You are on page 1of 15

IMPRESSED CURRENT RETROFITS ON OFFSHORE PLATFORMS THE GOOD, THE BAD AND THE UGLY

Jim Britton Deepwater Corrosion Services, Inc. 10851 Train Court Houston, TX 77041

ABSTRACT It has long been recognized that impressed current can offer significant economic advantages over galvanic anodes on certain types of offshore platforms that require a cathodic protection retrofit. In many cases however, these advantages have been cancelled out by poor performance of impressed current systems. This paper will review some historical design philosophies and discuss good and not so good points regarding the efficiency and reliability of the systems. Newer designs will be compared, and some project economics will be presented. Keywords: Offshore CP, CP Retrofit, Impressed Current, Platform CP INTRODUCTION Many offshore platforms exceed their original design life and thus require a cathodic protection retrofit to facilitate corrosion-free life extension. The economics and apparent simplicity of design and installation offered by impressed current systems have always attracted CP designers. It is in large part this apparent simplicity that has led to the failure of many early designs and some more recent attempts. The major causes of system failure can almost always be linked to the harsh offshore environment. Impressed current cathodic protection systems are no different from many other electrical and mechanical systems installed offshore, if they are correctly and adequately designed, they will fulfill the required design life. SYSTEM ECONOMICS Life cycle cost versus risk of failure is the controlling factor as to whether impressed current makes sense or not. When the economics of a CP retrofit are considered, the dominating number is nearly always installation cost. This is not surprising when the offshore environment is compared to an onshore or inshore location. Table 1. Shows a typical economic comparison for a Gulf of Mexico retrofit. Diving costs follow a non-linear curve as depth increases, and the upward cost shift seems to become quite steep at around 200 feet or greater, this is due to the need to switch from conventional air diving to mixed gas or even saturation diving at these depths. The divers earn more, the support staff and overall number of personnel offshore increases, the size and type of support vessel changes, all these factors lead to higher day rate cost.

Where does impressed current (ICCP) make economic sense? The two drivers are: current requirement and water depth. These factors are interdependent to a large degree but not always. For example impressed current is attractive in the Cook Inlet because of high current requirements and difficulties associated with the installation of galvanic anodes, rather than water depth. Similarly a very large, shallow water template type structure may be in shallow water but because of the steel area, has a very high current requirement. On the opposite side a very deep structure such as a tension leg platform (TLP) will have a very low subsea current requirement due to its design and the extensive use of subsea coatings, impressed current would probably not be a good retrofit option. As a general rule of thumb impressed current systems begin to look quite attractive when current requirements exceed 400 500 Amperes and/or when water depth exceeds 200 feet. What are the basic requirements for ICCP to be considered? Just because a structure may fall into the above category does not automatically make it an ICCP candidate. The following points must be considered early in the decision process. i) ii) iii) iv) v) vi) Does the platform have sufficient spare current capacity to power the system? Is there a place to install the transformer rectifier(s)? What is the distribution of pipelines on and around the structure; is there a risk of interference? Does the structure geometry lend itself to ICCP? Extremely intricate structures or use of very high strength steels may obviate the use of ICCP, or make installation unpractical. Are there any safety concerns? Sport divers, fishermen, endangered wildlife etc. could all be adversely affected by, or could adversely affect the system. Are trained personnel available to operate and maintain the system? SYSTEM COMPONENTS In order to compare performance of various types of system, let us first look at the system components and address some of the pros and cons of various materials and methodologies, let us discern whats good, bad and just downright ugly. Anode Material Over the years the following anode materials have been used in offshore impressed current systems. When selecting the most appropriate material the various properties can be compared in Table 2. Scrap Steel. Used in early system because it is cheap and readily available. Thats about all it has going for it. Unpredictable corrosion patterns, high consumption rate and low operating current density make this a poor selection option. High Silicon (14%) Cast Iron. Usually alloyed with 3-5% chromium for seawater application, the anode has good predictable performance in seawater and mud but the low operating current density, bulkiness and relatively fragile nature restrict its use to low current systems. Graphite. Usually impregnated with either wax or phenolic resin the material has similar properties to silicon iron, except that it is somewhat less dense. Large cylindrical graphite anodes in the order of 1218 diameter and 72 84 long have enjoyed success in Cook Inlet when deployed as remote sea bed anodes. Other applications are again restricted to those with low current requirement. Lead Silver. Lead anodes alloyed with either 2% silver or 1% Silver and 1% Antimony were very popular in the late 1960s and into the early 80s. They offered the advantage of reasonably high operating current density coupled with a fairly low consumption rate. The anode material was particularly popular for ship

systems and for close fitted dielectrically shielded anodes Fig.1. Concerns with the use of lead, coupled with technological improvements in other areas have rendered the material virtually non-existent today. Magnetite (Fe3O4). Cast magnetite anodes were largely pioneered in Scandinavia in the 1970s [1]. They had good current density and low consumption but suffered from being extremely brittle and difficult to connect to electrically. These anodes are not in common use today. Platinized Titanium. Platinized anodes offered high current densities coupled with extremely low wear rates. [2] [3]. Titanium was a good substrate material being relatively readily available and reasonably priced. One major drawback however was the applied voltage limitations [4]. The rutile (Ti02) film was susceptible to breakdown at applied dc voltage in excess of 12 Volts; this could result in rapid substrate corrosion. Because the most available form of the material was coated small diameter rods this 12 volt limitation restricted the use of the product in offshore high current applications, but the material was used extensively in inshore applications. Platinized Niobium. The use of Columbium (Niobium) as a substrate material offered performance advantages over titanium in that the operating current density was much higher and the voltage restriction was, for all practical purposes, eliminated. Platinized niobium anodes could happily operate at surface voltages in excess of 50 Volts. [5]. The platinum was applied to the substrate in several ways, cladding was a popular method [6], other systems used a small platinum wire spiraled around and stitch welded to the substrate. He most popular anode material for offshore use was an even deposited coating [5]. The material did exhibit one weakness that resulted in a failure; the coated material was subject to accelerated corrosion rates if excessive AC ripple was imposed on the DC waveform [7]. Once this phenomenon was understood it was possible to modify the power supplies to filter the rectified supplies. The material was used in a number of North Sea retrofits [8] and on at least new system [9]. Mixed Metal Oxide. As the name would suggest, these anodes are a mixture of metal oxides deposited onto a titanium substrate. Developed in Italy for the chlor-alkali industry they became popular for cathodic protection in the late 1970s. The material offered advantages over both types of platinized anodes, not the least of which was price related. The anodes can operate at high current density and are available in a variety of shapes. Most modern offshore retrofit systems utilize this anode material. [10] [11]. Anode Shape / Geometry. Offshore systems will normally be required to operate at high current density, thus anode shapes which concentrate current discharge will generally not be as reliable long term as those which promote even surface current density distribution. Of course the point at which the current is introduced into the anode will also be a factor. There are only two basic configurations, cylindrical shapes (rods, tubes or wires) and flat shapes (plates, expanded meshes). Generally speaking the cylindrical shapes have more even distribution especially if they are center connected and if end effect is suppressed. This is accomplished by placing a flat dielectric plane normal to the end of the cylinder (Fig 2). The plates and meshes tend to suffer more from edge and end effects that can lead to premature coating failure on some types of anodes when operating at high current density. Cable to Anode Connection This is a critical area, the point at which the dc current is transferred from the supply cable to the anode element. Any degradation that exposes copper conductor to the seawater or mud environment will lead to rapid failure of the anode system. Common errors here are trying to use onshore splicing and joining techniques for deep submerged application or in appropriate material selection for encapsulations. Good. Use flexible (soft) elastomeric materials that will compress around the joint with increasing pressure (depth), ensure that splice material is softer than cable jacket material. Use appropriate primers to seal the splice material to all surfaces involved. Select materials that are chlorine resistant and have low water absorption rates. Provide long water paths when designing joints. Stress-relieve and secure connections, provide mechanical (impact and abrasion) protection to the joint area. Ensure that the mechanical connection does not damage the anode or impart any significant electrical resistance to the circuit. If mechanical seals are used ensure seawater and wet chlorine resistance, always use backup seals

or double o-rings. Hot molded vulcanized connections are generally acceptable. If possible manufacture connections in a controlled shop environment. Bad. Most field connections are subject to possible integrity problems. Splices that run over active areas of the anode surface will tend to disbond with time. Ugly. Use of hard resin splices over softer cable jackets. Allowing the joint area to see movement or stress. Supporting anode on its lead wire. Anode Support Structure Different types of system have various specific support requirements, however the following general guidelines should avoid major pitfalls. Ensure that the structure is capable of withstanding offshore deployment and installation. If it is not practical to tie the structure into the platform (remote sleds for example), ensure that the structure will not corrode and fail; either provide independent CP to the structure or build using corrosion resistant materials. Ensure that the structure will not be subject to interference, it will necessarily be in the high local field gradient around the anodes; try to avoid asymmetrical designs or placement of the support elements directly between the anode and the protected structure. If the anode structure is non-rigid, ensure that there are no areas that will fatigue or abrade causing possible fretting failure. Ensure that the support structure does not entrap evolved chlorine gas; this could result in localized pH values below 1 which could have adverse consequences on materials in the area. Dielectric Shields Some system designs that are close fitted to the platform require dielectric shielding to promote current spread and to avoid localized over-protection of the structure. Shields should be designed to be of sufficient size to achieve the desired result. Material should be chlorine and seawater resistant and have the required dielectric properties. Care should be taken to ensure that the shield does not create a crevice and that the area behind the shield will be completely sealed or will receive adequate CP. Platform applications will require that the shield be monolithic, therefore it must be assured that the shield is adequately supported and will not be subject to undue flexing which could cause cracking. Painted on type shields will not normally be used for retrofit. Positive Anode Cable The main supply cable to the anode or anode array is probably the most common cause of ICCP system failure. There is a tendency to try to cut corners here because the cable represents a large portion of the hardware cost. The importance of correct cable selection cannot be over emphasized. When designing a cable construction the following points have to be considered. Conductor. Select a stranded copper conductor of sufficient size to accommodate the high currents that will not impart too much IR loss. Consider providing a completely redundant cable for designs which have cable routed across the seabed. 19-strand construction is generally preferred for un-conduited cables because a heavy armor will be required. Standard multi conductor cables may often present a viable option; the conductors can simply be made common. Insulation. A 600 Volt grade insulation is sufficient however care should be taken to ensure that the material will be compatible with the proposed jointing / splicing method. PVC, Polyurethane (PU) or Neoprene (PCP) are normally good candidates. Bedding. This is an important component in the cable, the bedding material and configuration must compress over and protect the primary insulation and fill the cross sectional voids in the construction. In addition forms the bed for the armor layers. Armor. It is strongly recommended that all exposed cables be armored using hard steel wires. These constructions have consistently provided the best long-term mechanical reliability. For seabed laid cabling

double wire armoring is recommended. The wires need to be contra-helical; this improves the handling of the wire as well as providing good conductor support for long vertical runs that are to be expected in these applications. Basket weave type armors are of minimal value. Most standard designs use Galvanized Improved Plow Steel (GIPS) for armor wire construction. Jacket. The jacket is the first line of defense for the cable integrity. Materials should be chemically inert in seawater, chlorinated water and to UV exposure. Jacket must have excellent abrasion and impact resistance and should not propagate notches or cuts. The high density cross-linked polymers are generally favored; cross-linked high density polyethylene is a good selection in most cases. Cable Joining. Some system designs require that a number of anodes be connected to a single header cable. This requires more joints that will probably be subsea. A lot of the same rules apply as for anode to cable joining. In some cases a better option may be to use oil filled, pressure compensated enclosures, if correctly designed, these systems can be made virtually fool proof. An example is shown (Fig 3). Cable Support / Routing Previously I indicated that the cable was responsible for many system failures, similarly, virtually all of the failures can be attributed to poor support or routing. Common failures are due to inadequate subsea support that leads to either fatigue or fretting/abrasion failure. This is a particular risk in the splash zone where the wave forces are amplified, and the number of wave cycles in a 10-year period could well exceed 15 million. No movement should be permitted in this area. Seabed Routing. When routing cable across the seabed take care to avoid seabed debris which could inflict damage, if it is not possible to jet the cable into the seabed, install sandbags over the exposed area. Vertical Routing. This covers any cable routing on the structure up to and through the splash zone. A number of different methods have been used including tensioned cables, subsea clamps, and pull tubes. If a system is designed to be tensioned, then the cable(s) will normally be attached to a central tensioned element, either a wire or synthetic rope. Care must be taken to ensure that the cable does not contact any part of the structure between tension points. If a pull tube is available from seabed to a point above the splash zone, this is the best option, indeed the success of many Cook Inlet systems can be attributed in large part to the fact that dedicated J-Tubes are installed for the CP systems. Spare J-Tubes can sometimes be found on these deeper structures. In the event a J-Tube or I-Tube is not available there is an option to install one, this may be expensive, but if the economics permit, it will greatly increase the long-term reliability of the system. If cables are to be routed on the structure without pull-tube protection, the cable supports must be spaced so as to adequately support the cable and prevent excessive movement. If this system is used a splash zone tube should be provided as a minimum. The splash zone tube should be adequately sized to allow the cables to be easily pulled through; the subsea exit point should be either belled or smoothed to eliminate the risk of local fretting. Unprotected cables transiting the splash zone are to be avoided, not only is there risk from normal wave action but also there is the risk of boat impact and impact from grating, flotsam or other debris during hurricanes or other major storms. Topside Cable Routing. The following guidelines should help minimize problems. Avoid lateral cable runs at the lower levels of the structure where they are subject to more damage. Take runs to a point at cellar deck or sub-cellar deck level before lateral runs are made. Avoid any junction boxes or joints in this same area. Ensure that topside cable support hardware is designed to survive the exposure. A CP system with corroded topside hardware doesnt instill customer confidence. Power Supplies Transformer rectifiers are generally very reliable and rarely are the cause of a system failure. Simply ensure that the unit is correctly rated both for capacity and code wise for installation the selected area of the platform. Try to select a sheltered area that is at least at cellar deck level, never install power equipment low on the structure near the waterline. Use oil immersed equipment if possible and specify a good marine coating system for the housing and corrosion resistant materials for the housing sealing

fastenings. Normally it is not necessary to use potentially controlled system. Three phase manually systems are generally preferred for efficiency at the high ratings. Multiple rectifiers are preferred for redundancy; if one goes out, let it only represent 25 30% of the total system capacity. Note that if PtNb anodes are used it may be necessary to smooth the output waveform. Monitoring It is smart business to install some permanent reference electrodes when installing an offshore ICCP system in order to be able to accurately verify system performance. As an aid in commissioning these are invaluable. Like any other impressed current system, offshore systems have IR error, which is probably magnified if a drop cell type reference electrode is used. Unlike most onshore systems, the platform will also often have residual galvanic protection, or may have a galvanic component. This eliminates current interruption as a viable corrector of the error; a close stationary reference electrode is the simplest, and most effective solution. Perhaps an even more compelling reason to install monitoring is to enable accurate long-term performance verification. Remember that the system will have to be de-energized in most cases during diver (and possibly ROV) inspections, therefore the true close potentials of the structure can only be monitored using permanent electrodes If possible reference electrodes (zinc/seawater recommended) should be located at the following areas on the structure: i) ii) iii) iv) Near the mud line. (Often a difficult area to polarize) In the conductor area. (Definitely a high surface area with possible shielding) At close anode cathode areas. (Where overprotection must be avoided) At typical parts of the structure that are remote from the anode system. (In order to verify current distribution)

In spite of all these good reasons to install reference electrodes many systems in the Gulf of Mexico have no monitoring provision. SYSTEM TYPES Having discussed important attributes that will ensure a reliable system, lets now investigate some of the more commonly used system designs and see where they succeed and where they may fail. Most of the examples quoted are taken from personal experiences of the writer: some are derived from his company's offshore inspection records. Suspended Anodes Anodes are freely suspended from above water locations either from the feed cable or a strain member, often weighted and contained within a dielectric frame. This can be a viable approach for shallow water structures with a relatively short life expectancy (<5 years) and a moderate to high current demand. Anode failure will occur on a regular basis, but with very low replacement cost the systems may still represent a viable short-term option. This is not a good solution for deeper water structures. Care must be exercised when locating the anodes to ensure that boats or sport fishermen cannot contact the live suspended wires. Silicon Iron or Graphite anodes can work well in this application (Fig. 4). Gravity Sleds Anode sleds designed to sit on the sea floor at some distance from the structure. (Fig 5). Some are designed to become silted other are much larger and are designed to keep the anodes in seawater. In either case this can be a good design. In the writers experience most failures of these systems have resulted from damage to the seabed cable or failure of the anode to cable connection. However if the design issues

are addressed a gravity sled is a good system basis. Most remote systems may need some galvanic anodes to assist in shielded area polarization. Buoyant Sleds Similar to gravity sleds but the anode elements are held up in the seawater by means of buoys, normally integral with the anode. (Fig. 6). A variation on this design is shown (Fig. 7). The advantage of the buoyant sled is that the critical elements can move freely if hit by falling debris, and the overall structure is much lighter. These systems have generally enjoyed good long-term success [8]. Close Fitted Anodes Anodes are attached directly to the structure and require dielectric shields (Fig. 1). This system does not lend itself to retrofit on platforms due to the excessive amount of pre-installation cleaning required and the complexity of the cable installations. Cantilevered versions of the same are available but have the same basic problem. These systems work well for docks and inshore facilities. Tensioned String Anodes This system uses a tensioned string of anodes (Fig 8), usually mixed metal oxide, although early versions used platinized niobium. These systems have had mixed results, failures typically have been caused by string failure due to wave action and abrasion with subsea members. As the strings get longer in deeper water more tension is required to minimize deflection of the string subsea, or alternatively a number of mid-string tiebacks are required to limit movement. Earlier system had tensioning equipment above the water line [10] (Fig.9), this made the section of anode string through and above the splash zone very susceptible to damage from storms, and system life was often short. Later projects moved the tension point to a sub-sea location [11], and used a pull tube to get the cables through the splash zone, it is expected that this version will perform much more reliably. Semi remote Chutes Sold in the 70s and early 80s these systems were original equipment on many structures. Vertical chutes were run through the jacket and attached by welding or clamping. They terminated at various elevations below the waterline. The anode protruded from the end of the chute, silver lead anodes were popular in early designs, but these were later replace by platinized anodes. The design was supposed to provide easy replacement should the anodes fail, however, although many of these systems fulfilled the original design life, replacement was not as easy as thought. The chutes became fouled with marine growth and were virtually impossible to pass a cable through; no successful retrofits have been made to the writer's knowledge. Hybrid Systems Using a combination of ICCP and galvanic anodes often will provide the best of both worlds. The ICCP provides large packages of current usually 80 90% of the total demand. Strategically located galvanic anodes assist in current distribution to hard to polarize areas. One of CPs more amusing myths is the line of sight protection theory, while this obviously is not valid, complex geometry shielding is a reality. This is more a function of current requirement than any line of sight effects, however hybrid systems can successfully address these areas. For this reason, installation of an impressed current retrofit on a platform originally protected by galvanic anodes will work very well if the project is timed such that some original galvanic material remains. CONCLUSIONS Impressed current systems can work very well and provide a cost effective alternative to galvanic anodes in certain situations. Use the following guidelines when considering a retrofit.

i)

ii) iii) iv)

Ensure that the platform is a viable candidate, that the current requirement and water depth are applicable. And that the structure has available power and sufficient remaining life requirement. Pre-qualify your system choice, get performance data, and check other client references. Many ICCP systems are poorly designed and will fail early, ask for a written warranty. If structure has galvanic anodes, try to schedule the retrofit to make use of the remaining current capacity. If applicable, prepare a galvanic retrofit design and get an as installed price for comparison. If the installed cost of the ICCP system isnt significantly less, then go with the galvanic system.

REFERENCES 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Bjorn Linder Magnetite Anodes for Impressed Current Cathodic Protection Materials Performance, August 1979. M.A. Warne Precious Metal Anodes Options for Cathodic Protection Materials Performance, August 1979 Richard A. Lowe Platinized Titanium as Anode Material Materials Performance, April 1966 M.A. Warne, P.C.S Hayfield Platinized Titanium Anodes for Use in Cathodic Protection Materials Performance, March 1976 P.C.S Hayfield Electrochemical Properties of Niobium in Impressed Current Cathodic Protection Materials Performance, November 1981 Robert Baboian Performance of Platinum-Clad Columbium Impressed Current Anodes in Fresh Water Materials Performance, December 1983 K. D. Efird Current Waveform Initiated Corrosion Failure of Platinum/Niobium Anodes in Seawater Cathodic Protection Systems Materials Performance, June 1982 Tim Ffrench-Mullen An Impressed Current System for the Protection of Offshore Platforms Materials Performance, November 1980 J.D. Edwards et al Retrofitting Offshore Structures with Tubular Metal Oxide Activated Titanium Anodes NACE - CORROSION 91, Paper 91240. M.L Smith, C.P Weldon Impressed-Current Tensioned Anode Strings for Offshore Structures NACE CORROSION 97, Paper 97476

Figure 1. Close Fitted Dielectrically Shielded Anode

Figure 2. Buoyant Anode Module - MMO Anode Rods Arranged to Minimize End Effect

Figure 3. Pressure Compensated Oil Filled Junction Box On a Retrofit Sled

Figure 4. Typical Suspended Anode

Figure 5. Typical Gravity Sled

Figure 6. Single Buoy Anode

Figure7. Multi Buoy Anode Sled Ready for Offshore Deployment

Figure 8. Vertically Tensioned Anode String

Figure 9. Upper Suspension Point for a Tensioned Anode String

Table 1. Hybrid Retrofit on 2100 8 Pile Platform Gulf of Mexico 755-Ampere Current Required Cost Comparison with Conventional Aluminum Anode Retrofit Item 1.0 2.0 3.0 4.0 5.0 6.0 7.0 Qty 3 2400 3 6 3 60 Lot Unit pcs feet pcs pcs pcs pcs Lot Description 250 Ampere ICCP Buoyant Sled 4/0 AWG DGSWA Wire (2 per Sled) 250 Amp 24 Volt Oil Immersed Marine Rectifier Class1 Div. 2 Group D Zinc Reference Electrode 4 I-Tube Assembly Cable Supports Topside Electrical Hardware ICCP Equipment Cost 8.0 10 pcs $119000

Dual 410 lb Suspended Anode Assembly c/w fittings (Aluminum Anodes) Galvanic Anode Cost $ 14000

9.0 4.0 5.0

Estimated Installation time 5 Days @ $25000 Estimated Mob-DeMob $40000 Topside Installation 7 Days @ $1500 Sub Total Installation $175500

Total Installed Cost Estimate $308500 (Note this system includes 250 A Redundancy) CONVENTIONAL CLAMP ON GALVANIC OPTION Item 1.0 Qty 90 Unit pcs Description Dual 325lb Assemblies with Hardware $76500

Material Cost 3.0 4.0

Estimated Installation time 16 Days @ $25000 Estimated Mob-DeMob $40000 Sub Total Installation $440000

Total Installed Cost $516500 67.5% More Than ICCP Hybrid Option

Table 2. Comparison Of Impressed Current Anode Performance Material Scrap Steel Silicon Iron Graphite Lead Silver Platinized Anodes Mixed Metal Oxide Current Density Range < 0.1 A/sqft (<1.0 A/sqM) 2 - 3 A/sqft (20 - 30 A/sqM) 1.5 - 2.5 A/sqft (15 - 25 A/sqM) 20 - 30 A/sqft (200 - 300 A/SqM) 50 A/sqft (500 A/sqM) 50 A/sqft (500 A/sqM) Consumption / Wear Rate 20 lb/A-yr (9 Kg/A-yr) 0.5 lb/A-yr (225 g/A-yr) 0.5 lb/A-yr (225 g/A-yr) 0.2 lb/A-yr (100 g/A-Yr) 8 - 10 mg A-Yr 1 - 2 mg A-yr

You might also like