UAE ARMED FORCES Reference
COMMAND OF MILITARY WORKS RPT E 1719
Date Rev.
DESIGN OF PIPELINE CP SYSTEM
18-Oct-12 00
Document Title: DESIGN OF PIPELINE CP SYSTEM
RPT-E-1709 Page 1 of 15
UAE ARMED FORCES Reference
COMMAND OF MILITARY WORKS RPT E 1719
Date Rev.
DESIGN OF PIPELINE CP SYSTEM
18-Oct-12 00
REVISION HISTORY PAGE
Revision Description Originated Reviewed Authorized Date
00 Issued for Review
Reviewed and approved for conformance with the contract documents by:
KN Klumpp & Partner International Architects + Engineers
Signature:
STRABAG Abu Dhabi LLC
Signature:
Commander of Military Works
Signature:
RPT-E-1709 Page 2 of 15
UAE ARMED FORCES Reference
COMMAND OF MILITARY WORKS RPT E 1719
Date Rev.
DESIGN OF PIPELINE CP SYSTEM
18-Oct-12 00
TABLE OF CONTENTS
1.0 INTRODUCTION 4
2.0 CODES, STANDARDS AND REFERENCE DOCUMENTS 4
3.0 SCOPE OF WORK 4
4.0 STRUCTURE DETAILS 4
5.0 GUIDELINES FOR DESIGN OF CP SYSTEM 5
6.0 DESIGN PARAMETERS 6
7.0 PROTECTION CRITERIA 7
8.0 CATHODIC PROTECTION SYSTEM DESIGN CALCULATIONS 7
9.0 SPECIFICATION FOR MAJOR CP MATERIALS 14
RPT-E-1709 Page 3 of 15
UAE ARMED FORCES Reference
COMMAND OF MILITARY WORKS RPT E 1719
Date Rev.
DESIGN OF PIPELINE CP SYSTEM
18-Oct-12 00
1.0 INTRODUCTION
This document details the design and engineering details, calculations, specifications, for
the pipeline cathodic protection system associated with the above mentioned project.
2.0 CODES, STANDARDS AND REFERENCE DOCUMENTS
The design is in accordance with established codes and engineering practices but may not be
limited to the following:
• NACE SP-0177 Mitigation of Alternating Current and Lightning Effects on Metallic Structure
and Corrosion Control system
• NACE SP-0 9 Control of External Corrosion on Underground or Submerged Metallic Piping
Systems
• NACE SP-0286 Electrical Isolation of Cathodically Protected Pipelines
• NACE-SP-0572 Design, Installation, Operation and Maintenance of Impressed Current Deep
Ground Beds
• ISO 15589 Petroleum and Natural Gas Industries – Cathodic protection of Pipeline
Transportation Systems – Part 1: On-Land Pipelines
3.0 SCOPE OF WORK
The following activities are covered under the scope of work to be performed.
• Design of cathodic protection system for the diesel pipeline from the tank farm area to the port
area up to the trenches
4.0 STRUCTURE DETAILS
Sl.No Dia.of pipeline (m) Length of pipeline (m) Surface area(m2)
1 0.254 565.95 451.608
2 0.254 36.22 28.90228
3 0.254 21.1 16.83705
4 0.254 10 7.979645
5 0.254 15.47 12.34451
6 0.254 25.78 20.57153
7 0.254 27.76 22.1515
8 0.254 26.54 21.17798
9 0.254 3.97 3.167919
RPT-E-1709 Page 4 of 15
UAE ARMED FORCES Reference
COMMAND OF MILITARY WORKS RPT E 1719
Date Rev.
DESIGN OF PIPELINE CP SYSTEM
18-Oct-12 00
10 0.254 8.53 6.806637
11 0.254 72.37 57.74869
12 0.254 11.53 9.200531
13 0.254 74.54 59.48028
14 0.254 13.83 11.03585
15 0.254 49.2 39.25986
962.79 768.2723
Only 10” line is covered under this scope
5.0 GUIDELINES FOR DESIGN OF CP SYSTEM
Temporary CP system:
The following summarizes the basic design concepts for temporary CP system:
• The temporary cathodic protection for the new pipelines shall be achieved by utilizing
high potential magnesium ribbon anodes.
• Magnesium ribbon anodes shall be installed horizontally along the pipeline route at pipeline
invert level. The anode cable tail shall be terminated in the test post (TP).
• The test facilities (test post / bond boxes, etc) provided for permanent CP system
shall be utilized for the termination of the temporary CP anode cables.
• At all Test Posts, two cables shall be connected to pipeline. The cables shall be in line with
the test facility schedule provided in the Permanent CP System design.
• All pipeline-to-cable connection shall be done by thermite welding technique.
• The pipeline-to-cable connections shall be encapsulated using Intergard 821 compound or
equivalent. (The repair of the coating, restoration of the insulation, etc shall be carried out by
contractor in line with the project approved procedures. The guidelines as set forth by the
pipeline coating contractor / coating manufacturer shall be followed to ensure that there is
no ingress of moisture or any other electrolyte during the service life of the pipeline).
In order to achieve adequate cathodic protection on the new buried pipeline, effective isolation
is mandatory to prevent leakage of cathodic protection current to other buried metallic structure.
The new pipeline shall be isolated (by Contractor) from the concrete foundation reinforcement
steel, foreign pipe Tap-Off/Tie-In, valves, vents, chambers, stacks, scraper traps, casings,
earthing and all other locations as deemed necessary.
Permanent CP system:
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UAE ARMED FORCES Reference
COMMAND OF MILITARY WORKS RPT E 1719
Date Rev.
DESIGN OF PIPELINE CP SYSTEM
18-Oct-12 00
A) Permanent Cathodic Protection shall be achieved using impressed current CP system with a
design life of 35 years.
B) One Deep well Ground bed is proposed for Permanent Cathodic Protection (PCP) for the
pipelines.
C) Cable connections for all facilities such as test posts, Junction boxes, drain cables,
isolating spark gaps, Foreign Pipeline Bond Box (FBB), Overhead Head Power line Test
Post (OHTP) etc, shall be installed during the construction phase.
D) All the pipelines shall be isolated from other structures by the installation of the insulating
flanges (supplied and installed by others) at either end and at tap-off locations.
E) All pipelines shall be connected to the TR unit negative terminal through NJB/ NDB to
form common cathode.
F) The pipeline shall be bonded to the foreign pipelines (only if required, to mitigate
interference) during the commissioning of the Cathodic Protection System. Bonding shall
be done after obtaining permission from the owner of the pipeline (as applicable).
G) All pipe-to-cable connections shall be made by Thermite Welding Method. The pipe-to-cable
connections on the foreign pipelines shall be done with prior permission from the
pipeline owner.
6.0 DESIGN PARAMETERS
The following parameters are considered for the design of the Cathodic Protection System:
For Permanent Cathodic Protection System:
Design Life - 35 Years (PCP)
Type of System - Impressed Current Cathodic Protection (ICCP)
Current Density - 0.5 mA / m 2
Temperature Correction - 25% rise in current density for every 10 °C rise
in temperature above 30 °C.
Spare Capacity of Power Supply - 30%
RPT-E-1709 Page 6 of 15
UAE ARMED FORCES Reference
COMMAND OF MILITARY WORKS RPT E 1719
Date Rev.
DESIGN OF PIPELINE CP SYSTEM
18-Oct-12 00
Protection “OFF” Potential Range - From -0.850 V to -1.2 V Vs Cu/CuSO4 reference
electrodes
Anode Type - Mixed Metal Oxide (MMO) Tubular Anodes
Anode Dimension - 25.4 mm diameter x 1000 mm length
Ground bed Type - Vertical Deep well Ground bed
Number of anode ground beds with - One
TR units
7.0 PROTECTION CRITERIA
The Permanent Cathodic Protection System shall be designed to ensure that at each
point of the buried pipeline, the “instant-off” (polarized) pipe-to-soil potential shall be
more negative than -850 mV with respect to a copper/ copper sulphate reference
electrode. The maximum polarization shall be limited to – 1200 mV with respect to a
copper/ copper sulphate reference electrode.
In addition to the above, 100mV criteria may be applied for pipelines only as an
alternative acceptance criterion in specific, irregular instance, however the criterion stated in
the above sub clauses is the preferred minimum negative acceptance values for effective
cathodic protection.
8.0 CATHODIC PROTECTION SYSTEM DESIGN CALCULATIONS
8.1 DESIGN FORMULA
For Permanent Cathodic Protection System:
A) Surface area of pipeline:
SA = πxDxL
Where:
SA - Surface Area of pipeline (m 2)
D - Diameter of pipeline (m)
L - Length of pipeline (m)
B) Total protective current:
I = SA x CD T x 1.3
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UAE ARMED FORCES Reference
COMMAND OF MILITARY WORKS RPT E 1719
Date Rev.
DESIGN OF PIPELINE CP SYSTEM
18-Oct-12 00
Where:
I - Total CP current required (A)
SA - Surface Area of pipeline (m 2 )
CD T - Temperature Current density of the pipeline (A/m 2)
1.3 - For 30% excess current capacity over the design life
to compensate for coating degradation
CD T = CD x 1.25 (to – 30)/10
Where:
CD - Current density at 30°C (A/m 2)
C) Anode Resistance (single vertical anode installation):
Rv = 0.159 x ρ/L x (ln4L/d-1)
Where:
Rv - Vertical Anode Resistance (Ohm)
ρ - Soil resistivity (Ohm-cm)
L - Length of the anode (cm)
d - Diameter of the anode (cm)
D) Surface current density of MMO anode:
Log 10 Y = 3.3 – log 10 (CD)
Where:
CD - Current Density on Anode (A/m2)
Y - Anode Life or Design Life (years)
E) Pipeline current spread (attenuation) :
Ea = E m Cosh (aL)
Where:
Ea - Change in potential at drain point.
Em - Change in potential at a point L meters from drain point.
a - square root of the product of g and r.
g - Coating Conductance (Siemens/linear meter of pipeline).
r - Pipeline Resistance (Ohm/linear meter of pipeline)
L - Length of Pipeline (m)
8.2 CP Current Requirement for the Pipelines Permanent CP system:
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UAE ARMED FORCES Reference
COMMAND OF MILITARY WORKS RPT E 1719
Date Rev.
DESIGN OF PIPELINE CP SYSTEM
18-Oct-12 00
I = SA x CDT x 1.3
CDT = CDx1.25(50-30)/10; (Assume temperature at the site as 500)
CDT = 0.5 x1.252
= 0.78125x10-3
Then I = 768.2723 x0.78125 x 10-3x1.3
CP current required is =780.28x10-3A
=0.78 A
Thus, a CP current of 2 A (considering a safety factor of 1.3) is more than sufficient to meet the
design requirements for proposed pipelines CP system. However in line with specifications, the
proposed transformer rectifier unit shall be rated for 50 Volts/ 50 Amp capacity.
8.3 PCP Anode Quantity Calculations
It is proposed to install Mixed Metal Oxide Anodes 25.4mm diameter x 1000mm long.
The anodes shall be supplied with required lengths of 25mm 2 Kynar/HMWPE cable.
The anodes shall have a Titanium substrate, which is coated with mixed metal oxide
anode catalyst (usually with Group VIII metals from periodic table). The coating thickness is 5-
microns and the consumption rate of the anode is less than 1 mg/A. year.
The general relationship between current density and anode life is given by the empirical
equation (source: Corrosion by L. L. Shreir, Vol.2, Section 10.3)
Log 10 CD = 3.3 – Log 10 Y
2
Where ‘CD’ is the current density in A/m of anode surface area and ‘Y’ is the design life in
years.
Hence, the current density for 35 years life = 57 Amp/m 2
SA of anode = π x 0.0254 x 1
= 0.0798 m 2
The maximum anode current output to meet the design life:
IA = 0.0798 x 57
= 4.55 A per anode for 35 years.
No. of Anodes = Total current required / Anode current output
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UAE ARMED FORCES Reference
COMMAND OF MILITARY WORKS RPT E 1719
Date Rev.
DESIGN OF PIPELINE CP SYSTEM
18-Oct-12 00
= 1.228251 /4.55
= 0.28, Say one anode
8.4 PCP Resistance Calculations
The anode ground bed and DC cables installed in the cathodic protection system DC
circuit shall have a resistance value that has an effect on the DC power supply voltage
requirement. The cables to be considered are as follows:
A) Ground bed Resistance (R V ):
Ground beds are utilized for the induction of current into the surrounding
environment to allow the current to reach the structure to be protected. The resistance of
the ground bed to the surrounding environment has an overall effect on the size of the cathodic
protection system. This ground bed to environment (in this case – soil/sand) resistance is
dependent on a number of factors:
• Type of ground bed and number of anodes utilized
• The anode diameter and length
• Spacing between anodes
• Depth of ground bed
• Use of low resistivity backfill to lower the interface resistance between the anode and
the environment (soil/sand), and hence the overall ground bed to environment
resistance.
• Environment – soil/ sand – resistivity
Considering a soil resistivity of 2000 ohm-cm (to allow contingency) for the active column, the
ground bed resistance can be calculated as under:
The anodes shall be installed vertically in the deep well anode ground bed. A coke breeze
column of 1m shall be maintained below the lowest anode and a column of 1.5 m above the top
most anodes. The end-to-end spacing between anodes shall be 1.5m. Thus the length of the
active column shall be:
Total active column length = 1.5 + (1x1) + 1 = 3.5 m.
Total anode ground bed depth = 60 + 3.5 + 0.5 = 64 m.
A 250 mm OD diameter steel casing shall be used for the active length of the deep anode
ground beds. In order to calculate the resistance of the deep anode ground bed, the entire
ground bed active column is considered as a single vertical anode.
RPT-E-1709 Page 10 of 15
UAE ARMED FORCES Reference
COMMAND OF MILITARY WORKS RPT E 1719
Date Rev.
DESIGN OF PIPELINE CP SYSTEM
18-Oct-12 00
The soil resistivity value to be considered for the design is 2000 ohm-cm. Therefore,
using the Dwight’s Equation for single vertical anode, the resistance can be calculated as
under:
RV = ρ /2 ΠL {ln (4L/d) -1}
Where,
RV = Ground bed resistance of deep well (Ohm)
L = Length of the active anode column (1600 cm)
D = Column diameter (25 cm)
ρ = Soil resistivity (2000 Ohm-cm)
Thus calculating the resistance of the deep well ground bed:
RV = 2000/2x3.14x 350 x (ln 4x350/25 -1)
= 2.75 ohm
B) Anode Cable Tail Resistance (R A):
The depth of the deep well borehole for both the ground beds is 78 meters with 3 anode strings.
Each anode string shall be connected with 25mm2 cable tail. Anode Junction Box (AJB) shall
be provided at the ground bed locations for the anode cable tail termination. Each
individual anode string cable tail shall be routed to the AJB.
The actual distance of the AJB from the ground bed shall be as per actual site
condition, for design consideration some additional cable length will be added to anode
cable tail to cover this distance.
The selected cable size for the anode tail is 25 mm 2 Kynar/HMWPE black cable with a specific
resistance of 0.000727 ohms per meter. The resistance of the anode cable tails the anode
ground bed is calculated as under:
The depth of the deep well bore hole = 64 m
Length of the cable up to AJB = 64 + 56
= 100 m
Resistance of the anode cable = 100 x 0.000727
= 0.00727 ohm
C) Positive Header Cable Resistance (R PH):
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UAE ARMED FORCES Reference
COMMAND OF MILITARY WORKS RPT E 1719
Date Rev.
DESIGN OF PIPELINE CP SYSTEM
18-Oct-12 00
Positive header cable from TR unit to the anode junction box (AJB) is
approximately 200 meters. Positive header cable size is 50mm 2 and cable resistance is
0.000387 ohm/m.
R PH = 0.0774 ohms
D) Negative Header Cable Resistance (R NH):
Negative header cable from TR unit to the pipeline (Drain point) is approximately 50 meters.
Negative header cable size is 50 mm 2 and cable resistance is 0.000387 ohm/m.
R NH = 0.0194 ohms
E) Negative Drain Cable Resistance (R NDC):
The actual distance of the NJB from the pipelines shall be determined during cable laying, for
design consideration some extra cable length has been included in the calculation. Negative
drain cable size is 25 mm 2 and cable resistance is 0.000727 ohms per meter. The resistance of
the drain cables from various pipelines is
RNDC =0.00727 ohms
F) Pipe to Earth Resistance(R P)
The following equation is used to calculate the pipe to earth resistance
Pipe to earth resistance (R p) = ρ/2πL x (lnLx2/ t x d) (t << L and L >> d)
(Refer NACE Level III course manual)
Where:
R p - Pipe to Earth Resistance (Ohm)
ρ - Soil resistivity (70 Ohm-m)
L - Length of the pipeline (m)
d - Diameter of the Pipe (m)
t - Depth of Pipeline below Grade (2m)
As the pipelines are coated the actual pipe to earth resistance can be calculated by
approximating the bare surface area (coating breakdown) of the pipeline in contact with
soil using the selected protective current density. This coating breakdown value is further
extrapolated to obtain the equivalent pipeline diameter and finally the pipe to earth resistance.
Following parameters were used for the calculations
2
1. Current density for bare steel in soil - 60mA/m
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UAE ARMED FORCES Reference
COMMAND OF MILITARY WORKS RPT E 1719
Date Rev.
DESIGN OF PIPELINE CP SYSTEM
18-Oct-12 00
2
2. Design Current Density - 0.5mA/m
3. Equivalent coating breakdown for 35yrs design life - 0.8 %
4. Calculated Equivalent Diameter (d) of pipeline (m)
Pipe to Earth resistance (RP) = 0.05 (approximately)
G) Total Circuit Resistance (R T):
The total circuit resistances (R T) are the sum of the deep well resistance to earth, the total cable
resistances and the pipe to earth resistances.
The total circuit resistance can thus be calculated as follows:
RT = R V + R A + R PH + R NH + R NDC + R P
= 2.75 + 0.0727 + 0.0774 + 0.0194 + 0.00727 + 0.05
= 2.97 Ohms
8.5 Transformer Rectifier Output Rating
Impressed current cathodic protection system requires a permanent source of power that will
supply a direct current and voltage. The DC output of the power supply shall be
adequately rated to meet the current output at the ground bed resistance.
The voltage output of the TR unit can be determined using Ohm’s Law:
V (voltage) = ITxRT
Where:
IT - Total design current for CP (Amp)
RT - Total circuit resistance (Ohms)
This calculated voltage does not take into account a back e.m.f. generated by a cathodic
protection system ground bed. This back e.m.f. is generally of the order of 2 volts. Thus, the
final DC voltage output shall be the calculated as voltage required plus 2 volts.
V = (I T x R T) + 2
V = (5 x 2.97) + 2
V = 14.85 Volts
However the DC power source for the ground bed is proposed to be rated for 50 Volts / 50
Amperes. The same should be adequate to meet the requirements of the impressed current
cathodic protection system for the required design life.
RPT-E-1709 Page 13 of 15
UAE ARMED FORCES Reference
COMMAND OF MILITARY WORKS RPT E 1719
Date Rev.
DESIGN OF PIPELINE CP SYSTEM
18-Oct-12 00
9.0 SPECIFICATION FOR MAJOR CP MATERIALS
This section covers the technical specifications for the major cathodic protection equipment and
materials required for the impressed current cathodic protection system.
9.1 Transformer Rectifier Unit
Transformer rectifier unit; 400V AC input, oil cooled, 50V/50A DC output. Suitable for installation
in non-hazardous areas, weather proof IP55.
9.2 MMO tubular anodes
MMO tubular anodes; 25.4 mm diameter x 1000 mm long supplied complete with 16mm2 Kynar/
HMWPE string cable of 75m long
9.3 Anode Junction Box (AJB)
Anode Junction Box (AJB) [300 x 300 x 200mm] with shunt (10A /100mV) in each of 3 circuits
for 3 strings of anodes, MS painted enclosure, with suitable size cable hubs. Suitable for safe
area without mounting frame.
9.4 Negative Junction Box (NJB)
Negative Junction Box (NJB) [400 x 600 x 260mm] with shunt (10A / 100mV) in each of 7
circuits and 1 circuit with shunt (25A/100mV), MS painted enclosure, with suitable size cable
hubs. Suitable for safe area without mounting frame.
9.5 CABLES
The cables for cathodic protection system shall be unarmoured cables and shall be rated to
minimum 600 / 1000V. The cable sizes shall be as follows:
• Main positive and Negative cables 1 x 50mm2 XLPE/PVC
• Bonding cables 1 x 25 mm2 XLPE/PVC
• Earthing Cable 1 x 25 mm2 XLPE/PVC
• Monitoring cables 1 x 10 mm2 XLPE/PVC
• Anode String cable 1 x 25 mm2 Kynar /HMWPE
• Reference electrode tail cable 1 x 10 mm2 XLPE/PVC
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UAE ARMED FORCES Reference
COMMAND OF MILITARY WORKS RPT E 1719
Date Rev.
DESIGN OF PIPELINE CP SYSTEM
18-Oct-12 00
• Coupon cable 1 x 10 mm2 XLPE/PVC
• Magnesium Anode cables 1 x 10 mm2 XLPE/PVC
• Zinc Ribbon Anode (ZRA) tail cable 1 x 10 mm2 XLPE/PVC
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