Design Calculation CP

Design Calculation
Of
TERMINAL A
CODE
CALCULATIONS
RESUL
TERMINAL A
SURFACE AREA OF STRUCTURE
Total Length of the terminal A = 475m
Width of a sheet piling = 1.4m
Actual width of a unfolded sheet piling = 1.6m
Correction factor for metre length of a sheet piling:
= 1.6
1.4
= 1.14
DNVRP-
a. Surface area of newly installed sheet piling, A1, 2.5m depth

= 475 * 2.5* 1.14
= 1,353.75 m2
1,353.75 m2
b. Surface area of existing sheet piling, A2, 5.5m depth
= 475 * 5.5 * 1.14
= 2,978.25 m2
2,978.25 m2
CODE
CALCULATIONS
RESUL
DESIGN PARAMETERS
The following parameters have been considered in the design of
Cathodic Protection System for Tin can Port Terminal A and
adequate values or categories have also been selected for these
parameters to ensure that a protective CP potentials would be
maintained for the sheet piling spanning the terminal.
DNVRP-
BS
7361DNVRP-
DNVRP-
a.
Current density for area below high tide level (initial) = 150 mA/m 2
b.
Current density for area below high tide level (mean) = 70 mA/m 2
c.
Current density for area below high tide level (final) = 100 mA/m2
d.
Driving potential (initial life) = 250 mV
e.
Driving potential (mid life) = 150 mV
f.
Design life = 15years
g.
Cathodic protection method: Sacrificial anodes
h.
Coating conditions: Category I
i.
Anode Material: GALVALUM-III
j.
Anode Utilization factor = 0.9
k.
Electrochemical capacity of Anode material (seawater) = 2000 AH/Kg (min.)
l.
CODES
Seawater resistivity = 0.25 ohm-m
CALCULATIONS
COATING BREAKDOWN FACTOR, FC

DNVRP-
Fci = Coating Breakdown factor at initial life of anode
RESUL
Fci = Coating Breakdown factor at mean life of anode

Fci = Coating Breakdown factor at final life of anode
Components
1 A1, newly
installed sheet
piling
2 A2, existing sheet
piling
CODES
DNVRP-
Status
Fci
Fcf
Remarks
0.1
Fc
m
0.6
Mild
1.0
Category;
a= 0.1,
b= 0.1
Severe
1.0
1.0
1.0
CALCULATIONS
RESUL
CURRENT DEMAND (INITIAL)

The following calculations would consider appropriate current
density stated above with other parameters for the initial current
demand of the structure for initial polarisation to a protective volt.
Current Demand, Ic = Ac ic fc
Where Ac = Surface Area of indicated components.
ici = Initial Current Density
fci = Coating Breakdown factor (initial)
1. Newly installed sheet piling, A1, 2.5m depth
Current Demand = 1,353.75 * 150 * 0.1
1000
= 20.31A
20.31A
2. Existing sheet piling, A2, 5.5m depth
Current Demand =
2,978.25 * 150 * 1.0

1000
= 446.74A
446.74A
CODES
DNVRP-
CALCULATIONS
RESUL
MASS OF ANODE REQUIRED (INITIAL)

The mass of anode required to maintain cathodic protection
through out the design life of 15 years for individual component at
initial current demand:
Ma = Ici tf 8760
u
where Ma = Mass of anode required.
Ici = Current demand (initial)
tf = Design life
u = Electrochemical capacity of the anode
= Anode utilization factor
Assumptions
1. 15 years of design life with adequate cathodic protection
is considered
2. Anode utilization factor of 0.9 is applied.
Mass of anode required, Ma = 20.31 * 15 * 8760
0.9 * 2000
= 1,482.63kg
1,482.63kg
0.9 * 2000
= 32,612.02kg
32,612.02kg
s/
n
Components
Newly Installed sheet

piling
Existing sheet piling
Total
CODES
Initial
Current
Demand,
A
20.31
Mass of
Anode,
kg
446.74
32,612.0
2
34,094.
65
467.05
CALCULATIONS
1,482.63
RESUL
CURRENT DEMAND (MEAN)

density stated above with other parameters for the mean current
demand of the structure.
Where Ac = Surface Area of indicated members.
icm = Mean Current Density
fcm = Coating Breakdown factor (mean)

Current Demand = 1,353.75 * 70 * 0.6
1000
= 56.86A
56.86A
Current Demand =
2,978.25 * 70 * 1.0
1000
= 208.47A
208.48A
CODES
CALCULATIONS
RESUL
MASS OF ANODE REQUIRED (MEAN)

mean current demand:
Ma = Icm tf 8760
u
Icm = Current demand (mean)
tf = Design life
Assumptions
is considered
0.9 * 2000
= 4,150.78kg
4,150.78kg
Mass of anode required, Ma =
208.48 * 15 * 8760
0.9 * 2000
= 15,219.04kg
15,219.04kg
s/
n
Components

piling
Total
CODES
Mean
Current
Demand,
A
56.86
Mass of
Anode,
kg
208.48
15,219.0
4
19,369.
82
265.34
4,150.78
CALCULATIONS
RESUL
CURRENT DEMAND (FINAL)

density stated above with other parameters for the final current
icf = final Current Density
fcf = Coating Breakdown factor (final)

Current Demand = 1,353.75 * 100 * 1.0
1000
= 135.38A
135.38A
Current Demand =
2,978.25 * 100 * 1.0

1000
= 297.83A
297.83A
CODES
DNVRP-
CALCULATIONS
RESUL
MASS OF ANODE REQUIRED (FINAL)

final current demand:
Ma = Icm tf 8760
u
Icf = Current demand (final)
tf = Design life
Assumptions
is considered
135.38 * 15 * 8760
0.9 * 2000
= 9,882.74kg
9,882.74kg
297.83 * 15 * 8760
0.9 * 2000
= 21,741.59kg
21,741.59kg
s/
n
Components

piling
Total
CODES
Final
Current
Demand,
A
135.38
Mass of
Anode,
kg
297.83
21,741.5
9
31,624.
33
433.21
9,882.74
CALCULATIONS
RESUL
ELECTION OF ANODE TYPE

DNVRP-
The selection of anode type for Terminal A Sheet piling was

determined by the size, spatial uniformity in the geometrical
configuration of the sheet piling and forces that would exert on the
fabricated anodes during installation and operation
Based on above criteria and several, The Stand-off Anode was
selected with following specifications:
Type
750NP
Net Wt, Kg
75
Width, mm
184
Height,
mm
184
Length,
mm
827
Overall
Length,
mm
1,469
Core
Specificati
on Flat
bar
50 * 12mm
Maximum
Current
available
1.917
Complete anode schematic is shown in the attached drawings.

DNVRP-
CALCULATION OF ANODE RESISTANCE IN SEAWATER

To find the resistance of 750NP
Manufacturer specification:
Seawater resistivity = 0.25 ohm.m
Driving potential = 250mV
Current = 1.917A
Ra =
2**L
CODES
4L
In
r
-1
CALCULATIONS
RESUL
where = seawater resistivity

L = Length of Anode material
r = radius of Anode cross-section
The cross-section of the selected anode is a rectangular,
Thus, radius =
radius =
2(w + h)
2*
736
6.284
radius = 117.12mm
Rai
0.25
4 0.827
2 3.142 0.827
In
-1
0.117
= 0.048 2.34
= 0.112 ohm
Rai = 0.112 ohm

CALCULATION OF ANODE CURRENT OUTPUT
DNVRP-
I a = E c - Ea
Ra
But Manufacturers specification states the following conditions
Driving voltage = 250mV
Max available Current = 1.917 (Initial Life Current)
Iai = 1.917 A
Therefore Ra = 0.250 / 1.917

= 0.130 ohm
The difference in resistance = 0.130 0.112 = 0.018 ohm can be
attributed to resistive component of the anode insert.
CODES
DNVRP-
CALCULATIONS
FINAL ANODE CURRENT OUTPUT

Mass of remaining Aluminium anodic material at the
Final life is 10% of the total mass i.e. 90% anode efficiency.
Mass (end-life) = Mass (initial life) (1 U)
Mass (end life) = 75 kg * (1 0.9)
Mass (end life) = 75 * 0.1
Mass (end life) = 7.5 kg
Volume of remaining net mass of anode, V (end life)
RESUL
= Mass of Aluminium
Density of Aluminium
Volume (end life) = 7.5 kg
2678 kg / m3
= 0.0028 m3
Widt
h
mm
184
Initi
al
Life
Final 0.00
Life
2
DNV-RPB401
Heigh
t
mm
184
Length Net
mm
Wgt
kg
827
75
Volume
m3
0.002
744.3
0.0028
7.5
0.0280
Assume the cross-section of the selected anode still remains rectangular

Thus, radius =
2(w + h)
2*
radius =
0.008
6.284
radius = 0.0012mm
CODES
CALCULATIONS
RESUL
Therefore, resistance of anode at end-life:

Rf
0.25
4 0.7443
2 3.142 0.7443
In
-1
0.0012
= 0.053 6.816
= 0.36 ohm
Raf = 0.360 ohm
I a = E c - Ea
Ra
Anode Output (end life),Iif = Ec - Ea

Rif
= 0.25
0.36
= 0.69A
Iaf = 0.694
A
CODES
CALCULATIONS
A. NUMBER OF ANODE (INITIAL LIFE)

1. New Installed sheet piling
= 20.31 / 1.917 = 10.59 approx. 11no.
2. Existing sheet piling
= 446.74 / 1.917 = 233.04 approx. 233
RESUL
s/
n
Components
Initial
Current
Deman
d, A
Newly Installed
sheet piling
20.31
12
Anode
Current
Output
(Initial
life), A
23.00
Existing sheet
piling
446.74
234
448.58
467.05
246
471.58
TOTAL
No of
Anode,
kg
B. NUMBER OF ANODE (FINAL LIFE)

= 135.38 / 0.694 = 195.07 approx. 196no.
= 297.83 / 0.694 = 429.15 approx. 430no.
s/
n
Components
Final
Current
Deman
d, A
Newly Installed
sheet piling
135.38
200
Anode
Current
Output
(Final
life), A
138.00
Existing sheet
piling
297.83
435
300.15
433.21
635
438.15
TOTAL
CODES
No of
Anode,
kg
CALCULATIONS
RESUL
ACCEPTANCE CRITERIA
DNVRP-
The current outputs as per the anode mass provided for respective
members are being considered if it satisfies the acceptance
criteria as stated below:
Thus:
i. Ca tot = N * Ca Icm * tf * 8760
ii. Iatot i = N * Iai Ici
iii. Iatot f = N * Iaf Icf

Ca = individual anode current capacity
Ca = m a X X u
ma = net mass per anode, kg
= anode electrochemical capacity, AH / kg
u = anode utilisation factor
Ca = 75 kg X 2000 AH/kg X 0.9
Ca = 135,000 AH per anode
Therefore; Ca tot = 135,000 AH per anode x 635 Icm * tf * 8760
= 85,725,000 AH 265.34 * 15 * 8760
= 85,725,000 AH 34,865,676 AH
Accepted
Iatot i = 635 * 1.917 467.05
= 1,217.29 A 467.05 A
Accepted
CODES
CALCULATIONS
RESUL

Iatot f = N * Iaf Icf
= 635 * 0.690 433.21 A
= 438.15 A 433.21 A
Accepted
The number of anodes on the members of Terminal A is
s/
n
1
2
Components
No of Anode, kg

piling
200
435
TOTAL
635
Design Calculation
Of
TERMINAL B
CODE
CALCULATIONS
RESUL
TERMINAL B
SURFACE AREA OF STRUCTURE
Total Length of the terminal B = 750m
Width of a sheet piling = 1.4m
Actual width of a unfolded sheet piling = 1.6m
Correction factor for metre length of a sheet piling:
= 1.6
1.4
= 1.14
DNV-
a. Surface area of newly installed sheet piling, B1, 2.5m depth

= 750 * 2.5* 1.14
= 2,137.50 m2
2,137.50 m2
b. Surface area of existing sheet piling, B2, 5.5m depth
= 750 * 5.5 * 1.14
= 4,702.50 m2
4,702.50 m2
CODE
CALCULATIONS
RESUL
DESIGN PARAMETERS
The following parameters have been considered in the design of
Cathodic Protection System for Tin can Port Terminal B and
adequate values or categories have also been selected for these
parameters to ensure that a protective CP potentials would be
maintained for the sheet piling spanning the terminal.
DNVRP-
DNVRP-
a.
Current density for area below high tide level (initial) = 150 mA/m 2
b.
Current density for area below high tide level (mean) = 70 mA/m 2
c.
Current density for area below high tide level (final) = 100 mA/m2
d.
Driving potential (initial life & final life) = 250 mV
e.
Driving potential (mid life) = 150 mV
f.
Design life = 15years
DNVRP-
g.
Cathodic protection method: Sacrificial anodes
h.
Coating conditions: Category I
i.
Anode Material: GALVALUM-III
j.
Anode Utilization factor = 0.9
k.
Electrochemical capacity of Anode material (seawater) = 2000 AH/Kg (min.)
l.
CODES
Seawater resistivity = 0.25 ohm-m
CALCULATIONS
RESUL
COATING BREAKDOWN FACTOR, FC

DNVRP-
Fci = Coating Breakdown factor at initial life of anode

Fci = Coating Breakdown factor at mean life of anode
Fci = Coating Breakdown factor at final life of anode
Components
1 A1, newly
installed sheet
piling
2 A2, existing sheet
piling
Status
Fci
Fcf
Remarks
0.1
Fc
m
0.6
Mild
1.0
Category;
a= 0.1,
b= 0.1
Severe
1.0
1.0
1.0
CODES
DNVRP-
CALCULATIONS
RESUL
CURRENT DEMAND (INITIAL)

density stated above with other parameters for the initial current
demand of the structure for initial polarisation to a protective volt.
ici = Initial Current Density
fci = Coating Breakdown factor (initial)
1. Newly installed sheet piling, B1, 2.5m depth
Current Demand = 2,137.50 * 150 * 0.1
1000
= 32.06A
32.06A
2. Existing sheet piling, B2, 5.5m depth
Current Demand =
4,702.50 * 150 * 1.0
1000
= 705.38A
705.38A
CODES
DNVRP-
CALCULATIONS
RESUL
MASS OF ANODE REQUIRED (INITIAL)

initial current demand:
Ma = Ici tf 8760
u
Ici = Current demand (initial)
tf = Design life
Assumptions
is considered
0.9 * 2000
= 2,340.38kg
2,340.28kg
0.9 * 2000
= 51,492.74kg
51,492.74kg
s/
n
Components

piling
Initial
Current
Demand,
A
32.06
Mass of
Anode,
kg
705.38
51,492.7
4
53,833.
02
Total
CODES
737.44
CALCULATIONS
2,340.28
RESUL
CURRENT DEMAND (MEAN)

density stated above with other parameters for the mean current
icm = Mean Current Density
fcm = Coating Breakdown factor (mean)
Current Demand = 2,137.50 * 70 * 0.6
1000
= 89.78A
89.78A
Current Demand =
4,702.50 * 70 * 1.0
1000
= 329.18A
329.18A
CODES
CALCULATIONS
RESUL
MASS OF ANODE REQUIRED (MEAN)

mean current demand:
Ma = Icm tf 8760
u
Icm = Current demand (mean)
tf = Design life
Assumptions
is considered
10.
Anode utilization factor of 0.9 is applied.
0.9 * 2000
= 6,553.94 kg
6,553.94kg

329.18 * 15 * 8760
0.9 * 2000
= 24,030.14kg
24,030.14kg
s/
n
Components

piling
Mean
Current
Demand,
A
89.78
Mass of
Anode,
kg
329.18
24,030.1
4
30,564.
08
Total
CODES
418.96
6,553.94
CALCULATIONS
RESUL
CURRENT DEMAND (FINAL)

density stated above with other parameters for the final current
icf = final Current Density
fcf = Coating Breakdown factor (final)
Current Demand = 2,137.50 * 100 * 1.0
1000
= 213.75A
213.75A
Current Demand =
4,702.50 * 100 * 1.0

1000
= 470.25A
470.25A
CODES
DNVRP-
CALCULATIONS
RESUL
MASS OF ANODE REQUIRED (FINAL)

final current demand:
Ma = Icm tf 8760
u
Icf = Current demand (final)
tf = Design life
Assumptions
11.
15 years of design life with adequate cathodic protection

is considered
12.
Anode utilization factor of 0.9 is applied.
213.75 * 15 * 8760
0.9 * 2000
= 15,603.75kg
15,603.75kg
470.25 * 15 * 8760
0.9 * 2000
= 34,328.25kg
34,328.25kg
s/
n
Components

piling
Total
CODES
Final
Current
Demand,
A
213.75
470.25
684.00
Mass of
Anode,
kg
15,603.7
5
34,328.2
5
49,932.
00
CALCULATIONS
RESUL
ELECTION OF ANODE TYPE

DNVRP-
The selection of anode type for Terminal B Sheet piling was

determined by the size, spatial uniformity in the geometrical
configuration of the sheet piling and forces that would exert on the
fabricated anodes during installation and operation
Based on above criteria and several, The Stand-off Anode was
selected with following specifications:
Type
750NP
Net Wt, Kg
75
Width, mm
184
Height,
mm
184
Length,
mm
827
Overall
Length,
mm
1,469
Core
Specificati
on Flat
bar
Maximum
Current
available
50 * 12mm
1.917
Complete anode schematic is shown in the attached drawings.

DNV-
CALCULATION OF ANODE RESISTANCE IN SEAWATER

To find the resistance of 750NP
Manufacturer specification:
Driving potential = 250mV
Current = 1.917A
Ra =
2**L
CODES
4L
In
r
-1
CALCULATIONS
RESUL
where = seawater resistivity

L = Length of Anode material
r = radius of Anode cross-section
The cross-section of the selected anode is a rectangular,
Thus, radius =
2(w + h)
2*
radius =
736
6.284
radius = 117.12mm
Rai
0.25
4 0.827
2 3.142 0.827
In
-1
0.117
= 0.048 2.34
= 0.112 ohm
Rai = 0.112 ohm

CALCULATION OF ANODE CURRENT OUTPUT
DNVRP-
I a = E c - Ea
Ra
But Manufacturers specification states the following conditions
Driving voltage = 250mV
Max available Current = 1.917 (Initial Life Current)
Iai = 1.917
A
Therefore Ra = 0.250 / 1.917
= 0.130 ohm
The difference in resistance = 0.130 0.112 = 0.018 ohm can be
attributed to resistive component of the anode insert.
CODES
DNVRP-
CALCULATIONS
RESUL
FINAL ANODE CURRENT OUTPUT

Mass of remaining Aluminium anodic material at the
Final life is 10% of the total mass i.e. 90% anode efficiency.
Mass (end-life) = Mass (initial life) (1 U)
Mass (end life) = 75 kg * (1 0.9)
Mass (end life) = 75 * 0.1
Mass (end life) = 7.5 kg
Volume of remaining net mass of anode, V (end life)
= Mass of Aluminium
Density of Aluminium
Volume (end life) = 7.5 kg
2678 kg / m3
= 0.0028 m3
DNV-RPB401
Widt
h
mm
184
Initi
al
Life
Final 0.00
Life
2
Heigh
t
mm
184
Length Net
mm
Wgt
kg
827
75
Volume
m3
0.002
744.3
0.0028
7.5
0.0280
Assume the cross-section of the selected anode still remains rectangular

Thus, radius =
2(w + h)
2*
radius =
0.008
6.284
radius = 0.0012mm
CODES
CALCULATIONS
RESUL
Therefore, resistance of anode at end-life:

Rf
0.25
4 0.7443
2 3.142 0.7443
In
-1
0.0012
= 0.053 6.816
= 0.36 ohm
Raf = 0.360 ohm
I a = E c - Ea
Ra
Anode Output (end life),Iif = Ec - Ea

Rif
= 0.25
0.36
= 0.69A
Iaf =
0.694 A
CODES
CALCULATIONS
RESUL
A. NUMBER OF ANODE (INITIAL LIFE)

= 32.06 / 1.917 = 16.72 approx. 17 no.
= 705.38 / 1.917 = 367.96 approx. 368
s/
n
Components
Initial
Current
Deman
d, A
Newly Installed
sheet piling
32.06
18
Anode
Current
Output
(Initial
life), A
34.51
Existing sheet
piling
705.38
370
709.29
737.44
388
746.80
TOTAL
No of
Anode,
kg
B. NUMBER OF ANODE (FINAL LIFE)

= 213.75 / 0.694 = 307.99 approx. 308 no.
= 470.25 / 0.694 = 677.59 approx. 678 no.
s/
n
Components
Final
Current
Deman
d, A
Newly Installed
sheet piling
213.75
310
Anode
Current
Output
(Final
life), A
215.14
Existing sheet
piling
470.25
700
485.80
684.00
1010
700.94
TOTAL
CODES
No of
Anode,
kg
CALCULATIONS
RESUL
ACCEPTANCE CRITERIA
DNVRP-
The current outputs as per the anode mass provided for respective
members are being considered if it satisfies the acceptance
criteria as stated below:
Thus:
Ca = individual anode current capacity
Ca = m a X X u
ma = net mass per anode, kg
= anode electrochemical capacity, AH / kg
u = anode utilisation factor
Ca = 75 kg X 2000 AH/kg X 0.9
Ca = 135,000 AH per anode
Therefore; Ca tot = 135,000 AH per anode x 1010 Icm * tf * 8760
= 136,350,000 AH 418.96 * 15 * 8760
= 136,350,000 AH 55,051,344 AH
Accepted
Iatot i = 1010 * 1.917 737.44
= 1,936.17 A 737.44 A
Accepted
CODES
CALCULATIONS
RESUL

Iatot f = N * Iaf Icf
= 1010 * 0.690 684.00 A
= 696.90 A 684.00 A
Accepted
The number of anodes on the members of Terminal B is

s/
n
1
2
Components
No of Anode, kg

piling
310
700
TOTAL
1010

Design Calculation CP

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Design Calculation CP

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Design Calculation

a. Surface area of newly installed sheet piling, A1, 2.5m depth

Driving potential (initial life) = 250 mV

Driving potential (mid life) = 150 mV

Design life = 15years

Cathodic protection method: Sacrificial anodes

Coating conditions: Category I

Anode Material: GALVALUM-III

Anode Utilization factor = 0.9

Electrochemical capacity of Anode material (seawater) = 2000 AH/Kg (min.)

Seawater resistivity = 0.25 ohm-m

COATING BREAKDOWN FACTOR, FC

Fci = Coating Breakdown factor at initial life of anode

Fci = Coating Breakdown factor at mean life of anode

CURRENT DEMAND (INITIAL)

2,978.25 * 150 * 1.0

MASS OF ANODE REQUIRED (INITIAL)

Newly Installed sheet

CURRENT DEMAND (MEAN)

fcm = Coating Breakdown factor (mean)

MASS OF ANODE REQUIRED (MEAN)

Newly Installed sheet

CURRENT DEMAND (FINAL)

1. Newly installed sheet piling, A1, 2.5m depth

2,978.25 * 100 * 1.0

MASS OF ANODE REQUIRED (FINAL)

Newly Installed sheet

ELECTION OF ANODE TYPE

The selection of anode type for Terminal A Sheet piling was

Complete anode schematic is shown in the attached drawings.

CALCULATION OF ANODE RESISTANCE IN SEAWATER

where = seawater resistivity

Rai = 0.112 ohm

Therefore Ra = 0.250 / 1.917

FINAL ANODE CURRENT OUTPUT

Assume the cross-section of the selected anode still remains rectangular

Therefore, resistance of anode at end-life:

Anode Output (end life),Iif = Ec - Ea

A. NUMBER OF ANODE (INITIAL LIFE)

B. NUMBER OF ANODE (FINAL LIFE)

iii. Iatot f = N * Iaf Icf

iii. Iatot f = N * Iaf Icf

The number of anodes on the members of Terminal A is

Newly Installed sheet

Existing sheet piling

a. Surface area of newly installed sheet piling, B1, 2.5m depth

Driving potential (initial life & final life) = 250 mV

Driving potential (mid life) = 150 mV

Design life = 15years

Cathodic protection method: Sacrificial anodes

Coating conditions: Category I

Anode Material: GALVALUM-III

Anode Utilization factor = 0.9

Electrochemical capacity of Anode material (seawater) = 2000 AH/Kg (min.)

Seawater resistivity = 0.25 ohm-m

COATING BREAKDOWN FACTOR, FC

Fci = Coating Breakdown factor at initial life of anode

CURRENT DEMAND (INITIAL)

4,702.50 * 150 * 1.0

MASS OF ANODE REQUIRED (INITIAL)

Newly Installed sheet

CURRENT DEMAND (MEAN)

MASS OF ANODE REQUIRED (MEAN)

2. Existing sheet piling, B2, 5.5m depth