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Project Ref: 12/P16227
CATHODIC PROTECTION
TETCO
GADARIF STRATEGIC DEPOT PROJECT
28/03/2012
DM
Rev.
Date
Description
Prepared
No.
SF
DM
Checked Approved
ORIGINATOR
CLIENT
Venture Way, Grantham, Lincs, NG31 7XS, UK. Tel: +44 (0) 1476 590666 Fax: +44 (0) 1476 570605
E-mail: cpc@cathodic.co.uk Website: www.cathodic.co.uk
Registered Office: Minalloy House, Regent Street, Sheffield S1 3NJ, UK Vat No. 116 8408 71
Registered in England No. 478098
TABLE OF CONTENTS
1
1.1
1.2
1.2.1
2
2.1
2.2
2.3
2.3.1
2.3.2
2.3.3
2.3.4
2.3.5
3
3.1
3.2
4
4.1
4.2
4.3
4.4
4.5
4.5.1
4.5.2
4.5.3
4.5.1
4.6
5
6
6.1
6.2
6.3
6.3.1
6.3.2
6.3.3
6.3.4
6.3.5
7
7.1
7.2
8
8.1
8.2
8.3
8.4
9
Document Title
Document No
CPCL Project No
INTRODUCTION........................................................................................................................ 3
GENERAL .................................................................................................................................. 3
REFERENCE DOCUMENTS..................................................................................................... 3
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INTRODUCTION
1.1
GENERAL
This document is the design philosophy and detailed calculations that shall be adopted to
provide the permanent cathodic protection system installed to protect the new tanks at the
Gadarif Strategic Depot project.
The requirements in this document apply to permanent corrosion protection by impressed
current cathodic protection to the external surfaces of the tank base and by sacrificial anode
current cathodic protection to the internal surfaces of the tank.
1.2
REFERENCE DOCUMENTS
This section lists the codes, standards and project documents / drawings, which are
applicable to the detailed design.
Document Title
Document No
CPCL Project No
Document Number
Title
BS 7361:Part1
NACE-RP-0193:1993
EDS-508 Revision A
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2.1 GENERAL
The corrosion protection system selected shall be based on a high integrity coating system in
combination with a cathodic protection system.
2.2 COATING SYSTEMS
The tank base plates shall be coated in line with the project specification.
2.3 CATHODIC PROTECTION
The permanent CP system for the tank will be an impressed current cathodic protection
(ICCP) system. The design criteria for the cathodic protection system are outlined in the
sections below:
2.3.1
DESIGN LIFE
The design life shall be 25 years for permanent CP system.
2.3.2
Structure Surface
Tank Bottom
For the protection of structure with elevated operating temperatures the minimum design
current densities given above shall be increased by 25% per 10 C rise in temperature above
o
30 C. All tanks will be at an operating temperature at 48 C therefore, a design current
2
density of 31.25 mA/m is considered suitable.
For the purposes of the design the coating breakdown has been assumed to be a maximum
of 50 %:
Structure Surface
Tank Bottom
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2.3.3
CURRENT DRAIN
The tank does not need to be electrically isolated from any foreign structures using isolation
joints / flanges and polarisation cells as this is a close anode system. Where possible the
tank should be electrically isolated from earthing / grounding systems and any re-bar used in
construction.
2.3.4
CURRENT DEMAND
The current demand for each tank is calculated based on the surface area and the applicable
final current density for steel as given in section 2.3.2.
2.3.5
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Structure to be protected
Diameter
25 m
17.5 m
17.5 m
Coating
50 % Coating Breakdown
Design Life
25 Years Permanent CP
31.25 mA/m
Soil Resistivity
100 Ohm.m
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The tank will be electrically continuous from the remainder of any piping and earthing but as this
is close anode system and there will be a containment layer hence will not be affected by any
current drains.
DC Power supply shall be transformer rectifiers to CPCL specifications. The current required is
less than 5 A for the 17.5 m tanks and 10 A for the 25 m tanks and it is recommended that a 5 A
or 10 A CP station is installed for each tank.
Due to the high surface soil resistivity anticipated it is recommended that a grid type anode is
installed at a minimum depth of 300 mm and maximum depth of 550 mm below the tank base in
a mesh arrangement with MMO coated ribbon running in one direction and Titanium conductor
bar in the other. The maximum current output of the anode is based upon a soil resistivity of up
to 100 Ohm.m which would be as anticipated in this method of installation and backfilling.
Impressed current anodes shall consist of a Mixed Metal Oxide (MMO) / Titanium ribbon anode
with Titanium conductor bar to carry the current and connected via cable and a junction box to
the transformer rectifier. The MMO ribbon is to be spot welded to the conductor bar at each
intersection. Various power feed connectors are then connected to each of the conductor bars
and to a cable which exits the tank to the junction box.
The negative cable will be connected to tank via a junction box from the transformer rectifier unit
o
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SA = .r 2
Where for Gas Oil in first column then Gasoline and Firewater in second column:
Pi
Radius
SA
3.142
3.142
12.5
8.75
490.87
240.53
m
m
The total current required can then be calculated using the following:
Document Title
Document No
CPCL Project No
SA
Surface Area
Current Density
Fc
Itot
Total Current
490.87
240.53
31.25
31.25
50
50
7.67
3.76
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mA/m
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Lmin =
I tot
Ia
Where,
Itot
Total Current
Ia
Lmin
7.67
3.76
0.019
0.019
410.0
201.0
The space between anodes should be adjusted to achieve uniform current distribution under the
tanks. The MMO ribbon spacing is calculated by:
S mmo =
Ia
J1
Where,
Ia
12
12
mA
J1
10
10
mA/m
S1
1.20
1.20
The ribbon anode output is considered to be a maximum of 3 A / m then for standard ribbon this is
equivalent to 0.035 A (35 mA) / linear m for a lifetime of 25 years and therefore any value lower is
acceptable.
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The lengths of the MMO ribbon anodes are calculated below using the following formula:
Initial Spacing = 0.5 x (MMO ribbon spacing m)
Subsequent Spacing = initial spacing + (MMO ribbon spacing m)
L1 = 4.S1 .(d S1 )
Where,
S1
0.6
0.6
Diameter of Tank
25
17.5
L1
7.65
6.39
The length of cord in each row is calculated from the above equation.
Row
Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Total
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Document No
CPCL Project No
Spacing
(m)
0.60
1.79
2.98
4.17
5.36
6.55
7.74
8.93
10.12
11.31
12.50
13.69
14.88
16.07
17.26
18.45
19.64
20.83
22.02
23.21
24.40
Length
(m)
7.62
12.88
16.19
18.63
20.52
21.98
23.11
23.96
24.54
24.89
25.00
24.89
24.54
23.96
23.11
21.98
20.52
18.63
16.19
12.88
7.62
413.65
Spacing
(m)
0.58
1.75
2.92
4.08
5.25
6.42
7.58
8.75
9.92
11.08
12.25
13.42
14.58
15.75
16.92
Length
(m)
6.28
10.50
13.04
14.80
16.04
16.87
17.34
17.50
17.34
16.87
16.04
14.80
13.04
10.50
6.28
207.26
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4 L2
R=
(ln
2)
2L
hw
Where
Soil Resistivity
100
100
Ohm.m
Length of Anode
7.62
6.28
0.5
0.5
0.005
0.005
Resistance
20.78
24.23
Ohm
The resistance of each cord is calculated from the above equation and the total resistance
calculated by summing the resistance of each cord. Thus the total anode resistance is
calculated:
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Row
Spacing
Resistance
Spacing
Resistance
Number
(m)
(ohm)
(m)
(ohm)
0.60
20.78
0.58
24.23
1.79
13.59
1.75
16.05
2.98
11.26
2.92
13.45
4.17
10.03
4.08
12.13
5.36
9.26
5.25
11.35
6.55
8.74
6.42
10.89
7.74
8.38
7.58
10.64
8.93
8.13
8.75
10.56
10.12
7.97
9.92
10.64
10
11.31
7.88
11.08
10.89
11
12.50
7.85
12.25
11.35
12
13.69
7.88
13.42
12.13
13
14.88
7.97
14.58
13.45
14
16.07
8.13
15.75
16.05
15
17.26
8.38
16.92
24.23
16
18.45
8.74
17
19.64
9.26
18
20.83
10.03
19
22.02
11.26
20
23.21
13.59
21
24.40
20.78
Total (Ohm)
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CPCL Project No
0.458
0.860
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L2 = 4.S 2 .(d S 2 )
Where,
S2
Diameter of Tank
L2
1.75
1.75
25
17.5
12.88
10.5
The length of cord in each row is calculated from the above equation.
Row Number
Spacing (m)
Length (m)
Spacing (m)
Length (m)
1.79
12.88
1.75
10.5
5.36
20.52
5.25
16.04
8.93
23.96
8.75
17.5
12.50
25
12.25
16.04
16.07
23.96
15.75
10.5
19.64
20.52
23.21
12.88
Total (m)
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CPCL Project No
86.6
70.6
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For the CP to be effective this total must be equal to or less than the voltage of the
Transformer Rectifier.
This can be expressed in the following formula:
Where,
V(vd1)
V(vd2)
V(vd3)
4.6
4.3
0.005
0.005
0.192
0.092
V(vd4)
5.45
2.73
Vlosses
4.0
4.0
VTotal
Total Voltage
14.23
11.13
VTR
24
24
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4.5.1
Groundbed current
4.5.2
RGB
Itot
V(vd1)
0.458
0.860
Ohm
Total Current
10
4.6
4.3
The MMO ribbon volt drop is calculated using the following formula:
V ( vd 2 ) = I .R.L
Where,
I
V(vd2)
0.021
0.02
0.138
0.138
1.79
1.75
0.005
0.005
Ohm/m
Where the load is the current required for half the distance between two conductor bars.
I = I tot / L1 /(0.5.S 2 )
Where,
Itot
Total Current
L1
S2
10
413.65
207.26
3.5
3.5
0.014
0.014
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4.5.3
The Conductor Bar volt drop is calculated using the following formula:
V ( vd 3) = I .R.L
Where,
I
Load
V(vd2)
0.223
0.152
0.069
0.069
Ohm/m
12.50
9.75
0.192
0.092
Where the load is the current required for half the length of the longest conductor bar (worst
case).
I = I tot / L2 /(0.5.L3 )
Where,
Itot
Total Current
L2
L3
10
139.7
70.6
25
17.5
0.006
0.008
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4.5.1
V(vd 4) = V1 + V2 + V3 + V4
Where,
V1
1.05
V2
1.05
V3
2.3
V4
1.05
V(vd4)
5.45
Individual cable volt drops are calculated using the following formula:
Resistance of Cable
Lcab
Icab
Vvd
0.524
0.524
Ohm/km
Length of Cable
200
200
Current in Cable
10
1.1
0.524
The volt drop of each cable is calculated from the above equation.
RCab
Lcab
Icab
Vvd
V1
0.524
100
10
1.05
V2
0.524
100
10
1.05
V3
1.15
100
10
2.3
V4
0.524
100
10
1.05
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Document Title
Document No
CPCL Project No
25 m
17.5 m
Unit
SA
490.87
240.53
Itot
Total Current
10
Lmin
414
208
L1
414
208
S1
1.2
1.2
L2
139.7
70.6
S2
3.6
3.5
VTotal
15
12
VTR
24
24
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Item
25 m
17.5 m
24 V
24 V
10 A
5A
414 m
208 m
Permanent CP Station
Document Title
Document No
CPCL Project No
16 mm
150 m
35 mm
16 mm
100 m
35 mm
200
200
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6.1 GENERAL
The corrosion protection system selected shall be based on a high integrity coating system in
combination with a cathodic protection system.
6.2 COATING SYSTEMS
The tank shall be coated internally in line with project specifications.
6.3 CATHODIC PROTECTION
The permanent CP system for the tanks will be a sacrificial anode cathodic protection (SACP)
system. The design criteria for the cathodic protection system are outlined in the sections
below:
6.3.1
DESIGN LIFE
The design life shall be 25 years for sacrificial anodes.
6.3.2
Tank Internals
100
For the protection of structure with elevated operating temperatures the minimum design
current densities given above shall be increased by 25% per 10 C rise in temperature above
30 C.
o
Document Title
Document No
CPCL Project No
Structure Surface
Firewater
10
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6.3.3
CURRENT DRAIN
The tanks do not need to be electrically isolated from any foreign structures using isolation
joints / flanges and polarisation cells as this is an internal system. Where possible the tank
should be electrically isolated from earthing / grounding systems and any re-bar used in
construction.
6.3.4
CURRENT DEMAND
The current demand for each tank is calculated based on the surface area and the applicable
final current density for steel as given in section 6.3.2.
6.3.5
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Gas Oil: 25 m / 1 m
Gasoline: 17.5 m / 1 m
Firewater: 17.5 m / 12.5 m
Coating
Design Life
25 Years Permanent CP
Current Density
156.25 mA/m at 30 C
Water Resistivity
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Tank
Gas Oil
Gasoline
Firewater
Unit
SA
570
296
928
If
Current
8.90
4.62
7.25
Ia
0.25
0.25
0.25
An1
36
19
29
No
Ma
25.2
25.2
25.2
kg
An2
37
19
30
No
At
40
24
34
No
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SA = .r 2 + .d .h
Where for tank,
Pi
Radius
12.5
Diameter
25.0
Height
1.0
SA
3.142
569.41
The current required for GAS OIL TANK can then be calculated using the following:
If = (SA.J .Fc )
Where for tank,
SA
Surface Area
596.41
Current Density
156.25
mA
Fc
If
Document Title
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CPCL Project No
Final Current
10
8.90
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Rf =
4l f
(ln
1)
2l f
rf
Where,
Water Resistivity
lf
rf
Rf
Ohm.m
112.5
cm
49.2
cm
1.19
Ohm
Then, the maximum current output per anodes is calculated using Ohms Law:
Ia =
V
Rf
Where,
V
Rf
Ia
0.30
1.19
Ohm
0.25
The minimum number of anodes is calculated from the total current required divided by the
maximum current output for each individual anode.
An1 =
If
Ia
Final Current
8.90
Ia
0.25
An1
36
No.
Anode Driving Potential is the potentials difference between the protected potential and the open circuit anode
potential
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Mt =
I m .t.8760
Z .UF
Current
Design Life
UF
Utilisation Factor
Mt
8.90
25
2500
A
Years
A.hours/kg
85
917.6
kg
Finally, the minimum number of anodes is calculated from the total mass required divided by
the mass of each individual anode.
An 2 =
Mt
Ma
Document Title
Document No
CPCL Project No
Mt
Ma
An2
917.6
kg
25.2
kg
Anode Number
37
No.
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An1
36
No.
An2
37
No.
An2
40
No.
At
40
No.
An1
19
No.
An2
19
No.
An2
24
No.
At
24
No.
An1
30
No.
An2
29
No.
An2
34
No.
At
34
No.
Gasoline Tanks:
Firewater Tank:
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