POLMAZ LIMITED

CATHODIC PROTECTION DESIGN FOR 6 & 8 PIPELINE AT ELEME

PETROCHEMICAL INDORAMA PLANT
TECHNICAL REQUIREMENTS
DESIGN OF CATHODIC PROTECTION SYSTEM
DESIGN OBJECTIVES:
The principal cathodic Protection design objectives for this design are as follows:
1. Provide sufficient current density continuously to all parts of the pipeline to polarize the
pipeline to an acceptable criterion.
2. Minimize interference effects to other metallic structure
3. Provide Sufficient operational Flexibility to accommodate expected changes in the
environment, the coating, and the operation of the structure during the system service life
4. Ensure the safety of the public and operating personnel and adhere to all applicable codes
and standards
5. Provide a system design life commensurate with the required life of the pipeline or total
system service life as stipulated by the owner or regulator ( 30 years)
6. Provide testing Facilities and monitoring equipment for the performance of the cathodic
protection system that can be tested and monitored with respect to industry standards and
regulations.

PARAMETERS FOR BOTH PIPELINES:

PIPELINE LENGTH (EACH)
PIPELINE DIAMETERS

__11.5Km ___11500m

________ 6 (0.1524m) & 8 (0.2032m)

COATING EFFICIENCY ________ 90%

CURRENT DENSITY
SOIL RESISTIVITY
DESIGN LIFE

________ 11

________ 4000

/ 2

________ 30YEARS

POLMAZ LIMITED

Introduction
Cathodic protection is a technique to control the corrosion of a metal surface by making it work
as a cathode of an electrochemical cell. Corrosion is an electrochemical process in which a
current leaves a structure at the anode site, passes through an electrolyte, and re-enters the
structure at the cathode site.

Cathodic protection (CP) is a method to reduce corrosion by minimizing the difference in

potential between anode and cathode. This is achieved by applying a current to the structure to
be protected (such as a pipeline) from some outside source. When enough current is applied, the
whole structure will be at one potential; thus, anode and cathode sites will not exist. A cathodic
protection system prevents corrosion by converting all of the anodic sites on the metal surface to
cathodic sites by supplying electrical current from an alternate source. Usually the alternate
source is a galvanic anode, which are more active than steel.

Types of Cathodic Protection

There are two main types of cathodic protection systems: galvanic and impressed current. Both
types use anodes from which current flows into the electrolyte, a continuous electrolyte from the
anode to the protected structure, and an external metallic wire connection. These items are
essential for all cathodic protection systems.

Galvanic system
A galvanic cathodic protection system makes use of the corrosive potentials for different metals.
Without cathodic protection, one area of the structure exists at a more negative potential than
another, and corrosion results. If, however, an object with much more negative potential, such as
a magnesium anode, is placed adjacent to the structure to be protected, such as a pipeline, and a
metallic insulated wire connection is installed between the object and the structure, the object
will become the anode and the entire structure will become the cathode.
Then the new object corrodes sacrificially to protect the structure. Thus, the galvanic cathodic
protection system is called a sacrificial anode cathodic protection system because the anode
corrodes sacrificially to protect the structure. Galvanic anodes are usually made of either
magnesium or zinc because of these metals higher potential compared to steel structures.
Today, galvanic or sacrificial anodes are made in various shapes using alloys of zinc, magnesium
and aluminium. The electrochemical potential, current capacity and consumption rate of these
alloys are superior for corrosion protection than iron.

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Galvanic anodes are designed and selected to have a more "active" voltage (i.e., a more negative
electrochemical potential) than the metal of the structure. For effective corrosion protection, the
potential of the steel surface is polarized or pushed - more negative until the surface has a
uniform potential. At that stage, the driving force for the corrosion reaction is halted. The
galvanic anode continues to corrode; consuming the anode material until eventually it must be
replaced.
The polarization is caused by the current flow from the anode to the cathode. The driving force
for the corrosion protection current flow is the difference in electrochemical potential between
the anode and the cathode.
In sacrificial anode systems the high energy electrons required for cathodic protection are
supplied by the corrosion of an active metal. Sacrificial anode systems depend on the differences
in corrosion potential that are established by the corrosion reactions that occur on different
metals or alloys.
For example, the natural corrosion potential of iron is about -0.550 volts in seawater. The natural
corrosion potential of zinc in seawater is about -1.2 volts. Thus if the two metals are electrically
connected, the corrosion of the zinc becomes a source of negative charge which prevents
corrosion of the iron.
The materials used for sacrificial anodes are either relatively pure active metals, such as zinc or
magnesium, or are magnesium or aluminum alloys that have been specifically developed for use
as sacrificial anodes. In applications where the anodes are buried, a special backfill material
surrounds the anode in order to insure that the anode will produce the desired output.
Sacrificial anodes are normally supplied with either lead wires or cast-in straps to facilitate their
connection to the structure being protected. The lead wires may be attached to the structure by
welding or mechanical connections. These should have a low resistance and should be insulated
to prevent increased resistance or damage due to corrosion. When anodes with cast-in straps are
used, the straps can either be welded directly to the structure or the straps can be used as
locations for attachment. A low resistance, mechanically adequate, attachment is required for
good protection and resistance to mechanical damage.
In the process of providing electrons for the cathodic protection of a less active metal the more
active metal corrodes. The more active metal - the anode - is sacrificed to protect the less active
metal the cathode. The amount of corrosion depends on the metal being used as an anode but is
directly proportional to the amount of current supplied.
Because the anodes in a galvanic cathodic protection system are sacrificial they must be
inspected periodically and replaced when consumed.

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Impressed Current Cathodic Protection Systems

Impressed Current Cathodic Protection systems use the same elements as the galvanic protection
system; only the structure is protected by applying a current to it from an anode. The anode and
the structure are connected by an insulated wire, as for the galvanic system. Current flows from
the anode through the electrolyte onto the structure, just as in the galvanic system. The main
difference between galvanic and impressed current systems is that the galvanic system relies on
the difference in potential between the anode and structure, whereas the impressed current
system uses an external power source to drive the current.

For larger structures, galvanic anodes cannot economically deliver enough current to provide
complete protection. Impressed current cathodic protection (ICCP) systems use anodes
connected to a DC power source known as a cathodic protection rectifier. Anodes for ICCP
systems are tubular and solid rod shapes or continuous ribbons of various specialized materials.
These include high silicon cast iron, graphite, mixed metal oxide, platinum and niobium coated
wire and others.
A typical ICCP system for a pipeline would include an AC powered rectifier with a maximum
rated DC output of between 10 and 50 amperes and 50 volts. The positive DC output terminal is
connected via cables to the array of anodes buried in the ground and is known as the anode
ground bed. For many applications the anodes are installed in a 200 foot deep, 10-inch diameter
vertical hole and backfilled with conductive coke. Conductive coke is a material that improves
the performance and life of the anodes. A cable rated for the expected current output connects
the negative terminal of the rectifier to the pipeline. The operating output of the rectifier is
adjusted to the optimum level after conducting various tests including measurements of
electrochemical potential.
As in sacrificial anode systems, impressed current systems depend on a supply of high energy
electrons to stifle anodic reactions on a metal surface. In the case of an impressed current system
these high energy electrons are supplied by a rectifier.
Low energy electrons that are picked up at a non-reactive anode bed are given additional energy
by the action of a rectifier to be more energetic than the electrons that would be produced in the
corrosion reaction.

The energy for the electron energy pump action of the rectifier is provided by ordinary
alternating current. The effect of these electrons at the structure being protected is the same as
that derived from the sacrificial anode type of cathodic protection system. However, the anode
material serves only as a source of electrons and need not be consumed in providing protective
current.

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The materials used for impressed current cathodic protection can pass a current into the
environment without being consumed at a high rate. Graphite and high silicon cast iron are the
most commonly used impressed current cathodic protection anode materials; however, other
materials (such as magnetite, platinum, and newly developed ceramic materials) have been
successfully used.
For buried anodes, a backfill of carbonaceous material is used to surround the anode to decrease
the electrical resistance of the anode, to provide a uniform, low resistivity environment
surrounding the anode and to allow gasses produced at the anode surface to vent. In practice,
materials such as graphite are used for impressed current cathodic protection system anodes that
are slowly consumed.
Anodes in impressed current systems must be inspected and replaced if consumed or otherwise
damaged. As is the case for any electrical equipment, rectifiers used for impressed current
cathodic protection systems require preventative maintenance to insure proper operation.

Major design considerations for an impressed current cathodic

protection system:
Structure to be protected The size and condition of the structure must
be known to adequately determine its current requirement.
Soil Resistivity The resistivity of the soil must be known to properly
size the ground bed for optimum current flow from the anode to the
electrolyte and from the electrolyte to the cathode.

Electrical Isolation The cathodic protection system must be sized based

on the amount of exposed steel to be protected. If the structure to be
protected is not electrically isolated from its surroundings, inclusive of all
above ground piping systems, the impressed current cathodic protection
system will not work. Therefore, an isolation joint must be installed at both
ends of the pipeline to be protected to ensure effectiveness of the system.

POLMAZ LIMITED

BETWEEN ABOVE GROUND PIPE SECTION AND BELOW GROUND PIPE SECTION THE
ISOLATION JOINT IS USED TO PROVIDE ELECTRICAL DISCONTINUITY BETWEEN PROTECED AND
UNPROTECTED SECTIONS OF THE PIPELINE NETWORK, IN THE Cathodic PROTECTION SYSTEM,
THE BURIED PART OF THE PIPELINE IS THE SECTION THAT IS PROTECTED AGAINST CORROSION
CATHODICALLY. ABOVE GROUND PIPE SECTIONS ARE PROTECTED BY THE APPLICATION OF
EXTERNAL COATING AND THEREFORE ARE NOT CATHODICALLY PROTECTED. THIS MEANS
THAT THERE MUST BE AN ELECTRICAL DISCONTINUITY BETWEEN THESES SECTIONS, HENCE
THE PROVISION OF ISOLATION JOINT.

DESIGN CALCULATIONS
SOIL RESISTIVITY: 4000ohm-cm
CURRENT DENSITY: 11mA/m2
PIPELINE LENGTH: 11500m
PIPELINE DIAMETER: 0.2032m
a) DETERMINE CURRENT REQUIRED TO PROTECT THE PIPELINE:
CURRENT DEMAND:

DESIGN CALCULATIONS

I=i A

1. Calculate current required using the 8 Pipeline as a basis for the design.
Using metric units in metres:
Total Surface Area = dL
Therefore, d = 8 = 0.2032
L = 11500m

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Area = 3.142 x 0.2032 x 1150 = 7342.22m2

Take coating effectiveness as 90%

Therefore: Actual bare surface area:

7342.22 x 100 90
50

= 734.222m2

Current required: {Current density = 11mA/m2}

Therefore = 734.222m x 11mA/m2

= 8,076.442mA

= 8.07644Amps

Calculate minimum Anode weight required:

Anodes:
Using 21kg high silicon cast iron anodes having a consumption rate (Cr) of 1kg/A -y
Wt = Cr x ICP x L
Cr = Consumption rate
ICP = Current Required
L = Design Life

Wt = Total weight of Anode material

For L = 30 years

Wt = 1 x 8.076442 x 30
Wt = 242.29326kg
Therefore:

N = 242.29326
21

N = 11.537
Therefore:

Minimum numbers of Anodes = 12

These numbers (12 Anodes) represent the minimum number of anodes to be used in the
impressed current deep well ground bed installation to protect the pipelines.

CALCULATE GROUNDBED RESISTANCE

RN =

[( In 8L ) -1 + (2L x In 0.656N)]
2 NL
d
S

Where:
= 4000 ohm cm
L = 213.4cm
d = 20.3cm
S = 609.6cm
N = 12 Anodes [Minimum]
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POLMAZ LIMITED

POLMAZ LIMITED

RN =

[( In 8L ) -1 + (2L x In 0.656N)]
2 NL
d
S

RN =

4000
2 x 3.142 x 12 x 213.4

RN =

[(In 8 x 213.4) -1 + (2 x 213.4 x In 0.656 x 12)]

20.3
609.6

4000
[(In 84.0985) -1 + (0.70013 x In 7.872)]
16092.06

RN =

0.2485

[(4.431988) -1 + (0.70013 X 2.06331)]

RN =

0.2485

[(4.431988) -1 + (1.44458)]

RN =

0.2485

[3.431988 + 1.44458]

RN =

0.2485

[4.876568]

RN =

1.2118 Ohms

POLMAZ LIMITED

CALCULATE CABLE RESISTANCES

Experience has shown that No. 6 AWG cable works well for the impressed current Cathodic
protection system.
The resistance of No. 6 AWG cable is 1.322 Ohm/1000m
Negative cable - (Connection from transformer rectifier to pipeline) (100m)

Positive cable (Connection from transformer rectifier to deep well groundbed) (150m)

Effective Total cable in soil = 350 m

Cable resistance = Rc = 350 x 1.322
100

Rc = 0.4627 Ohms

Total circuit resistance, RT

RT = RN + RC + Rpre
RN = Anode resistance to remote earth = 1.2118 ohms..
Rc = cable resistance = 0.4627 ohms
Rpre = Pipe to electrolyte resistance = 0.30 ohms

Therefore: RT = 1.2118 + 0.4627 + 0.30

RT = 1.9745
RT = 2 Ohms

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DETERMINE RECTIFIER OUTPUT RATING

Rectifier Voltage; EO
EO = (I x RT) + 2.0V [Back Voltage]
EO = (8.076 x 2) + 2V
EO = 18.152 Volts
The impressed current system has been designed for a system life span of 30 years and the
CP system components.

Current requirement being a critical part of design calculations for Cathodic Protection
Systems on existing structures is the amount of current required per square foot (called
current density) to change the structures surface potential to -0.85 volts. The current density
required to shift the potential indicates the structures surface condition.

The backfill will provide the following:

(1.) Decrease the anode-to-earth resistance by increasing the anodes effective size.
(2.)Extend the system operational life by providing additional anode material.
(3.) Provide a uniform environment around the anode, minimizing deleterious localized
attack.

The carbonaceous backfill however, cannot be expected to increase the ground bed life
expectancy unless it is well compacted around the anodes.

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POLMAZ LIMITED

From the value of RT, the Transformer Rectifier System output voltage can also be calculated
from:

VREC = 1.5 x I x RT
VREC = Rectifier output voltage
I = Total protection current, Amps = 8.076Amps
RT = Total circuit resistance, ohms = 2 Volts

VREC = 1.5 x 8.076 x 2

= 24.228 Volts DC

This value shall represent the maximum value to achieve cathodic protection
of -0.85volts DC. The actual value can be less than this value. Also, over the
life of the installation this value can change based on operational and
environmental conditions over time.
Therefore, the larger value shall be used to choose the needed output of the Transformer
Rectifier for the impressed current cathodic protection system.
Note:

Fundamentally, the 150% (1.5) is a factor to allow for aging of our normal rectifier stacks.

The impressed current cathodic protection system has been designed for a system life of 30 years
and the Cathodic Protection components shall comprise of the following:
` ONE UNIT OIL COOLED TRANSFORMER RECTIFIER (shall comply with IEC 146)
The rectifier shall be constructed using high current density selenium cells or silicon
diodes so arranged as to provide full wave rectification. The current rating of the diodes
shall be more than 1.25 times the maximum current rating of the rectifier and have a
minimum peak inverse voltage of 1200 V.
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The transformer/rectifier shall be provided with an isolator or Moulded Case Circuit

Breaker (MCCB) on its incoming circuit and, where applicable, on its AC sub-circuits.
Additionally, suitably sized fuses (type gG to IEC 269) shall be installed on the
transformer/rectifier's phase AC sub-circuits and negative DC output circuits.

The transformer/rectifier shall be provided with approximately 70 mm diameter meters

or similarly sized square pattern meters to read the output voltage and current. The
measuring accuracy shall be better than 2% of full scale.
The polarity of the DC terminals and AC supply terminals shall be clearly marked. AC
and DC cables shall be physically separated by an insulating panel.
Transformer/rectifiers should be installed in a non-hazardous area. If this is not possible,
the construction of the rectifier units shall fulfill the requirements of the hazardous area
classification applicable for the site. The Contractor shall obtain the required
information on area classification from the Principal (INDORAMA ELEME
PETROCHEMICAL).
The rating shall be 230/460 volts AC input 3 phase. Maximum DC output voltage shall be
50volts DC and 30Amp output current.
GROUND BED:
The system shall comprise of a total number of 12 anodes vertically installed to a depth
of 300feet (maximum) and shall be sited at a location 150meters from the pipeline.
Anode type shall be MMO ANODES, TYPE CENTERTECT TUBULAR: DIMENSIONS:
2.6 x 84 LONG; (THIS ARE PARAMETERS TO GUIDE, BUT CAN BE CHANGED DURING
COMMERCIAL FOR SUPPLY FOR ACTUAL JOB INSTALLATION WITH THE CONSENT OF
THE CLIENT)
The deep well ground bed shall be backfilled with the necessary backfill material.

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For the Cathodic Protection system to work effectively, an isolating

joint/ISOLATING FLANGE KIT is to be installed at all locations where the pipeline
enters the soil and exit the soil at pipe flanges connection locations.
These locations are 4 in number (2 locations on each pipeline). Isolating joints for
pipelines need to be suitable for the operating conditions encountered on the
particular installation, e.g. pressure and temperature, and the product.
Isolating joints shall be welded into the pipe at the required locations specifically for the
purpose of cathodic protection isolation. Isolating joints that may have to be dismantled for
the servicing of other equipment (valves, spading off) are not recommended.

For this pipeline, isolating joints shall be supplied and installed (welded) into the pipeline
length mono block. Before installation, the assembled isolating joint set shall be tested in
accordance with the procedure for isolating joints in line with pipeline acts and the
resistance shall be at least 1 M ohms. On the other hand Isolating Flange Kits can be
installed.
The welding and all necessary process of installing the isolation joints shall take a minimum of
2weeks and the lines will be placed out of service for this operation, as it is a major hot work.

BOND BOXES
(PDBB POISTIVE DISTRIBUTION BOND BOX)
(NDBB NEGATIVE DISTRIBUTION BOND BOX)
The junction boxes shall be either a 5-way or a 16-way type. The type shall be shown in
the completed installation as built drawing. The negative distribution and positive
distribution bond boxes are constructed standing beside the transformer rectifier. The
main supply cables from the positive and negative terminal of the TRR goes to the positive
distribution bond box and negative distribution bond box respectively. From the bond
boxes supply cables are then routed to the pipelines and anodes feeder cables.

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CABLES

All cables shall be No. 6 AWG copper cables, suitable for DC use and shall be double
insulated and sheathed to withstand the prevailing chemical and mechanical (soil)
conditions. The cables shall be NO.6 AWG stranded annealed copper cable with double
insulation having primary insulation layer of Kynar or Halar.
All negative cables (runs to the negative bond boxes and to the pipe lines) shall be black
outer sheathed. Unless otherwise specified by INDORAMA.
The positive cables shall be red and unless otherwise specified by the company
INDORAMA, the positive cable shall run the between transformer rectifier to the positive
distribution bond box and ground bed.

Cable entries to the transformer-rectifier are to be fitted with flame-proof glands and
cable shrouds and all cable are to be run in ducts through the transformer-rectifier plinth
into the ground. DC cable connections are to be made with sweated or crimped cable lugs.

TEST POINTS
Test points/posts shall be installed at locations along the pipeline right of way and at the
starting point of the pipelines within INDORAMA plant. The test post shall provide
sufficient room for the termination of test cables and for the installation of bonding
cables.
Generally, the test posts shall be located at intervals of 1 kilometer. The exact location
and type of test point installation shall be agreed with INDORAMA before any work
commences on the installation of a test point.
The test post shall be constructed from 3 or 4 diameter pipe and shall be about 1.4m long.
Measurement shall be taken with the cover in-place.
Stubs of 13mm reinforcing bar shall be welded to the bottom of the post to increase
anchorage and prevent rotation.
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To reduce vandalization of test posts, it shall be constructed from common pipe material
of low cost. Also the pipe base and support shall be installed within a concrete structure.

PLEASE FIND THE TOTAL COST FOR THE IMPRESSED CURRENT CATHODIC
PROTECTION SYSTEM IN THE COMMERCIAL.

PDH engineering Continuing Education for Engineer

NACE SP0169 2007
Standard Practice
Control Of External Corrosion on
Underground or Submerged Metallic Piping Systems
NACE SPO572: -Design, Installation, Operation, and
Maintenance of Impressed Current Deep Anode Beds

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