Pipeline Design Training

Cathodic Protection Design

16 August 2006

NRG ENGINEERING

training@nrgengineering.com

The Power to Deliver

Pipeline Design Training Module I Overview

August
2 2 August 28,
by Mr. 4Eng Bin NG
5
1
3
Pipe
Allowable
Applicable
Codes

On-bottom
Stability
(Concrete
Coating)
Design

Wall
Thickness
Design

7
Cathodic
Protection
Design

Expansion
Calculations

Free Span
Calculations

Flexibility
Analysis
Methodology

On-bottom
Roughness
Analysis

Use of
Spoilers for
Pipe Selfburial

&
Unconventional

against
Anchors, Wave
Liquefaction &
Earthquake

10

Pipeline
Construction
- Conventional

Pipeline
Protection

Installation
Engineering
(1/2)

Installation
Engineering
(2/2)

Workshop, revision, exercise

NRG ENGINEERING

27 May 2015

The Power to Deliver #2

Pipeline Design Training Module I Schedule

Weekending
Aug 4
Aug 11
Aug 18
Aug 25
1 2

28

10 11 14 15 16 17 18 21 22 23 24 25 28

Applicable Codes, Wall Thickness

Design
On-bottom Stability (Concrete
Coating) Design
Pipe Expansion Calculations,
Flexibility Analysis Methodology
Allowable Free Span Calculations,
On-bottom Roughness Analysis
Pipeline Protection against Anchors,
Wave Liquefaction & Earthquake
Cathodic Protection Design
Use of Spoilers for Pipe Self-burial
Pipeline Construction - Conventional
& Unconventional

Today

Installation Engineering

Workshop, revision, exercise

NRG ENGINEERING

27 May 2015

The Power to Deliver #3

Cathodic Protection Design

In the cathodic protection analysis, calculations are carried
out to ensure that the anodes provided are sufficient to
provide the total current needed to protect the pipeline
during its design life.
The initial and final current demands are to be checked to
ensure that the anodes can provide sufficient current
output to polarise the pipeline throughout its entire life.

NRG ENGINEERING

27 May 2015

The Power to Deliver #4

Cathodic Protection Design (contd)

Half-shell aluminium alloy bracelet anode is typically used
for cathodic protection of pipeline.
The CP design can typically be carried out using either one
of the following codes:
DNV RP-B401
DNV RP-F103

NRG ENGINEERING

27 May 2015

The Power to Deliver #5

The parameters utilised in the cathodic protection design

calculations and the applicable reference to the appropriate
codes are presented below:
CATHODIC PROTECTION DESIGN DATA
Parameters

Unit

Internal fluid Temperature

ANODE SURFACE TEMPERATURE

DESIGN LIFE, T
Current Density when fluid
temperature (TF) @ 25 oC

Mean

Close Circuit Anode Potential for AluminiumE a

o
Pipeline Protective Potential, E c

Mud/ Seawater Resistivity,

Anode Utilisation Factor, u
Electrochemical Efficiency, max

Coating Break-down
Factor Percentage

Relevant
Clauses in RPF103

Relevant
Clauses in RPB401

Cl. 5.2.4

Cl. 5.4.4

Cl 6.3.8, 6.6.4

YEARS

Cl 6.2,

mA/m2

Cl. 5.2.3 5.2.4

Cl 6.3,
Table 6.3.1,
Table 6.3.2.

V
V

Cl. 5.5.1,
ISO 15589-2
(Table 4)

Cl 6.6.5,
Table 6.6.2

.m

Cl. 5.5.2

CL 6.8

Cl. 5.4.2

Cl 6.9

Ah/kg

Cl. 5.4.3, 5.4.4,

ISO 15589-2
(Table 4)

Cl. 6.6.1 6.6.4

Annex A1, Table

A1

Cl. 6.4, 6.5

Assumptions
The following assumptions are made in the analysis:
Anode surface temperature is assumed to be the same as the
operating temperature of the pipeline
The anode is assumed to be at the end of its lifetime when the
anode material is consumed up to the steel strap
reinforcement
Anode length remains constant throughout its design life

NRG ENGINEERING

27 May 2015

The Power to Deliver #7

Analysis Methodology
The procedures typically adopted for CP design calculation
are presented below:
1.Current Demand
In order to determine the amount of anode required for the
cathodic protection system, it is necessary to calculate the
current demand, Ic, to achieve polarisation during the
design life of the system as follows:
Ic

NRG ENGINEERING

Ac f c icm

27 May 2015

The Power to Deliver #8

Analysis Methodology (contd)

Where
Ic

Current demand for a specific surface area

(mean, final) (A)

Ac

icm

Surface area to be protected (m2)

= Design mean current density (A/m2)

Dic

= Current density temperature adjustment (A/m2/C)

ic

Design mean current density at 25 oC (A/m2)

fc

Coating breakdown factor (mean, final)

The current demand for mean and final life of the anode is determined
by the above equation.
NRG ENGINEERING

27 May 2015

The Power to Deliver #9

Anode Nett Mass

The total mass of anode, Mrequired, required to maintain
cathodic protection for the design life can be calculated as
follows:
I c ( mean ) t 8760
Mrequired =

Where Mrequired

I c(mean)

=
=

8760
t
u
e

=
=
=
=

Total nett anode mass required (kg)

Mean (maintenance) design current
density (A/m2)
Hours per year (hr/year)
Design life (years)
Anode utilisation factor;
Electrochemical efficiency (A.h/kg)

The total nett anode mass provided, Mprovided, must be more than or equal to that
required, Mrequired for cathodic protection to be sustained throughout the design life.
NRG ENGINEERING

27 May 2015

The Power to Deliver #10

Anode Current Output

The anode current output, Ia, is obtained from Ohms Law:
Ia
Where Ia

=
output
=
E co (A)
E ao =
Raf =
=
=
A

NRG ENGINEERING

E co E ao
Raf

initial/final current
Design protective potential (V)
Design closed circuit potential of the anode (V)
Anode resistance ()
0.315

for flush-mounted bracelet anode

Sea water resistivity (.m)
A

Anodes exposed surface area (m2)

27 May 2015

The Power to Deliver #11

Anode Current Output (contd)

The final anode resistance is determined from the final
anode dimensions.
The final anode resistance is calculated by assuming that
the anode is consumed to its utilisation factor, u, which
would give a final exposed surface area and corresponding
anode resistance.
For cathodic protection to be effective throughout the
design life, the final current output, Ia, must equal or
exceed the final current demand, Ic.
Ia (final) Ic (final).
NRG ENGINEERING

27 May 2015

The Power to Deliver #12

Examples For Comparison Of RP-B401

and RP-F013
PIPELINE AND ANODE DATA
Parameters

Unit

Value

30

30

DESIGN LIFE, T

Year

50

PIPE OUTSIDE DIAMETER

mm

914.4 (36-inch)

3-layer PE

mm

2.50

PIPELINE LENGTH

5000

ANODE MATERIAL

Al-based

mm

80

g/cm3

2.700

kg

150

Internal fluid Temperature

ANODE SURFACE TEMPERATURE

EXTERNAL COATING MATERIAL

EXTERNAL COATING THICKNESS

ANODE THICKNESS
ANODE DENSITY
ANODE MASS
NRG ENGINEERING

27 May 2015

The Power to Deliver #13

CATHODIC PROTECTION DATA AND RESULTS

Parameters

Unit

RP-B401

RP-F103

Buried

Unburied

Buried

Unburied

20

150

Mean

20

70

20

50

Final

20

90

0.95

1.05

1.00

1.05

0.8

0.8

0.8

0.8

.m

100

30

100

30

Cathodic Protection Data

Current Density when fluid
temperature

Pipeline Protective Potential,

E co

Initial

Close Circuit Anode Potential for Aluminium, E a

Mud/ Seawater Resistivity,

Anode Utilisation Factor, u

mA/m2

0.8

Max. Electrochemical Efficiency, max

Ah/kg

2000

2000

2500

Electrochemical Efficiency,

Ah/kg

1730

1600

2000

0.02

Coating Break-down Factor

Percentage

Initial
Mean

0.09

Final

0.19

0.8

Line Pipe Coating (a = 0.1; b =

0.003)
Field Joint Coating (a = 3; b = 0.3)

Cathodic Protection Results

ANODE MASS

kg

150

150

150

150

Length of Anode

mm

240

240

240

240

ANODE THICKNESS

mm

80

80

80

80

Anode Spacing

joint

24*

24*

kg

30750

30750

2700

2700

Mass of Anode Required

* Max. distance between anodes = 300m

Pipeline Design Training

Any questions?

NRG ENGINEERING

training@nrgengineering.com

The Power to Deliver