M.SH.

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TABLE OF CONTENTS
1.0

INTRODUCTION PART.
1-1 Corrosion

1-2 Cathodic protection difination

1-3 Type of cathodic protection

1-4 Preliminary data definition cathodic protection

2.0

COMPONENTS SPECIFICATION OF
2- 1 Transformer

2-2 Enclosure
2-3 Anodes

3.0

DESIGN CALCULATION.
3-1 Current demand

3-2 Couting breakdowen factor

3-3 Anode weight

PROJECT CALCULATION EXAMPLES.

4-1 Pipe line of Suez golf

4-2 Mina mussafah, abo Dhabi

13
4-3 Extension of berth no.(13) in damitta port

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1.1

Corrosion

Corrosion is electrochemical process in which a current leaves structure at

the anode site passes through an electrolyte and reenters the structure at the
cathode site as
fig. (1-1) shows. For example one small section of a
pipeline may be anodic flows because of a potential difference between the
anode and cathode . that is, the anode potential is more negative than the
cathode potential, and this difference is the driving force for the corrosion
current.


1-1


.()

Fig (1-1)
1.2 Cathodic protection :

Its method to reduce corrosion by minimizing the difference in potential

between the anode and cathode by applying a current to the structure to
protected from some out side source. When enough current is applied, the
whole be structure will be at one potential:

1.3

Types of cathodic protection systems.

There are two main types of cathodic protection systems.

Fig A -Impressed Current Cathodic Protection

Fig B - Galvanic Cathodic Protection

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Anodes

Fig (B)
1.4

Fig (A)

Preliminary Data Definition of Cathodic Protection:

Before the system is design, certain preliminary data must be gathered:

1.4.1 Dimensions :
(surface area to be protected)

For example, length, width, height and diameter.

1.4.2 Layout

Material type, and location parts of the structure to

be protected

1.4.3 Insulators

some times parts of structure or system are electrically

isolated from each other by insulator.

.

1.4.4 Short circuit :

a short circuit can occur when one pipe system contacts
another.

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1.4.5 Electrolyte resistivity

as electrolyte resistivity increases, the corrosion rate
decreases the resistivity data will be used to
calculate the sizes of anodes and rectifier required
in designing the cathodic protection system

1.4.6 Electrolyte PH:

Steels corrosion rate increases as PH decreases when
soil resistivity remains constant, the potential
requirement for cathodic protection is negative
(cathodic) potential of at least 850 mV as measure
between the structure and a saturated Copper - Copper
Sulfate reference electrode in contact with electrolyte



850
(

1.4.7 Current density:

A well coated structure (for example, a pipeline well
coated with coal-tar epoxy ) will required avery low
current density An uncoated structure would require
high current density
)
(

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2 1 Transformer

55 %80

Transformer should be designed for continuous operation at ambient

temperature of 55 C and humidity 80 %.

)a

Transformer should be auto and double wond transformer

)b

380
) 220(

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c)

Transformer of 1 Kw output and above should be three phase (380 V) and

if less than power it should be single phase (220 V)

d) Cooling of transformer is oil or air cooled if it oil cooling type it shall has
the minimum following accessories:1.

Oil filler cap

2.

Level gauge

3.

Drain plug

4.

Thermometer pocket

5.

Silica gel breather

:

e) (T/R) testes are required on the following:

1. Wiring connections

2. Insulation resistance test .

3. Operation at full output current and voltage

4. Manufacture shall submit test certificate with results of A/M test

Enclosure 2 - 2
a) Enclosure for outdoor T/R, sheet steel construction, weatherproof less
than IP 55 class of protection
b) All units shall be provided with output D.C. voltammeter and ammeter

Anodes type Specification 2-3

a- anode material specification as the following table:-

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Item
1
2
3
4
5
6
7
8
9

Type of anode
Platonized titanium wire anode
Platonized titanium anode in retainer
Platonized niobium anode in retainer
Platonized titanium anode in retainer
Platonized titanium dick-anode in retainer
Silicon iron anode
Silicon iron with coke breeze backfill anode
Silicon iron chromium anode
Mixed metal oxide anode

ACR
(Kg/Ay)
0.01
0.01
0.01
0.01
0.01
0.4
0.4
0.4
0.000001

0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.85
0.9

* Acr : anode consumption rate

b- Anodes cables shall be stranded soft annealed copper than 10 mm 2 minimum.
wire copper cross section, 600/1000 volt, pvc/pvc insulation.
c- Manufacturer shall submit a test certificate including the metal consumption
.rate at typical current density composition and typical current density (A/m)

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3-1 Current demand calculation (Ic):

The current requirement to protect the steel structure or other structure.
Ic = A*BD*J
Where :

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= Total Surface Area. ( mm 2 )

= Current Density. A/ m 2

BD

= Coating Break-Down factor.

3-2 Coating Breakdown factor:

fc = k1+k2*t
Where fc = coating breakdown factor
t = coating life time
k1, k2 = constants dependent on coating properties
Depth

0-30
>30

i
k1=0.1
k2
0.1
0.05

Coating category
ii
iii
iv
k1=0.05 k1=0.02 k1=0.02
k2
k2
k2
0.03
0.015
0.012
0.02
0.012
0.012

-:Anodes weight calculation 3-3

.Total Anodes Weight = [ACR x AY) / ]

Where
W = Total net anode weight (kg)
ACR= Anode consumption rate kg/A. year
Ay = Total ampere - year
= efficiency

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M.SH.C3

Summery And Data Given:

Cathodic protection system shall be executed by using impressed
current system for protecting buried pipeline:

For 1st pipeline:

Total surface area to be protected
length
Diameter

348340 m2
79200 m
1.4 m

For 2nd pipeline:

Total surface area to be protected
length
Diameter

69806 m2
20200 m
1.1 m

Cotenant items for the & . pipeline :

- Current density (J)

: 10 mA/ m2

- Considered coating damage

:5%

- Design life time (LT)

: 25 years

- Anodes type

: Fe- Si Cr Anode

- Anodes Consumption Rate (ACR)

: 0.4 kg/A. Year

- Anodes efficiency ()

: 0.85

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Anodes Calculations:For 1st pipeline:

AY = A * J* BD * LT

AY = 348340 x 10 x 10-3 x 0.05 x 25

= 4354.25

Amp-Year.

Anode Consumption Rate

= 0.4

kg/Amp-Year.

Anode Efficiency ()

= 0.85

Total Anodes Weight.

= [ACR * AY / ]
= 0.4 * 4354.25 / 0.85
= 2049 kgs

Anode Calculations for 2nd pipeline:

AY = A * J* BD * LT

AY = 69806 x 10 x 10-3 x 0.05 x 25

= 872.58

Amp-Year.

Anode Consumption Rate (ACR)

= 0.4

kg/Amp-Year.

Anode Efficiency ()

= 0.85

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Total Anodes Weight.

= [ACR * AY / ]
= 0.4 * 872.58 / 0.85
=410 kgs

Where
AY = total ampere year
LT = design life time

Transformer Rectifier (T / R) Units Calculations:

Current demand:
Total Surface Area to be
Protected
Current Demand (I)

= A1+A2
=348340+69806
=418146 m2
= A JD
= 418146 10-3 * 0.05
= 209 A

Consider about 15 % extra for transformer rectifier saving during life

time.
Total Required Current

= 209 x 1.15
= 240.35A.

Apply 3 T/R units each rated (24 V. DC, 80 A DC).

In case of weight of anode
No. of anodes = 50 anodes
REMARK

Suppler used in the project

a) 60 anodes, 50kg weight
b) three transformer 3 x100 A

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= 50 Kg

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:Summery and Data Given

Cathodic protection system shall be executed by using impressed current
system for protecting buried pipe line, & tanks:
For Tanks TK-01 & TK-02:
Total surface area to be protected
Height
Diameter

628.32 m2
11 m
20 m

For Tanks TK-03:

Total surface area to be protected
Height
Diameter

78.54 m2
6.5 m
10 m

For 1st pipeline ( 8" ):

Total surface area to be protected
533 m2
length
848m
Diameter
0.2 m
nd
For 2 pipeline( 6" ):
Total surface area to be protected
length
Diameter

67 m2
142 m
0.15 m

For 1st pipeline( 4 "):

Total surface area to be protected
length
Diameter

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12 m2
38 m
0.1 m

- Current density for tanks

- current density for pipeline

: 15 mA/ m2
: 5 mA/ m2

Considered coating damage

- Design life time
- Anodes type

: 100 %
: 20 years
: silicon iron anode

- Anodes Consumption Rate

: 0.2 kg/A. Year

- Anodes efficiency

: 0.75

Anodes Calculations for Tanks TK-01, TK-01 & TK-03

AY = A * J* BD * LT

Total Area =628.32+78.54

= 706.85 m2

AY = 706.85 x 15 x 10-3 x 1 x 20

= 212 Amp-Year.

Anode Consumption Rate

= 0.2

kg/Amp-Year.

Anode Efficiency ()

= 75.0

Total Anodes Weight.

= [ACR * AY / ]
= 0.2 * 212 / 0.75
= 56.5 kgs

In case of weight of anode

No. of anodes

= 10 Kg
= 6 anode

Anode calculations For pipeline:

AY = A * J* BD * LT

Total Area =533+67+12

= 612 m2

AY = 612 x 5 x 10-3 x 1 x 20

= 61.2Amp-Year.

Anode Consumption Rate

= 0.2

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kg/Amp-Year.

Anode Efficiency ()

= 75.0

Total Anodes Weight.

= [ACR * AY / ]
= 0.2 * 61.2 / 0.75
=16.32 kgs

In case of weight of anode

= 10 Kg

No. of anodes

= 2 anode

Transformer Rectifier (T / R) Units Calculations:

Current demand for tanks:
Total Surface Area to be
Protected

= 2*A1+ A3
=628.32+78.54
=706.85 m2
= A JD
= 706.8 10-3 * 1
= 10.6 A

Current Demand (I1)

Consider about 15% extra for transformer rectifier saving during life time
Total Required Current

= 12.2 A

Current demand for pipe line:

Total Surface Area to be
Protected
Current Demand (I2)

= A1+ A2 +A3
=533+67+12
=612 m2
= A JD
= 612 10-3 * 1
= 3.1 A

Consider about 15 % extra for transformer rectifier saving during life

time.
Total Required Current

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= 3.6 A

Apply One Transformer 24 V DC with Two outputs one for tanks =15 A
other for pipe line = 5A
Remark
Suppler used in the project
a) Anode, 10 kg weight
b) Transformer 24V.DC 25/5A

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DESIGN CRITERIA
Cathodic protection system shall be executed by using impressed current system for
protecting only the sea word side of the sheet piles .
- Total surface area to be protected (One side):
Splash zone
: Involved in the Permanent immersed zone
Permanent immersed zone
: 10110 m2 (approx.).
Buried zone
: 5900 m2 (approx.).
- Coating nature

: None

- Current density of the bare steel:

Splash zone
Permanent immersed zone
Buried zone

: 45 mA/ m2
: 90 mA/ m2
: 20 mA/ m2

- Water resistivity

: 0.33 ohm m

- Considered coating damage

: 100 % (of the sea side piles).

- Design life time

: 30 years

- Anodes type

: (MMO) Mixed Metal Oxide, 35 A

output.

- Anodes Consumption Rate

: 1.0 mg/A.Year

- Min. potential limit ref. to the sea water

: - 800 mV acc.to Ag/Ag Cl half cell after

polarization.

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DESIGN CALCULATIONS
Based on formula:
AY = A * J* BD * LT

Anodes Calculations:
For Immersed zone:
AY = 10110. x 90 x 10-3 x 1.0 x 30
say

= 27297.0
= 27300.0

Amp-Year.
Amp-Year.

MMO Anode Consumption Rate

= 1.0

mg/Amp-Year.

MMO Anode Efficiency ()

= 85.0

Total Anodes Weight.

= [ACR * AY / ]
= 1 * 27300 /[(1000000)*( 0.85 )]
= 0.032 kgs

For Buried zone:

AY = 5900. x 20 x 10-3 x 1.0 x 30
say

= 3540.0
= 3600.0

MMO Anode Consumption Rate

= 1.0 mg/Amp-Year.

MMO Anode Efficiency ()

= 85.0

Total Anodes Weight.

= [ACR x AY) / ]

Amp-Year.
Amp-Year.

= 1 x 3600 /[(1000000) x (0.85)]

= 0.004 kgs

Total weight of MMO Anode required for both immersed and buried zone
= 0.032 + 0.004
= 0.036 kgs
Total Number of Anodes required

= 1 anodes

- We shall apply 32.0 Anodes (For best distribution along sheet piles).
- The attached drawing will indicate anodes connection .

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Transformer Rectifier (T / R) Units Calculations:

Current demand for immersed zone:
Total Surface Area to be Protected

= 10110.0 m2

Current Demand (I)

= A JD
= 10110 10-3 * 1.0
= 909.90
(910.0 A)

Say

Current demand for buried zone:

Total Surface Area to be Protected

= 5900.0 m2

Current Demand (I)

= A JD
= 5900 10-3 * 1.0
= 118.00
(120.0 A)

Say
Total Required Current

= 910 + 120
= 1030.0 A

Consider about 15 % extra for transformer rectifier saving during life time.
Total Required Current

= 1030 x 1.15
= 1184.50 A.

We shall apply 4 T/R units each rated (24 V. DC, 300 A DC).

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