework must be earthed. Note that PCRs shall be fitted between pipeline facilities and earthing
systems where required.
CP is only provided to protect the buried carbon steel pipelines and shall not be designed to cater for
current losses/drains to other CPS or FM piping (above- or below-ground), other steelwork (such as
pipe supports, cable trays, fences, etc.) and any plant earthing system. Any pipe supports on the above-
ground sections will thus need to be electrically isolated from the pipeline outer casing and ground.
Note that all monolithic isolation joints shall have Over-Voltage Protectors (OVP) or similar fitted across
them for protection against high-voltage transients, such as AC fault current or high current lightning
strikes..
Note that per Section 5.6.9 of this report, above ground piping at the CPS4-FM8 road crossing and
CPS5 will be buried (at CPS5 to avoid blocking access) and these segments will need to be isolated
using flange isolation kits and provided with independent galvanic anode CP.
5.6.8 Transformer Rectifier Unit (TRU) Rated Output
The TRU power supplies shall be rated to provide an output in excess of the calculated end-of-life
current demand. The rated voltage shall be sufficient to allow the output to exceed the design current
demand at the design circuit resistance.

In order to quantify these requirements, the following shall be required:

 That the transformer rectifier rated current output shall be at least 125% of the design end-of-
life current demand
 That the transformer rectifier rated voltage shall be at least 125% of that required to pass a
current equal to the design end-of-life current demand across a resistance equal to the design
circuit resistance
Given the likely availability of domestic power within each CPS, each CPS can be best considered as
a ‘hub’; housing a TRU and associated groundbed. TRUs will thus nominally be specified to operate
from a 230 VAC, 50 Hz, single phase supply; although this may ultimately need to be amended; and all
pipeline TRUs shall be air-cooled and suitable for installation in a safe area, under indoor ambient
conditions within the CPS. If this is not possible, TRUs will need to be positioned outside and will need
to be oil cooled and fitted with sunshades.
Positive and negative junction boxes shall be provided in order to facilitate current distribution.
It is not known at this stage whether remote monitoring is a requirement. However, to facilitate this as
an option, as a minimum, SCADA 4-20mA current loop signals shall be provided for power on/off, output
A and output V. Alternative remote data acquisition methods (and data requirements) can be considered
during Detail Design. Note that provision of SCADA telemetry systems and equipment is outside the
scope of this supply and would be a third-party responsibility. If this is not a Client requirement, this
option can ultimately be ignored.
Minimum TRU requirements, meeting the above criteria, for the entire trunkline network (including those
listed as future dual lines) are provided in Table 5.6, below:
Table 5.6: TRU Requirements and Distribution
(1) (2) (3) (4) (5) (6) (7) (8) (9)
Priority CPS FM OD OD WT Length SA Coating CD Current Hub Hub
2 2
(") (m) (mm) (m) (m ) (mA/m ) (A) (A) (A)
2 CPS1 FM5 24 0.6096 27.96 4258 8970.0 3LPE 0.2 1.97
1 CPS1 FM7 24 0.6096 27.96 3832 8072.6 3LPE 0.2 1.78 5.18 15.00
1 CPS1 FM7 24 0.6096 27.96 560 1179.7 PU 0.3 0.39
1 CPS2 FM9 24 0.6096 27.96 1781 3751.9 3LPE 0.2 0.83 1.04 15.00
1 CPS3 FM10 24 0.6096 27.96 2279 4801.0 3LPE 0.2 1.06 1.33 15.00
2 CPS4 FM6 24 0.6096 27.96 1192 2511.1 3LPE 0.2 0.55
2.86 15.00
1 CPS4 FM8 24 0.6096 27.96 3755 7910.4 3LPE 0.2 1.74
1 CPS4 FM8 24 0.6096 27.96 550 1158.6 PU 0.3 0.38
2 CPS5 FM1 24 0.6096 27.96 4267 8989.0 3LPE 0.2 1.98
2 CPS5 FM2 24 0.6096 27.96 5053 10644.8 3LPE 0.2 2.34
11.15 15.00
2 CPS5 FM3 24 0.6096 27.96 4034 8498.1 3LPE 0.2 1.87
1 CPS5 FM4 24 0.6096 27.96 5898 12424.9 3LPE 0.2 2.73
(1)
OD values confirmed
(2)
(4)
(5)
(6)
Most conservative CD quoted for 3LPE in ISO 15589‐1
(7)
(8)
Includes 25% additional TRU capacity allowance
(9)
Rounded up to nearest 15A output for consistancy and ease of spares provision
Trunklines in the above table are colour-coded to indicate where they are located and from which TRU
they will receive CP.

TRUs are designed as identical at each of the required CPS, such that there is consistency and
interchangeability, plus a simplification of maintenance and ease of providing across-the-board
commissioning and operational spares. Each TRU shall be 15A36V DC output and capable of voltage
or current control and shall be designed and configured for manual control. Each shall be equipped with
facilities to feed output and fault condition data to a central control room, if so required.
Current shall be distributed to individual pipelines via a dedicated cathode return junction box, fitted
with balancing resistors and shunts to proportionally split the current to different pipeline diameters
and/or lengths.
Note that new trunkline tie-in points are, in some cases, several hundred metres from the TRU location
within the CPS perimeter. Allowance has been made to utilise greater cross-section feeder cables in
these instances. Full voltage drop balancing will be required during Detail Design.
5.6.9 CPS Piping Underground Sections
Above ground piping between trunkline CPS tie-in point and pig traps is generally run above ground on
sleepers but there are two locations where part of this will be buried:
i. CPS4-FM8 Road Crossing
Figure 5.4: CPS4 Road Crossing
For the CPS4-FM8 buried road crossing segment, assumed to be direct buried, galvanic CP will be
required. Recommendation is to use flanged upper bend and fit flange isolation kits above ground to
isolate the crossing section. CP test post with cables to be connected to 'live' and 'dead' sides of isolated
flange each side of road; plus 2 x 17kg 1.7V packaged magnesium (Mg) anodes, connected via link bar
to 'live' (crossing) side. Note that Mg anodes are necessary due to high local resistivity but Mg anodes
will need to be replaced after 10-12 years due to self- corrosion.

ii. CPS 5 Underground Transit
Figure 5.5: CPS5 Underground Transit
For the CPS5 buried segment, assumed to be direct buried, galvanic CP will be required.
Recommendation is to use flanged upper bend and fit flange isolation kits above ground to isolate the
crossing section. CP test post with cables to be connected to 'live' and 'dead' sides of isolated flange
each end of the buried section of each trunkline; plus 2 x 17kg 1.7V packaged magnesium (Mg) anodes,
connected via link bar to 'live' (buried) side. Note that Mg anodes are necessary due to high local
resistivity but Mg anodes will need to be replaced after 10-12 years due to self- corrosion.
5.6.10 Anchor Blocks
If anchor blocks are fitted to any of the pipelines, it is essential that:
a. The pipeline is electrically isolated from any metallic portion of the anchor block, including
rebars;
b. Any CP associated with the anchor block is independent GACP, with independent monitoring
facilities
5.6.11 Protection Levels and Over-Protection
In accordance with industry norms and site carrion history, a design protected potential at least as
negative as -0.95 V vs. Cu/CuSO4 is to be considered for buried onshore piping. Note that the definition
of cathodic protection being achieved is when a polarized (Instant ‘OFF’) structure-to- soil potential of
–0.95V wrt Cu/CuSO4 is achieved. For most types of modern coatings, a maximum negative instant
‘OFF’ should not exceed –1.50V wrt Cu/CuSO4 to minimize the risk of cathodic disbondment.
These criteria are industry standards utilised to determine the effectiveness of the cathodic protection
systems and the level of protection achieved.
As stated above, a pipe-to-soil potential more negative than the recommended values can lead to over-
protection of the substrate, which can in turn lead to cathodic disbondment of coatings or the risk of
hydrogen embrittlement.
Susceptibility to hydrogen-induced cracking (‘embrittlement’) can be a result of the introduction of
hydrogen during forming, coating, plating, cleaning, and finishing operations’. Hydrogen can also be
introduced over time through environmental exposure (soils and chemicals, including water), corrosion
processes (especially galvanic corrosion), cathodic protection, and/or from hydrogen generated by
corrosion under a coating. To be susceptible, a combination of three factors is required: presence of
(and diffusion of) hydrogen, susceptible material, and stress, which is application-dependent.
For susceptible materials (such as coated high-strength bolts, where hydrogen is often present after
manufacturing and may also be added over time by cathodic protection, galvanic connections, etc.),
cracking will initiate when a sufficient stress has been reached.
Careful control of CP potential will ensure that hydrogen embrittlement does not occur.

5.6.12 Onshore Coating Integrity Assessment

On a standard dielectrically-coated pipeline it is possible to conduct a Direct Current Voltage Gradient
(DCVG) survey along the pipeline Right of Way (ROW), which allows both an empirical and numerical
analysis of coating defects detected along the pipeline route. Such a survey does, however, rely upon
the existence of either an energised permanent ICCP system, or a temporary ICCP system that can be
installed and dismantled as the survey progresses; the output of which is interrupted on a timer cycle.
It is also usual to conduct a Close Interval Potential (CIP) survey after stabilisation of the installed CP
systems has occurred. This survey detects changes in local potentials, which can also be indicative of
coating defects or other current drain issues (such as lack of, or poor, isolation, unknown crossings).

6 Preliminary ICCP MTO

Item No Item Description Unit Quantity
Permanent ICCP System Vertical Groundbed Option
1 Transformer Rectifier Unit (TRU). Oil cooled, safe area outdoor installation, suitable each 5
for plinth mounting.
Input: 230VAC, 50Hz, 1 phase supply *
Output: 15A36V DC, 1+ve, 1‐ve output, with Ammeter, Voltmeter and Reference
Voltmeter
Manual operation, optional Voltage/Current/Potential control
4‐20mA signal suitable for SCADA indicating on/off, A, V
GPS Synchronous timer
Complete with commissioning spares, full listing to be provided
OR
1a Transformer Rectifier Unit (TRU). Air cooled, safe area indoor installation, suitable for each 5
wall or plinth mounting.
Input: 230VAC, 50Hz, 1 phase supply *
Output: 15A36V DC, 1+ve, 1‐ve output, with Ammeter, Voltmeter and Reference
Voltmeter
Manual operation, optional Voltage/Current/Potential control
4‐20mA signal suitable for SCADA indicating on/off, A, V
GPS Synchronous timer
Complete with commissioning spares, full listing to be provided
2 2 Years' TRU Operational Spares, full listing to be provided lot 1
3 MMO Anode (1000 x 25mm dia tubular) string c/w integral, fully sealed, 40m x each 6
25mm2 KYNAR/HMWPE cable tail, comprising 6 off anodes at 1.2m spacing from (incl 1
bottom anode (approx 12m active length), 40m x 6mm polypropylene support rope, spare)
6 off anode spacers, end weight
Groundbed headworks to be provided by Civils Contractor
4 Calcined Petroleum coke breeze tonne 5
Density approx 800‐900kg/m3
Bulk resistivity <50 ohm cm
Suitable for pumping into deepwell borehole
5 SS316 Anode Junction Box, typically 600h x 500w x 320d each 5
fitted with backing board, shunts, bus bar
2 way, glanded to suit
c/w galvanised steel mounting frame
6 SS316 Cathode Junction Box, typically 600h x 500w x 320d each 5
fitted with backing board, resistors and shunts, bus bar
7 SS316 Bonding/Interference Test Box, typcially 600h x 500w x 320d each 53
fitted with backing board, resistors and shunts, bus bar
8 Lockable Big Fink test post cap and fittings, c/w 11‐way terminal panel and Ni‐plated each 236
brass bolts/washers/nuts, 1.75m x 3"Φ galvanised steel conduit; for IJ testing, CP
testing, bonding
9 MC Miller, or equivalent, Polarisation Coupon, c/w 10m x twin 4mm2 THHN cable tail each 246

Item No Item Description Unit Quantity

Permanent ICCP System Vertical Groundbed Option
10 MC Miller or Borin, or equivalent, Permanent Cu/CuSO4 reference electrode c/w each 246
10m x 4mm² XLPE cable tail
11 Royston Handy Cap IP, adhesive lined cable connection cover. No primer required each 600
12 Pin brazing machine with all necessary equipment accessories set 1
13 M8 direct pin braze pins, lugs and ferrules (supplied in tins of 50) each 400
GACP system
14a 4.1kg nett weight 1.75V pre‐packaged magnesium anode, c/w 10m x 10mm2 each 45
XLPE/PVC cable tail
14b CPS underground transit provision: 14.5kg nett weight 1.75V pre‐packaged each 20
magnesium anode, c/w 10m x 10mm2 XLPE/PVC cable tail
14c Pipeline interference mitigation provision: 7.7kg nett weight 1.75V pre‐packaged each 100
magnesium anode, c/w 10m x 10mm2 XLPE/PVC cable tail
15 Lockable Big Fink test post cap and fittings, c/w 11‐way terminal panel and Ni‐plated each 10
brass bolts/washers/nuts, 1.75m x 3"Φ galvanised steel conduit; for IJ testing, CP
testing, bonding
Commissioning/Testing Equipment (Optional)
16 High Impedance Digital Multimeter, Fluke Type 287 or equivalent each 1
17 Portable Cu/CuSO4 reference electrode with 10m cable tail, 6mm² XLPE/PVC each 1
Test Post cables, connections and bonding
18 10mm² XLPE/PVC, 600/1000V Test & Monitoring cable m 4000
19 16mm² XLPE/PVC, 600/1000V Bond box cable m 2650
20 35mm² XLPE/PVC, 600/1000V Main Positive and Main Negative Header cable (based m 750
on minimum 150m per cathodic protection station)
21 50mm² XLPE/PVC, 600/1000V Main Positive and Main Negative Header cable (based m 1000
on minimum 350m per cathodic protection station)
22 Cott Bonding straps for Big Fink each 10
23 Crimp lugs to suit M10 bolt, 50mm2 cable lot 1
2
25 Crimp lugs to suit M6 bolt, 16mm cable lot 1
2
26 Crimp lugs to suit M6 bolt, 10mm cable lot 1
IJ and Earthing Protection Items
28 3.7kA PCR, NEMA4 each 20
Manufactured by Dairyland Inc.
OR
29 OVP‐2/2‐3.7‐100 each 20
Manufactured by Dairyland Inc.
30 Pre‐packaged 1524 x x 50 x50 mm, 27.2kg nett weight zinc earthing electrode, c/w each 40
10m x 25mm² XLPE/PVC cable tail; for optional earthing purposes
* Nominal AC supply only, to be amended to suit actual supply available (which may be 440VAC 3‐phase)
Monolithic isolation joints and flange insulation kits to be specified and supplied by pipeline contractor on confirmation of all
relevant pipeline and flange details

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RUMAILA PROJECT

Digitally signed by Julia Digitally signed by Digitally signed by

B01 Approved for Use 10-Mar-2023 JT PW/CCU PW

A01 Issued for Review 17-Nov-2022 JT PW PW

Rev. Revision Description Date Originated Reviewed Approved

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Acronyms and Abbreviations

Acronym / Abbreviation Description

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Acronym / Abbreviation Description

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Ref Document Number Description

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Table 2.1: Source Water Trunklines to be Replaced

2.2 Process Schematic

Figure 2.1: Process Schematic

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3 Preliminary Pipeline Routing

3.3 Routing – Pre-FEED phase

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4 Material Selection and Corrosion Control

4.1 External Corrosion

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4.1.4 Independent ICCP

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5 ICCP System Design

5.2 Soil Resistivity

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5.3.2 Design Protected Potential

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For a finite length pipeline:

Therefore, at the drain point:

Considering the 24 Inch pipeline:

Based on typical values for line pipe steel resistivity:

and on typical figures for the assumed coating type on application

Therefore for the 24 Inch pipeline(s):

Therefore for the 24 Inch pipeline(s):

Figure 5.1: Attenuation for 24inch Flowline

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5.4 ICCP Groundbed Configurations

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SEMI-DEEPWELL VERTICAL GROUNDBED DESIGN

532014 Rumaila North CO99 Source Water pipelines

Groundbed Design Data

Design Soil Resistivity 2,500 .cm

Anode Diameter (Tubular) 25 mm

Backfill Resistivity 50 .cm

Length Of Anode Cable 100 m

Groundbed Design Current Output 15.0 A

Weight Of Backfill 448 kg

Figure 5.2: Semi-deep Vertical Groundbed Resistance

0430WD-N-WM-CP00-ML-REP-0001 Rev B01 Page 23 of 33

5.5 Temporary Protection

If : 2,500 = Electrolyte Resistivity ( cm)