Specification for Cathodic Protection Design

Version 2.0

Petroleum Development Oman L.L.C.

UNRESTRICTED
December 2005

Document ID : SP-1128
Filing key : xxxx

Specification for
Cathodic Protection Design
Keywords:
Cathodic protection
Design requirements
Monitoring
Internal wetted surfaces
Impressed current
Sacrificial anodes
Groundbed
Current density
Protection potential
Pipelines
Buried structures
Anodes
Transformer rectifiers
Test facilities/junction boxes
Isolating couplings

This document is the property of Petroleum Development Oman, LLC. Neither the whole nor any part of this document may be
disclosed to others or reproduced, stored in a retrieval system, or transmitted in any form by any means (electronic, mechanical,
reprographic recording or otherwise) without prior written consent of the owner.

Specification for Cathodic Protection Design

Version No.
ERD-65-12
1.0
2.0

Date
Aug.91
Sept.99
Dec.05

Author
TTH/5
OTT/11
UEC/121

Version 2.0

Scope / Remarks
Original ERD Document
Updated and in new PDO format
Updated with minor changes

INSTRUCTIONS TO USER
Make sure this is the latest issue of this specification. Refer to the EMDS for the last issue date.

Where this Specification refers to DEPs and International Standards, it refers to the issues that were in-use
when the author wrote this Specification. Exceptions are references to specific issues. If you use DEPs or
International Standards with this Specification, make sure you use the latest issues.

Do not change this Specification without approval. Only the Custodian, the Corporate Functional
Discipline Head (CFDH) who owns this Specification, can give approval for changes. If you think the
Specification is not correct, write your comments on a copy of the User Comment Form. The form is the
last page of this Specification.

Specification for Cathodic protection Design

Version 2.0

Contents
Authorised For Issue

Error! Bookmark not defined.

1 PREFACE
1.1
Introduction
1.2
Applicability
1.3
Language and units of measurement

5
5
5
5

2 FACILITIES TO BE PROTECTED
2.1
Facilities Requiring Protection
2.2
Selection of Type of Cathodic Protection System
2.2.1 External Protection
2.2.2 Internal Protection

6
6
6
6
7

3 CATHODIC PROTECTION PERFORMANCE CRITERIA

3.1
General
3.2
Protection Criteria
3.2.1 Impressed Current Systems
3.2.2 Sacrificial Anode Systems
3.3
Current Requirements
3.3.1 General
3.3.2 Pipeline Current Requirements
3.3.3 Well Casings
3.4
Avoidance of Cathodic Protection Interaction
3.4.1 General Guidelines
3.4.2 Testing

8
8
8
8
8
9
9
9
10
11
11
11

4 SITE SURVEYS
4.1
Introduction
4.2
Description of Terrain
4.3
Soil Resistivity Measurements
4.4
Soil Investigation
4.5
Current Drainage Tests
4.6
Stray Currents

12
12
12
12
12
12
13

5 CATHODIC PROTECTION DESIGN DETAILS

5.1
Introduction
5.2
Design Requirements
5.2.1 Isolation and Earthing
5.2.2 Cable Sizing
5.2.3 Hazardous Areas
5.2.4 Electrical Isolation
5.2.4.1 Buried In-Station Pipework Tanks and Vessels
5.2.4.2 Buried In-Station Pipework
5.2.4.3 Interstation Pipelines and Main Transmission Pipelines
5.2.5 Flowlines and Short Buried Sections
5.2.5.1 Well Casings
5.2.6 Electrical Earthing
5.2.6.1 Tanks and Vessels
5.2.6.2 Buried In-Station Pipework, Interstation and Transmission Pipelines
5.2.6.3 Transmission Pipelines Paralleling Overhead High Voltage Power Lines
5.2.6.4 Well Casings
5.3
External Cathodic Protection
5.3.1 Current Source
5.3.1.1 Impressed Current

14
14
14
14
14
14
15
15
15
15
16
16
16
16
16
17
17
17
17
17

SP-1128

December 2005

Specification for Cathodic Protection Design

Version 2.0

5.3.1.2 Current Capacity of DC Source

5.3.1.3 Sacrificial Anodes
5.3.2 Station Tanks, Vessels, In-Station Pipework and Interstation Pipelines
5.3.3 Transmission Pipelines
5.3.4 Buried Sections of Above ground Pipelines and Flowlines
5.3.5 Well Casings
5.3.6 Groundbeds
5.3.6.1 General
5.3.6.2 Groundbed Resistance and Soil Resistivity
5.3.6.3 Positioning
5.4
Internal Cathodic Protection
5.4.1 General
5.4.2 Sacrificial Systems
5.4.2.1 Anodes
5.4.2.2 Anode Quantity
5.4.2.3 Anode Distribution
5.4.2.4 Anode Fixing
5.4.2.5 Anode Monitoring
5.4.3 Impressed Current Systems
5.4.3.1 Anodes
5.4.3.2 Anode Quantity
5.4.3.3 Anode Fixing
5.4.3.4 Anode Monitoring

18
18
18
18
19
19
19
19
20
20
21
21
21
21
21
22
22
22
22
22
22
22
23

6 MONITORING AND TEST FACILITIES

6.1
Introduction
6.2
Tanks and Vessels
6.2.1 External CP Potential Measurement
6.2.1.1 Tanks
6.2.1.2 Vessels
6.2.2 Internal CP Potential Measurement
6.2.2.1 Tanks
6.2.2.2 Vessels
6.3
Buried In-Station Pipework
6.3.1 Potential Monitoring
6.4
Interstation and Main Transmission Pipelines
6.4.1 Potential Monitoring
6.4.2 Isolating Joint / Insulated Flange
6.4.3 Drain Point
6.4.4 Combined Drain Point and Isolation Joint / Insulated Flange
6.4.5 Buried Cathodic Protection Coupons
6.4.6 Foreign Service Bonding
6.4.7 Cased Crossing
6.4.8 Grouted Sleeve
6.4.9 Buried Sections Of Surface Laid Pipeline/High PressureGas Flowlines

24
24
24
24
24
24
24
24
24
25
25
25
25
25
25
25
25
25
25
25
26

7 Appendix A Glossary of Definitions, Terms and Abbreviations

7.1
Standard Definitions
7.2
Special Definitions
7.3
Abbreviations
7.4
Calculation of ICCP Station Spacing For Main Transmission Pipelines
7.5
Groundbed Resistance Calculations
7.5.1 General
7.5.2 Horizontal Groundbeds
7.5.3 Vertical/Borehole Groundbeds
7.6
Sacrificial Anode Example Calculation

27
27
27
28
29
31
31
31
32
32

SP-1128

December 2005

Specification for Cathodic protection Design

Version 2.0

8 References

35

9 USER COMMENT FORM

36

SP-1128

December 2005

Specification for Cathodic Protection Design

Version 2.0

1 PREFACE
1.1

Introduction

This Specification gives the minimum requirements for the design of cathodic protection systems for
internal surfaces of tanks and vessels, the external surfaces of tank bottoms, buried vessels, buried instation pipework, buried flowline sections, interstation pipelines, main transmission pipelines and well
casings.
Marine facilities (e.g. jetties and sub-sea pipelines), internal surfaces of pumps, valves etc and internal
surfaces of pipelines are not dealt with in this Specification.

1.2

Applicability

If this Specification is applicable to the work that you do, you shall obey its instructions. You shall get
approval, in writing, from the Custodian, the CFDH Corrosion who owns this Specification, before you use
procedures other than those that this Specification specifies.
This Specification is not applicable retroactively.

1.3

Language and units of measurement

You shall use the English language and the International System (SI) units of measurement in all
documents and drawings. Where the SI unit is a conversion of a manufactured dimension, you can put the
original dimension, in brackets, after the SI units. For example, 50mm (2in) pipe.

SP-1128

December 2005

Specification for Cathodic protection Design

Version 2.0

2 FACILITIES TO BE PROTECTED
This section defines the structures which shall be cathodically protected. It also gives guidance on the type
of CP system(s) which may be employed on specific structures.

2.1

Facilities Requiring Protection

The following steel structures shall be cathodically protected:

Internal tank and vessel surfaces where these contain an uninhibited water phase unless GRE lined or
alloy steel cladExternal surfaces of tank bottoms ( See note 1 below )

Buried vessels

Buried in-station pipework

Buried flowlines (where specified- see note 2 below)

Buried interstation pipelines

Buried transmission lines

Buried sections of above ground laid interstation or transmission pipelines and high pressure gas
flowlines

Well casings (where specified- see note 2 below)

Note 1

The use of asphalt carpet beneath tank bottoms is NOT recommended as the carpet acts as a shield
that prevents the protective cathodic protection current from reaching its intended target of the tanks
bottom. The asphalt carpet does NOT offer protection to the tanks bottom against corrosion in the
absence of cathodic protection.

Experience in PDO has shown that the use of dry bitumen sand mixes and oiled sand under the tank
bottom is appropriate.

Where tanks are to be placed on a concrete base and where cathodic protection is required, specific
guidance shall be sought from the Materials and Corrosion Engineering Department (CFDH).

Note 2

2.2
2.2.1

The Materials and Corrosion Engineering Department will advise when CP is required for these
structures.

Selection of Type of Cathodic Protection System

External Protection

Cathodic protection of buried external surfaces should, where technically and economically practical, be
by Impressed Current Cathodic Protection (ICCP) systems. This covers all the external categories stated in
section 2.2 above except for the part buried short lengths of above ground pipelines and flowlines which is
explained below.
For short buried sections e.g. road crossings, of surface laid pipelines and high pressure gas flowlines,
either ICCP or sacrificial anode systems shall be used as applicable. These sections shall be coated as per
DEP 31.40.30.31 & 31.40.30.32.
SP-1128

December 2005

Specification for Cathodic Protection Design

Version 2.0

Where the use ICCP cannot be justified and application of sacrificial anode system is technically not
feasible , the short buried section or road crossing of surface laid pipelines and high gas pressure flowlines
shall be protected by the application of three layer factory applied PE or PP coating as applicable with an
additional rock shielding coat to a minimum total thickness of 6mm. Coating field joints shall be kept to a
minimum for such crossings. Field joints shall have a double seal arrangement which shall ensure that
water cannot penetrate. Coating and field joints shall be inspected with high voltage holiday detector
immediately prior to backfilling .
For road crossings of LP flowlines where the use of cathodic protection can be justified, either ICCP or
sacrificial anode systems may be used as applicable. In general LP flowlines road crossings may be
protected by application of a coating system in accordance with PCS-2 of SP-1246 and GU-368.
Pipelines installed in cased crossings shall be cathodically protected by either the principal pipeline CP
system or, where required, by a dedicated sacrificial anode or ICCP system.
2.2.2

Internal Protection

Cathodic protection of the internal surfaces of hydrocarbon containing tanks or vessels, with a continuous
unhibited water layer, shall be by sacrificial anodes. Unless the equipment is GRE lined or alloy clad.
For tanks which do not contain hydrocarbons (e.g. Fire Water Tanks, potable water tank) cathodic
protection of the internal surfaces shall be achieved using either impressed current or sacrificial anodes.
For potable water tanks that require protection ONLY sacrificial magnesium anodes shall be considered .

SP-1128

December 2005

Specification for Cathodic protection Design

Version 2.0

3 CATHODIC PROTECTION PERFORMANCE CRITERIA

This section specifies the criteria for the design and operation of CP systems.

3.1

General

The structure to soil potential is the criterion for effective cathodic protection. For well casings only,
where potential measurements cannot be reliably made, a downhole casing current density profiling tool
shall be used to confirm the effective application of cathodic protection.

3.2
3.2.1

Protection Criteria
Impressed Current Systems

Impressed current CP systems shall be designed such that instantaneous OFF potentials can be measured
for assessing the CP system performance.
CP systems shall be designed to provide sufficient current to the structure, over its design life, to achieve
an OFF potential over the entire structure, equal to or more negative than stated in Table 3.1. In
particular, on tank base plates, the OFF potential shall be achieved at the centre thereof.
To avoid detrimental effects on the applied coating (disbondment) or on the structure (hydrogen induced
stress cracking) due to over protection, OFF potentials for carbon steel shall not be more negative than
the overprotection limit value as stated in Table 3.1.
Some corrosion resistant steels and high strength steels (e.g. Duplex stainless steels) are more susceptible
to hydrogen induced stress cracking than carbon steel. The protection criteria for structures made of such
materials shall be determined on a case by case basis, but shall not under any circumstance be more
negative than the over protection limit given in Table 3.1. When such materials are to be cathodically
protected, the Company Materials and Corrosion department shall be consulted for specific
recommendations and requirements.
Anaerobic environments are not generally encountered on buried pipelines or other structures in
the Sultanate of Oman. They may be encountered on internal CP systems however. The
protection criteria potential shown in Table 3.1 shall be used for anaerobic conditions when
medium (electrolyte) analysis confirms the presence of active sulphate reducing bacteria in
anaerobic environments, or when consideration of the operating conditions allows that these may
exist. The CFDH Materials and Corrosion shall indicate if this requirement applies.
Table 3.1. Potential Limits for Cathodic Protection for ICCP Systems
ENVIRONMENT

POTENTIAL
Instantaneous OFF Potential (mV)
Cu/CuSO4 Reference Electrode

3.2.2

Protection potential for steel in aerobic soil

environment.

-850

Protection potential for steel in anaerobic soil

environment

-950

Over protection limit for corrosion resistant and

high strength steels.

-1150

Over protection limit for carbon steel

-1200

Sacrificial Anode Systems

SP-1128

December 2005

Specification for Cathodic Protection Design

Version 2.0

Sacrificial anode systems are not normally designed to enable OFF potentials to be recorded. Cathodic
protection systems shall therefore be designed to provide sufficient current to achieve a minimum ON
potential on the structure, over the design life.
For tank and vessel internal sacrificial anode systems, using Company standard composition aluminium
anodes, the design shall provide sufficient current to achieve an ON potential equal to or more negative
than minus 800mV, with respect to a silver/silver chloride reference electrode.
If used for cathodically protecting buried sections of above ground pipeline and flowlines, where
magnesium alloy is the sacrificial anode material, the design shall provide sufficient current to achieve an
ON potential equal to or more negative than minus 1000mV with respect to a Cu/CuSO 4 reference
electrode.

3.3
3.3.1

Current Requirements
General

The total minimum current requirements for all new structures requiring cathodic protection shall be
calculated from the area of the structure, the current density requirements and the estimated coating
breakdown. Data for current density requirements and coating defect estimates are given in the Tables 3.2
and 3.3.
When applying cathodic protection to the external surfaces of structures, care shall be taken to ensure that
an allowance is made in the design current requirement calculations for all metallic surfaces in contact with
the environment and electrically continuous with the structure. The size of the allowance shall depend on
the relative proximity of the cathodic protection groundbeds to the main structures to be protected and
ancillary structures (e.g. earthing systems). If remote groundbed(s) are used then the allowance shall be to
the full current density requirement to achieve cathodic protection on the main and ancillary structures; if
close groundbeds are used then a smaller provision for the ancillary structures shall be used.
Where a number of structures, such as tanks, vessels and interstation pipework, are to be protected and/or a
variety of coating systems have been used, each item shall be considered individually. The total current
requirement shall then be the summation of individual current requirements.
When designing retrofit CP systems, current drainage tests (see Specification-SP-1129) shall be performed
wherever possible to determine the minimum current requirements. The results of these tests shall be
compared to calculated current demands and the highest value used to identify CP system capacity.
3.3.2

Pipeline Current Requirements

The Contractor shall carry out pipeline current attenuation calculations to determine the spacing between
cathodic protection stations as required during the pipeline life. The current densities in Tables 3.2 and 3.3
shall be used as minimum design values for new projects. This data is valid for pipelines with operating
temperatures upto 30C.
The current density values in Table3.2 are to be related to the total pipeline surface area and take into
account coating deterioration during the design life of the pipeline.
It is assumed that pipeline construction is carried out in a manner to avoid coating damage during
construction and operation.
For protection of pipelines with elevated operating temperatures the minimum design current densities
given in Table3.2 shall be increased by 25% per 10C rise in temperature above 30C. The increase shall
be compounded per 10C rise in temperature.
For pipelines, or other structures, operating at temperatures above 60C the Company Materials
and Corrosion department shall be consulted for advice on appropriate design current densities.
In such circumstances, it may be required to provide temporary CP to the structure, until such a
time that current drainage tests may be conducted to establish the actual current requirement.
SP-1128

December 2005

Specification for Cathodic protection Design

Version 2.0

Table 3.2. Design Current Densities For Different Pipeline Coatings

PIPELINE LIFE (Years)
COATING TYPE

0-5

5 - 15

15 - 30

CURRENT DENSITY (mA/m)

Fusion bonded epoxy
Liquid epoxy
Coal tar epoxy
Polyethylene
Polypropylene

0.010

0.020

0.05

0.002

0.005

0.01

The current densities given in Table3.2 already include the current requirements due to the expected
coating breakdown during the design life of the pipeline.
3.3.3

Tanks, Vessels and Buried Pipework

The Contractor shall carry out calculations based on resistivity data and coating breakdown factors as
detailed in Tables 3.3.and 3.4.
Table 3.3. Minimum Current Density Requirements for Non-coated Steel in Common Environments
Environment Ohm.m
Soil with resistivity of:
>10
1-10
<1
Water with resistivity of:
>1.5
0.5-1.5
<0.5

Current Density mA/m

10
20
35
50
75
110

Table 3.4. Assumed Coating Defects for the Purpose of CP Design Calculations

Surface Coating

Assumed Coating Defects

(%)

None (Bare steel) and Galvanised

Steel

100

PCS 2,7 & 8

10

When other coating systems are used the Company Materials and Corrosion department shall be consulted
during CP design.
3.3.3

Well Casings

When specified by the Company, well casings shall be provided with cathodic protection.

SP-1128

10

December 2005

Specification for Cathodic Protection Design

Version 2.0

The application of cathodic protection on well casings should be undertaken retrospectively so that current
requirements can be determined on an existing well casing.
The minimum current requirement for design purposes shall be determined by E log i tests on at least one
and preferably more of each type of casing completion in any given field.
Where conditions allow, a casing current density profiling tool should also be used to confirm that
cathodic protection is achieved with a given current.
The data determined from such tests shall form the basis for the cathodic protection design for all well
casings in the field, with a suitable allowance made for any expected variation through the field.
This specification shall not be used for obtaining design criteria of pulse rectified CP systems for well
casings. Such design criteria shall be established by the PDO approved pulsed rectified CP vendors.

3.4
3.4.1

Avoidance of Cathodic Protection Interaction

General Guidelines

Where a CP system is designed for installation on a structure which is in the vicinity of a foreign structure
the design shall include features to minimise possible interaction.
Design features to be considered shall include the provision of supplementary anodes, facilities to allow
resistive bonds between the structures, selective positioning of material with the appropriate insulating
properties and selective positioning of the groundbed.
3.4.2

Testing

Where it has been necessary to incorporate measures to mitigate possible CP interaction, Interaction
Testing as described in BS 7361 (Part 1) : 1991 shall be carried out prior to commissioning.

SP-1128

11

December 2005

Specification for Cathodic protection Design

Version 2.0

4 SITE SURVEYS
4.1

Introduction

Prior to designing a cathodic protection system for a pipeline a pre-design route survey shall be carried
out.
Information obtained during previous surveys for the proposed pipeline route may be used provided that
the date, conditions and source of such surveys are included in the site survey report.

4.2

Description of Terrain

The survey shall include general information of the terrain along the pipeline route, including:

4.3

Type of terrain and vegetation e.g. urban areas, industrial areas, farm land, forests,
desert, rocks.

Visible relevant features and crossings (main roads, overhead power lines, other
pipelines, wadis)

All other information that is considered relevant to the design of a cathodic protection
system.

Soil Resistivity Measurements

Soil resistivity measurements shall be carried out along the route of the pipeline at pipeline depth.
The number of measurements should be determined locally depending on the length of the
pipeline and known data (maximum 5 kms separation) but measurements should at least be
carried out when there are visual changes in soil characteristics at a maximum separation of
2kms. On completion of the Project results shall be handed over to the Company
For each type of soil, readings should be taken in at least two different locations. At each location a
minimum of 2 measurements shall be carried out. Soil resistivity measurements shall be made using four
terminal (Wenner) resistivity method.
When the soil resistivity measurements are used to locate suitable places for surface groundbeds, the four
terminal Wenner method shall also be used to determine the resisitvity at greater depths (25 m maximum).
For measurement of resistivity at depths greater than 25m the Schlumberger technique may be used.
Other soil resistivity measuring methods require approval by the CFDH for Materials and Corrosion.

4.4

Soil Investigation

If it may be assumed that corrosive conditions are present due to bacterial activity, further chemical and
bacterial soil analysis shall be carried out. For test methods, refer to BS 1377 parts 3 and 9.

4.5

Current Drainage Tests

When designing a cathodic protection system for existing pipelines a current drainage test should be
performed to determine the current and optimal current distribution. This may necessitate temporary
installation of one or more groundbeds and DC power sources (e.g. batteries or portable rectifiers), timerunits, and test facilities to the pipeline under investigation.

SP-1128

12

December 2005

Specification for Cathodic Protection Design

Version 2.0

To obtain relevant results, pipeline isolation equipment (Section 5) and monitoring facilities (Section 6)
should be installed before current drainage tests are carried out.
The required current is determined when, after full polarisation is achieved, the OFF potentials measured
at regular points along the pipeline are within the protection criteria as given in Table 3.1. A further
allowance for future deterioration of the coating, during the remaining life of the pipeline, shall also be
made.
If the pipeline has been previously cathodically protected, historical data and data trends may be used to
determine the current demand.

4.6

Stray Currents

The Contractor shall investigate possible sources of detrimental DC stray currents and include proposals in
the design on how to mitigate the effect of such stray currents.
If the effect of stray currents cannot be predicted, the Contractor shall carry out a stray current survey at
the time of commissioning.
Stray currents shall be eliminated at the source by suitable insulation or other means. If this is impossible
other measures such as installation of a current drainage system shall be designed.
The presence of overhead AC power transmission systems shall also be identified. As a minimum, the
length and separation of parallelism(s), number of crossings, crossing angle(s) and AC rating shall be
recorded. The requirements of SP-1102 and SP-1114A shall also be considered during the survey.

SP-1128

13

December 2005

Specification for Cathodic protection Design

Version 2.0

5 CATHODIC PROTECTION DESIGN DETAILS

5.1

Introduction

Design of a correctly sized and located cathodic protection system is vital to achieving the required design
life. Technical considerations shall be the principal factor for consideration but where more than one
technical solution is acceptable economics also becomes important. This Section addresses all
considerations to be made by the Contractor during design of a cathodic protection system.

5.2
5.2.1

Design Requirements
Isolation and Earthing

Structures cathodically protected using close groundbeds shall not be isolated from adjacent plant and
earthing systems but shall be isolated from reinforcing bars in concrete constructions associated with the
structure.
Structures which are cathodically protected using remote groundbeds shall be electrically isolated from
common earthing schemes, foreign structures, pipelines and from reinforcing bars in concrete
constructions.
This shall be accomplished using independent earthing, insulated flanges, monobloc isolating joints,
electrically insulating sleeves and / or isolating spool pieces.
Standard insulated flanges, monobloc isolating joints and isolating spool pieces are shown in drawings
STD-7-5001, 5002 and 5003 respectively.
The CP design shall be such as to minimise the number of isolating devices by placing them, wherever
possible, in common pipework but always between a cathodically protected structure or pipeline and other
earthed plant items.
Structures isolated from common earthing schemes shall have an independent earthing system as detailed
in section 5.2.4. Isolation from common earthing systems shall be used to stop current flow through the
common earth bonds to structures which are required to be outside the CP system, and thus avoid
excessive current demand and the possibility of failure to adequately protect the targeted structure.
5.2.2

Cable Sizing

Cables shall be sized as follows:

Groundbed to T/R to protected structure/pipeline: The voltage drop between the structure/pipeline and
the groundbed shall not be more than 5V at the full rated output of the T/R. Preferred cable sizes have 10,
35 or 70mm cross sectional areas.
Groundbed to Solar Generator to CP structure/pipeline: 70mm cable shall be used.
In both the above cases the driving potential between the groundbed and structure / pipeline shall be
sufficient to drain the minimum required current from the structure / pipeline.
Ancillary equipment, Sacrificial Anodes etc.: see standard drawings Specification-SP-1136.
5.2.3

Hazardous Areas

All CP power sources and junction boxes shall be located outside of hazardous areas.
Test posts (e.g. for tanks, vessels) should be located outside of hazardous areas. When this is not feasible,
e.g. for monitored internal anodes, under tank monitoring duct test posts and tank circumference soil pots.

SP-1128

14

December 2005

Specification for Cathodic Protection Design

Version 2.0

These may be located adjacent to the structure. Appropriate safety measures (e.g. Class A work permit, gas
test, intrinsically safe meters) shall be taken during monitoring activities.
Isolation shall be effected outside hazardous areas or be protected against inadvertent short circuiting
across the insulation.
5.2.4

Electrical Isolation

5.2.4.1

Buried In-Station Pipework Tanks and Vessels

Cathodic protection of the external bottoms of tanks and the external surfaces of buried vessels shall be by
the use of close anodes or groundbeds which are located sufficiently close to ensure that current flows
preferentially to the vessels or tank whilst achieving an even spread of protection. Under these
circumstances isolation of this vessel or tank is not required.
Likewise isolation is not required for internal protection of tanks and vessels.
5.2.4.2

Buried In-Station Pipework

Whenever possible buried in-station pipework should be manufactured from suitable non-metallic
materials.
Buried in-station steel pipework shall be cathodically protected using a close anode system, designed to
ensure that current flows preferentially to the pipework whilst achieving an even spread of protection. It is
not, therefore, required to provide any isolation of this pipework from tanks, vessels or plant earthing
systems.
5.2.4.3

Interstation Pipelines and Main Transmission Pipelines

Pipelines which have low BS&W (>1.0%) and gas lines shall generally be electrically isolated by means of
internally coated monobloc isolating joints (DEP 31.40.21.31 refers), installed above ground at both ends
of the pipeline.
If the product transported by the pipeline is an electrolyte (e.g. water) or it may be anticipated that it may
contain an electrolyte at any time during the life of the pipeline, then isolating spools designed as per the
following rules shall be installed. Where a pipeline has an HDPE liner, isolating spools may not be
required. Isolation is still required, and this may be achieved by the use of an isolating flange kit.
If the resistivity of the electrolyte is higher than 1 Ohm.m, or the volume occupied by the electrolyte is less
than 5% of the pipeline volume, the overall length of the isolating spool shall be four times the pipe
diameter (with a minimum of one metre).
If the resistivity of the electrolyte is below 1 Ohm.m, or the volume of electrolyte is more than 5%
of the pipeline volume, the length of an isolating spool shall be determined by the following
formula:

L (400/ ) D L =
Where:
L = length of spool (cm),
= electrolyte resistivity (Ohm.cm)
D = nominal pipe diameter (cm).
Acceptable isolating spools are:
(a) Glass reinforced epoxy pipe designed and manufactured in accordance with DEP31.40.10.19;
(b) Pipe spool fitted with PE liner or RTP

SP-1128

15

December 2005

Specification for Cathodic protection Design

Version 2.0

(c) Internally coated pipeline spool and holiday free when tested by high voltage spark detection
equipment. Seek Materials and Corrosion Discipline advice for specific coating recommendations.
5.2.5

Flowlines and Short Buried Sections

For new facilities where CP is applied all flowlines shall be isolated from the station inlet manifold into
which they flow. This shall be done by the use of an isolating flange. For new stations that have close
groundbeds this will not be required.
Short buried sections of above ground pipelines shall be isolated from the above ground section by use of
isolating flanges. For road crossings that have CP the buried protected section shall be isolated from the
above ground section.
5.2.5.1

Well Casings

All well casings shall be isolated from flowlines, gas lift, gas / water injection lines or electrical
earthing systems associated with Beam Pump / Submersible Pump producers, irrespective of
whether CP is proposed at time of completion.
Flowlines and water injection lines shall be isolated by spool pieces designed as detailed in the preceding
sub-subsection.
Gas lift and gas injection lines shall be isolated by insulated flanges.
Any of the above devices shall be installed at the edge of the respective well pad location.
5.2.6

Electrical Earthing

5.2.6.1

Tanks and Vessels

The effect that the earthing system has on the cathodic protection system will largely depend on the
proximity of the CP anode groundbeds to the structure and the type of earthing material. If the anode
groundbed is located close to the structure then the CP current will flow preferentially to the structure and
the effect of the earthing system will be minimised. This is the mandatory method that has been adopted by
PDO for applying cathodic protection to all new structures. The following paragraphs are to be used as a
guideline and are included to give an understanding of how existing systems effect electrical earthing.
If the anode groundbed is remote from the structure then the earthing system will have a large effect on the
CP system. The size of this effect will depend on the material used for the earthing system. If copper
earthing is used then very high current requirements are expected and the effects of current straying to
foreign structures shall be evaluated and recommendations for alleviating their effect on existing
equipment submitted to the Company. Such recommendations shall consider the use and efficiency of
isolation of the tank or vessel and the use of an independent earthing system.
If earthing of tanks and vessels consists of a dedicated earthing grid of insulated copper
conductors and earthing electrodes constructed of DN50 galvanised steel pipe in accordance
with the guidelines of DEP 33.64.10.10 Gen, Section 6.4 Earthing and Bonding current
requirements will be considerably less than required to protect a structure which is earthed using
copper. In this case straying currents, to foreign structures, should not be a problem.
5.2.6.2

Buried In-Station Pipework, Interstation and Transmission Pipelines

Surge diverters shall be installed across all isolating joints and insulated flanges as shown in
STD-7-3007.

SP-1128

16

December 2005

Specification for Cathodic Protection Design

5.2.6.3

Version 2.0

Transmission Pipelines Paralleling Overhead High Voltage Power Lines

Three main problems can exist from the parallelism of high voltage overhead power lines and buried or
above ground pipelines and flowlines:

Induced AC voltages may be hazardous to personnel, see Procedure-11345 on Safe

Working Procedures on Cathodic Protection Systems.

Induced AC currents can adversely effect the cathodic protection system

Very high transient voltages can occur during fault conditions, e.g. lightning strikes or
phase imbalance, which present a hazard to personnel and may damage the pipeline
coating.

From a cathodic protection point of view the induction of AC voltages on the pipeline can cause AC
current to flow to earth via the rectifying elements of the transformer rectifier and the groundbed. This
current, which has been half wave rectified, can flow back into the pipeline as DC current, cause increased
DC potentials on the line, make the control and monitoring of the CP systems difficult and may possibly
damage T/R components and the pipeline coating. Additionally, high AC potentials on the line may be
hazardous to personnel engaged in routine pipe to soil potential measurements.
The Contractor shall submit proposals to the Company for mitigating the effects of induced AC on buried
or surface pipelines where the overhead power lines are rated at 132kV or above, and the pipeline is
separated therefrom by less than 500m over a minimum 0.5 km parallelism (Refer to SP-1114A). Different
considerations are required for parallelisms between overhead powerlines and surface laid
flowlines/pipelines, when lower voltage systems may create a hazard. In such cases, where the overhead
power lines are rated at 33kV and the pipeline/flowline is separated laterally by less than 15m over a
0.5km parallelism (Refer to SP-1102), proposals shall be made for mitigating the effects of induced AC.
In each case the Contractor shall consider all factors relating to the extent of potential AC voltage which
may occur. These include overhead powerline rating, minimum/maximum separation of parallelism, length
of parallelism, number and angle of overhead powerline/pipeline crossings, soil resistivity, coating
conductance, type of AC powerline support pole (e.g. wood/metal) and any other factors as may be
applicable on a case by case basis. If the Contractor is not sufficiently experienced to undertake this
assessment, he shall appoint another suitably qualified authority for this.
5.2.6.4

Well Casings

Electrical earths shall be isolated from thewell head by use of solid state polarisation devices. Alternatively
a galvanised steel earth may be used such that isolation is not required.

5.3
5.3.1

External Cathodic Protection

Current Source

5.3.1.1

Impressed Current

Where a continuous AC power supply is available, CP current shall be supplied using a T/R with a rated
output voltage no greater than 48V and shall comply with DEP 33.64.10.10 - Gen. and Specification-SP1130
When a suitable continuous AC power supply is not available solar generators should be used. Alternative
power sources (e.g. TEGs) shall be subject to Company approval.
The use of multi-channel power supplies shall be considered in appropriate circumstances, e.g. multi-tank
external base CP systems with close anodes.

SP-1128

17

December 2005

Specification for Cathodic protection Design

Version 2.0

All CP power sources shall be located in compounds which shall consist of a concrete foundation and be
individually fenced and provided with an access gate. The access gate shall be a single personnel gate,
with a lockable latch type closure, suitable for locking with a padlock. The concrete foundations shall be
large enough to accommodate all of the necessary equipment (T/Rs, solar panels, mains switch box,
current distribution box etc.) allowing a 1 m working space all around. The foundation shall be provided
with conduit(s) for all cabling. Cables shall not be run on the concrete surface and shall not be cast in the
concrete. Where a T/R or other non-solar power supply is used a sunshade shall be fitted over the
compound, in accordance with SP-1283.
Compound fencing shall be either of the leaf gate type or the chain link type. If the compound is on-plot it
shall be located adjacent to the facility perimeter fence and the single mangate located in the perimeter
fence. The compound fencing shall be to the same standard as the facility fencing and fitted with two gates
so as to allow access to the compound from the outside and the inside of the facility.
All buried positive and negative cable runs shall be marked using cable route markers to comply with
STD-7-7001.
A review of development plans in the vicinity of the projected CP system shall be carried out. Where it is
found that additional structures which will require CP are to be built, the CP design shall allow for this
expansion.
5.3.1.2

Current Capacity of DC Source

Design current requirements shall be determined as described in Section 3. The DC current source shall be
capable of providing at least 120% of the design current where current drainage testing has been
performed and at least 130% of the design current where this has been determined through calculation. In
any event the current source rating shall be minimum 10 amps, but for higher ratings should not be capable
of providing more than 150% of the design current requirement, unless it can be shown to be technically or
economically appropriate.
5.3.1.3

Sacrificial Anodes

Sacrificial magnesium anode cathodic protection systems may be employed for short buried sections where
their use can be both technically and commercially justified. The maximum design life for sacrificial anode
systems shall be 5 years.
5.3.2

Station Tanks, Vessels, In-Station Pipework and Interstation Pipelines

Each structure shall have a discrete drainpoint connection and a separate negative return cable. These
connections shall be made using welded pads to comply with STD-7-2001 or STD-7-2003.
Where groups of structures are to be protected using the same current source, cables shall run from each
structure to common, centrally located NDB(s). Cables from these shall run to an NJB and cables from this
shall terminate at the current source.
5.3.3

Transmission Pipelines

A series of dedicated CP stations distributed along the length of the pipeline shall be used to provide
current.
Distances between neighbouring stations shall be based on current attenuation calculations with due
consideration for local variations in terrain and geology. Example calculations are given in Appendix 1.
Where a pipeline is being constructed parallel to an existing pipeline and is within 50 metres of that
pipeline then the pipelines shall have the facility to be electrically bonded at intervals of 10km. The
operating history of the existing CP system and the current demand of the new line shall be reviewed to
determine the need to provide additional CP stations.

SP-1128

18

December 2005

Specification for Cathodic Protection Design

Version 2.0

If the pipeline is to be constructed inside steel casings or culverts at major crossing features, the
requirement for cathodic protection of the carrier pipe inside the casing or culvert shall be considered. The
provision of supplementary cathodic protection shall then be designed on a case-by-case basis.
5.3.4

Buried Sections of Above ground Pipelines and Flowlines

All new buried sections of essentially above ground pipelines and flowlines shall be coated as stated in
section 2.4 and cathodically protected. The preferred method for achieving this, where economically
justified, is via an impressed current source. The selection between use of existing current sources or
installation of dedicated current sources shall be made by the specialist design engineer (Contractor).
Sacrificial magnesium anode cathodic protection systems may be employed where their use can be both
technically and commercially justified. The maximum design life for sacrificial anode systems shall be 5
years.
When considering a single flowline or pipeline buried section at the design stage, the Contractor shall take
into account nearby or parallel buried pipework and any possible interference that may occur. In such
cases necessary mitigation shall be considered during the design period.
5.3.5

Well Casings

Well casings may have dedicated groundbed and impressed current power supplies or may be linked
together in clusters such that one power supply / groundbed protects more than one well.
Power supplies shall be either conventional DC transformer-rectifiers, pulsed rectifiers or solar generators
depending on the field layout and application.
Borehole type groundbeds installed below the water table shall be used for well casing cathodic protection.
Principal factors influencing choice of power supply include :

Casing depth

Casing current demand

Separation between adjacent wells

Availability of AC power supply

The Contractor shall consider each well casing and field on a case-by-case basis and propose the most
suitable option for approval.
5.3.6

Groundbeds

5.3.6.1

General

The selection of type and design of groundbeds shall take into account the following:

Soil resistivity at the location

The location shall be capable of providing satisfactory current distribution to the

structure(s) intended

Minimising the risk of harmful interference and installation costs.

Groundbeds shall be designed to comply with STD-7-6001,STD-7-6003, STD-7-6004

STD-7-6005 STD-7-6006 or STD-7-6007 as appropriate.

SP-1128

19

December 2005

Specification for Cathodic protection Design

Version 2.0

The number of groundbeds shall be equal to or exceed the number of power supply
sources for each location.

The number and size of impressed current anodes shall be sufficient to operate at the calculated current
output for 20 years. For horizontal and vertical shallow groundbeds PDO standard size Silicon-IronChrome 1525 mm x 75 mm anodes or cannistered anodes shall be used. For borehole groundbeds either
Mixed Metal Oxide, Platinised Titanium / Niobium or Silicon-Iron-Chrome (1220 mm x 50mm size)
anodes shall be used, based on a techno-economic review of required groundbed depth, active length,
number of anodes and current requirement. Refer to section 5.1of SP-1130 for anode details. All anodes in
horizontal, vertical and borehole groundbeds shall be individually monitored via an anode junction box.
On new tanks or on tanks which have been re-bottomed the external anode system shall consist of flexible
or wire type ribbon anodes placed below, and in close proximity to, the tank base. The system design,
anode type, sizing and its location and method of installation shall be subject to Company approval.
On pipelines installed in steel casings or concrete culverts, the anode system shall consist of impressed
current flexible or wire type anodes or sacrificial magnesium or zinc ribbon anode, as appropriate,
designed on a case-by-case basis.
5.3.6.2

Groundbed Resistance and Soil Resistivity

Groundbeds (apart from close anode type groundbeds) shall be designed to have a resistance to remote
earth of less than 0.5 Ohm and to fulfil anode current output characteristics under normal soil conditions.
Example design calculations are given in Appendix 2.
Soil resistivities, used in shallow groundbed calculations, shall be measured using the Wenner four pin
method for depths of 25, 20, 15, 10, 5, 2, 1 and 0.5 metres in accordance with DEP 30.10.73.10-Gen. For
deeper resistivity data alternative methods (e.g. Schlumberger method) may be proposed for Company
approval.
For very deep borehole groundbeds (>100m) data on nearby groundbeds and water table depth may be
used to design new groundbeds. In such cases the data and design shall be subject to Company
confirmation and approval.
5.3.6.3

Positioning

The minimum separation of horizontal and vertical groundbeds from any buried facilities such as pipelines,
wells, flowlines, and other groundbeds shall be 200 metres.
The minimum horizontal separation of borehole groundbeds from any buried onplot facilities such as
piping, flowlines, tanks, vessels and other groundbeds should be 50 metres or so as to minimise the spread
of current to other structures.
Where groups of structures exist, shielding may occur. In these instances it is sometimes desirable to
distribute borehole groundbeds such that the minimum separation is less than that given above. Where
doubt over groundbed distribution arises the CFDH for Materials and Corrosion shall be consulted.
In any event the cable run between the CP power supply and its associated groundbed(s) should be
minimised and shall not exceed 1000 metres.
Close anode systems shall be positioned so as to minimise the spread of current to other structures whilst
providing an even level of protection over the surface of the structure under protection.

SP-1128

20

December 2005

Specification for Cathodic Protection Design

5.4
5.4.1

Version 2.0

Internal Cathodic Protection

General

The internal surfaces of tanks and vessels, as defined in section 2.1, which contain an uninhibited
continuous phase of water in normal operation shall be protected using a CP system separate to the
external CP system.
Only sacrificial anode systems shall be used for tanks which contain hydrocarbons. For tanks not
containing hydrocarbons either impressed current or sacrificial systems may be used.
Sacrificial anodes shall not be applied to parts of tanks or vessels lined with glass fibre reinforced epoxy
(GRE) coating. If required anodes may be placed on the tank walls above the GRE lining.
5.4.2

Sacrificial Systems

5.4.2.1

Anodes

Aluminium anodes in accordance with Specification-SP-1130 shall be used for hydrocarbon service. For
tanks containing hydrocarbons anodes shall be either placed on the floor or on the walls depending on the
coating type used
For potable water service magnesium anodes shall be used.
For vessels anodes shall be mounted along the bottom of the vessel.
Anodes shall be of commercially available dimensions and weight to satisfy design requirements and
achieve an even spread of current across the surface of the structure under protection.
5.4.2.2

Anode Quantity

The number of anodes required shall be determined such that the surfaces will be fully protected for a 20
year period.
The number of anodes, N, has to satisfy two criteria:

Total Theoretical wt
Individual anode wt

Total current required

Individual anode current output

The electrochemical efficiency of the anode material shall be calculated using the equation:

E 2000 - 27 (T - 20)
-1

Where: E = capacity of anode material (Ah.kg )

T = operating temperature of electrolyte in degrees centigrade (C)
Current requirements for tank walls and floors and vessel surfaces shall be calculated as described in
Section 3.5. For these calculations the area of the wall/surface shall be taken as the average area which
under normal operating conditions is in contact with the water phase.
An example calculation to calculate the number of anodes required is given in Appendix B.

SP-1128

21

December 2005

Specification for Cathodic protection Design

5.4.2.3

Version 2.0

Anode Distribution

Anode distribution in tanks and vessels is heavily influenced by the presence of internal baffles and
localised flow regimes. These features will vary considerably depending on the nature of the vessels to be
protected. As a general rule anodes should be spaced such that they see all of the areas which require
protection; areas of low flow such as corners require a heavier concentration of anodes.
For tanks not containing hydrocarbons in which anodes are wall mounted they shall be positioned in the
water phase to within 0.5 metres of the water height expected under normal operating conditions. (The
minimum fixing height shall be 0.5 metres from the floor.) For tanks containing hydrocarbons the anodes
shall be evenly distributed around the perimeter of the floor at a distance of 0.5 metres from the wall.
Anodes which are required to protect the floor shall be evenly distributed over the entire area in a
staggered fashion.
In drains vessels anodes shall be positioned in a line along the bottom of the vessel.
5.4.2.4

Anode Fixing

In tanks anodes shall be mounted with 0.3m of stand-off height by bolting and tack welding on steel
supports welded to the steel surface.
In onplot equipment the anodes shall be mounted by bolting and tack welding on steel supports welded to
the steel surface. Welding of the supports shall take place during construction of the vessel and be in
accordance with the appropriate construction code.
After mounting, the steel surface around the support and the entire anode support and anode core shall be
coated to the same standard as the internal coating.
5.4.2.5

Anode Monitoring

At least one anode in each tank shall be mounted such that its current output can be monitored. This shall
be achieved by isolating the anode from the stand offs and connecting it via a shunt. The cables shall exit
the tank via a coffadam arrangement as per STD - 7-4003.
Monitoring of vessel anodes is not required.
5.4.3

Impressed Current Systems

5.4.3.1

Anodes

Impressed current systems shall only be used in tanks / vessels which do not contain hydrocarbons.
Impressed current anodes for internal cathodic protection shall be selected from mixed metal oxide, silicon
iron, platinised titanium or platinised niobium. The latter may be preferred in higher resistivity water
environments.
5.4.3.2

Anode Quantity

Anodes shall be selected to provide a 20 year design life when operating at the design current.
The current requirements for the area to be protected shall be determined as indicated in section 3.5
5.4.3.3

Anode Fixing

Anodes shall be suspended from a suitable mounting fixed to the underside of the tank roof. The anode
must be suitably insulated from the mounting to prevent shorting.
A facility to remove the anode for inspection should be incorporated so that the anode may be removed
without emptying the tank.
SP-1128

22

December 2005

Specification for Cathodic Protection Design

Version 2.0

Care must be taken to ensure that the anodes will be submerged regardless of water level during the normal
operation of the structure.
5.4.3.4

Anode Monitoring

All impressed current anodes or anode strings used for internal CP shall be individually monitored via an
externally located junction box.

SP-1128

23

December 2005

Specification for Cathodic protection Design

Version 2.0

6 MONITORING AND TEST FACILITIES

6.1

Introduction

Regular monitoring of cathodic protection systems is vital to maintaining the design life integrity of the
structure. This Section specifies the minimum requirements for design of monitoring systems for all types
of cathodic protection system within the scope of this Specification.

6.2
6.2.1

Tanks and Vessels

External CP Potential Measurement

6.2.1.1

Tanks

All new or re-bottomed tanks shall have a slotted, non-metallic monitoring duct installed below the base
plates, extending from the tank centre to beyond the rim, to allow measurement of tank base plate potential
by insertion of a portable reference electrode as detailed in drawing STD-4001.
On all new and re-bottomed tanks of diameter greater than 10m potential measurement coupons shall be
installed, adjacent to the duct, at tank centre and half radius. Tanks of diameter 10m or less shall only have
one coupon installed at the tank centre. Coupons shall be positioned such that the cable tails terminate in a
common test facility adjacent to the above ground access point to the duct.
Potential measurement soil pots shall be installed within 1m of the tank rim, located equidistantly around
the tank. Tanks of diameter upto 50m shall have 4 No. soil pots and tanks of greater 50m diameter shall
have 6 No.
All shall be in accordance with STD-7-4001
6.2.1.2

Vessels

All new buried vessels shall have two potential measurement coupons and associated soil pots in
accordance with STD-7-4002.
6.2.2

Internal CP Potential Measurement

6.2.2.1

Tanks

When cathodically protecting internal tank surfaces one or more 2 inch nozzles complete with full bore
valves shall be provided to allow for insertion of reference electrodes. Fittings shall be clear of both
internal and external obstructions or remote frame works and should be easily accessible from the outside.
In all cases a fitting shall be positioned as close as possible to the tank floor.
Where a water level equal to or greater than 4 metres from the base is expected during normal operation, a
second 2 inch fitting shall be installed. This shall be positioned 0.5 metres below the expected water level.
For sacrificial systems one anode in each tank shall be installed to allow external monitoring of current
flow. Monitoring cable(s) shall exit the tank via a cofferdam, all in accordance with STD-7-4003.
6.2.2.2

Vessels

The internal CP system of onplot equipment does not require the installation of monitoring facilities.

SP-1128

24

December 2005

Specification for Cathodic Protection Design

6.3
6.3.1

Version 2.0

Buried In-Station Pipework

Potential Monitoring

Buried in-station pipework shall be protected by close anode systems. Monitoring facilities, therefore,
shall consider the buried length of pipework and the anode type/number installed. As a minimum potential
monitoring facilities shall be installed at each end of buried pipe sections. For longer buried pipe sections
the maximum spacing between test facilities shall be 50m. For systems using discrete anodes (e.g. Si-Fe-Cr
or MMO) distributed along the buried piping, monitoring facilities shall be located at the most remote
points from the anode(s). If required other test facilities shall be installed in accordance with the relevant
drawing shown in SP-1136

6.4
6.4.1

Interstation and Main Transmission Pipelines

Potential Monitoring

Combined potential monitoring test posts/distance markers shall be installed at 2 km intervals along the
pipeline route, unless the position of this test post coincides or is in close proximity ( 100m) to another
type of test point. Installation shall comply with STD-7-3012.
6.4.2

Isolating Joint / Insulated Flange

An isolating joint / insulated flange (or spool) test facility shall be installed at all pipeline isolating joints /
insulated flanges(spools). The installation shall be in accordance with STD-7-3007.
6.4.3

Drain Point

A test station in accordance with STD-7-3003 shall be installed at every drain point connection.
6.4.4

Combined Drain Point and Isolation Joint / Insulated Flange

Where drain point and isolating joint / insulated flange (spool) test facilities coincide, a combined test
facility in accordance with STD-7-3019.
6.4.5

Buried Cathodic Protection Coupons

Coupon test facilities in accordance with STD-7-3016 shall be installed at the mid-points between all
Drain Point test facilities.
6.4.6

Foreign Service Bonding

Foreign service test facilities shall be installed at all foreign service crossings in accordance with STD-73005 and STD-7-3010 .
Where one or more foreign pipelines parallel the protected line, but are not included in the protection
scheme, test facilities complete with bond boxes shall also be installed at 5 km intervals.
6.4.7

Cased Crossing

Where a pipeline is cased, for example at road crossings, then cased crossing test facilities shall be
installed in accordance with STD-7-3018. Where a casing is less than 10m in length a single test facility at
one end of the casing is required. For casings of length 10m or greater test facilities shall be installed at
each end of the casing.
6.4.8

Grouted Sleeve

Where grouted sleeves are installed on pipelines these shall also have test facilities in accordance with
STD-7-3017 provided to allow for a bond between pipeline and sleeve.

SP-1128

25

December 2005

Specification for Cathodic protection Design

6.4.9

Version 2.0

Buried Sections Of Surface Laid Pipeline/High PressureGas Flowlines

Standard CP test post shall be installed per section buried in accordance with STD 7-3001.

SP-1128

26

December 2005

Specification for Cathodic Protection Design

Version 2.0

7 Appendix A Glossary of Definitions, Terms and

Abbreviations
The following terms and abbreviations used in this document, are defined below:

7.1

Standard Definitions

The list that follows tells you the meaning of some words in all Specifications:
Company:

Petroleum Development Oman LLC

Contractor:

The person or organisation that supplies the

company with services.

Vendor:

The person or organisation that supplies the

company with materials and/or equipment.

Discipline:

A specific set of technical knowledge and skills

Corporate Functional Discipline

Head:

The person within the Company responsible for

the discipline to which the specification belongs.
The CFDH approves the Specifications that
apply to his discipline

User:

The person or organisation that reads, and uses

the information, in this and other Specifications

Shall:

Indicates a requirement

Should:

Indicates a recommendation.

May:

Indicates a possible course of action.

7.2

Special Definitions

Cathodic Protection: Process to reduce or prevent corrosion of structures in contact with an electrolyte
by maintaining the flow of electrical current through the electrolyte into the surface of the structure being
protected. The flow of current into the surface of the structure results in a negative change in the surface to
electrolyte potential of the structure. When a critical surface to electrolyte potential is achieved the
structure surface is fully protected from corrosion. Cathodic protection can be achieved using impressed
current or sacrificial anode systems.
Structure: The electrically continuous steel plant or equipment to be protected using cathodic protection.
(Not inclusive of pipelines)
Foreign Structure (or Pipeline): A structure or pipeline which is either not Cathodically Protected or is
protected by another separate system.
Potential: Refers to the surface to electrolyte potential of a structure measured in Volts, with respect to a
reference cell, unless specifically stated otherwise.
Electrolyte: A liquid or the liquid component in a composite material in which electric current flows by
the movement of ions. For the purposes of this Specification electrolyte shall indicate either soil and/or
water.

SP-1128

27

December 2005

Specification for Cathodic protection Design

Version 2.0

Drain Point: The point on a structure or pipeline to which the current return (negative) cable is attached.
ON Potential: Electrical potential measured while cathodic protection system is operating.
OFF Potential Or Instantaneous OFF Potential: Electrical potential measured within 100
milliseconds after the cathodic protection system has ceased operation and with no current flowing to or
from the structure.
Impressed Current: Method of providing cathodic protection by connecting the structure to a DC power
supply.
Sacrificial Anode: Metals and alloys with a more negative electrochemical potential than steel which are
connected to structures to provide cathodic protection. They are consumed during cathodic protection,
require periodic Specification and are typically alloys based on Aluminium, Zinc or Magnesium.

7.3

Abbreviations

AC: Alternating Current

CP: Cathodic Protection
DC: Direct Current
DP: Drain Point
FBE: Fusion Bonded Epoxy (Coating)
FRP: Fibre Reinforced Polymer
GRE: Glass Fibre Reinforced Epoxy (Coating)
ICCP: Impressed Current Cathodic Protection
NDB: Negative Distribution Box
NJB: Negative Junction Box
PCS: PDO Painting and Coating System (Refer to Specification-48-01)
PE: Polyethylene (Coating)
PP: Polypropylene (Coating)
T/R: Transformer/Rectifier

SP-1128

28

December 2005

Specification for Cathodic Protection Design

7.4

Version 2.0

Calculation of ICCP Station Spacing For Main Transmission Pipelines

If impressed current cathodic protection is applied to a long pipeline, the length of pipeline that may be
protected from a single cathodic protection station (in each direction from the drain point) can be
estimated from the following equations.

Ea Em cosh aL(V) ..(1)

Where:
L
= length of pipeline (m)
Ea
= change in pipeline potential (V) at the drain point due to the
application of impressed current
Em
= Change in pipeline potential (V) at a point L due to the
application of impressed current
g
r
a

= coating conductance per unit length (mho/m)

= pipeline resistance per unit length (Ohm/m)
= square root of the product of g and r

These equations assume a number of conditions such as the use of remote groundbeds, uniform coating
conductance, uniform pipe resistance and zero soil resistivity, although the latter is only really important
on bare or poorly coated pipelines where it is significant compared with the coating resistivity. Any
deviations from these conditions shall be taken into account and if necessary sections of the pipeline shall
be treated separately i.e. coating system changes, pipeline diameter changes.
EXAMPLE
An 80 km pipeline of 16 inch nominal diameter and a wall thickness of 0.344 inches is manufactured to
API 5L X 42 pipe. The external coating is fusion bonded epoxy powder of nominal DFT 500 microns.
Design temperature is 50C.
What is the end of life (30 year) current demand and how many cathodic protection stations are
required due to attenuation of current along the pipeline ?
a)

Pipeline design current demand is calculated using Table 3.2

Pipeline surface area dL m

= x (16 x 0.0254) x 80,000 m
= 102,140m
Current density at 30C = 0.05 mA/m
Current density at 50C = 0.05 x 1.25

(Table 3.2)

= 0.078mA/m
Therefore design current demand,
= 102,140 x 0.078
= 7967 mA
= 7.967 Amps
b)
SP-1128

Pipeline current attenuation (spread) is calculated from equation (1) above,

29

December 2005

Specification for Cathodic protection Design

Version 2.0

Ea EmCosh aL
Assuming a natural pipeline potential of minus 0.5V (wrt Cu/CuSO4 reference), then when the protection
potential criteria limits are minus 1.2V at the drain point and -0.95V at the furthest point.
Ea = 0.7V
Em = 0.45V
Calculate the value of g
g = surface area per metre length / resistance of 1m of coating
(in the absence of other information a value of 9,000 Ohm/m is a reasonable design value for fusion
bonded epoxy coating. See note 1 for basis and values for other coating materials).
g = .d.1 / 9000
= 1.28 / 9000
= 1.419 x 10-4 mho / m
Calculate the value of r
r = steel resistivity / cross sectional area of pipe
= 0.16 x 10-6 / ( x 16 x 0.0254 x 0.344 x 0.0254)
= 0.16 x 10-6 / 0.0112
= 1.429 x 10-5 Ohm / m
Calculate the value of a from:

a g.r
a = 4.503 x 10-5 m-1
From equation (1),

Ea
cosh aL
Em
1.556 = cosh aL
1.011= aL
= 22.45 km

One CP station would be insufficient to protect the whole of the pipeline.

The introduction of additional CP stations on the same pipeline require, in theory, modification of the
value of Em, since the required potential shift at the mid-point between CP stations will be influenced by
each station.

SP-1128

30

December 2005

Specification for Cathodic Protection Design

Version 2.0

In such instances, the minimum allowable potential shift (Em) at the mid-point shall be taken as 0.25 V,
this equating to a theoretical pipeline potential at that point of 1.00V, when under the influence of two CP
stations.
Notes
1.

Coating resistance figure based on 75% of the value obtained by back-calculations in the formula :

a
E m sinh aL,
r

and equation (1), based on current density figures given in Table 3.2.
Design values for other coatings are as follows:
Coating Type

Design Coating Resistance

(15 - 30 year life)
Ohm / m

Fusion bonded epoxy

Liquid epoxy
Coal Tar epoxy

9,000

Polyethylene
Polypropylene

30,000*

* Value based on 50% of calculated figure.

7.5
7.5.1

Groundbed Resistance Calculations

General

In order to accurately predict the power requirements of a CP power source it is necessary to know the
resistance of the output circuit. As the resistance to earth of the goundbed is a major part of the output
circuit resistance its calculation is of obvious importance.
7.5.2

Horizontal Groundbeds

For a PDO standard horizontal groundbed consisting of 1525 mm x 75mm Silicon-Iron-Chrome anodes
installed in a 300mm x 300mm trench of carbonaceous backfill at 1.2m depth in soil of 1000 Ohm.cm.
Groundbed resistance is calculated using the Dwight Formula:

4 L

4L
4L
log e
log e
2
r
S

S
S2

2 L 16 L2

Where,

2L
r
S

= total length of groundbed (cm)

= radius of groundbed section (cm)
= depth to centreline of groundbed (cm)
= soil resistivity (Ohm.cm)

Therefore, if L = 2500cm, r = 15cm, S = 240cm and = 1000 Ohm.cm

SP-1128

31

December 2005

Specification for Cathodic protection Design

Version 2.0

1000
4x2500
4x2500
240
2402
loge
loge
2

2
4 2500
15
240
2x2500 16x2500

R = 0.0318 (loge 666.67 + loge 41.67 2 + 0.048 0.0006)

R = 0.0318 (6.502 + 3.73 2 + 0.048 0.0006)
R = 0.624Ohm

7.5.3

Vertical/Borehole Groundbeds

For vertical anode and borehole groundbeds, the resistance to earth (R) is best calculated from the
following formula, which is based on the Modified Dwight Formula for a single vertical anode;

Rv

4L
1 (1)
log e
2L
r

Where,

L
r

= soil resistivity (Ohm.cm)

= length of groundbed (cm)
= radius of groundbed (cm)

The above calculation directly yields the theoretical resistance to earth of a single vertical anode or
borehole.
For multiple vertical anodes, minimum parallel spacing 1m, the resistance to earth (Rn) of n anodes is
given by.

Rn

Fn
n
Rv

Fn R v
( 2)
n

= paralleling factor
= number of anodes
= resisance of a single anode to earth from equation ---(1)

The paralleling factor, Fn, is calculated using:

Fn = 1

log e(0.66n)
SRv

Where, S = spacing between electrodes.

7.6

Sacrificial Anode Example Calculation

A crude oil storage tank has an average surface area in contact with the water phase of 5,000 m. The
internal surfaces are coated in accordance with ERD-48-01 and the water has a resistivity of 0.25 Ohm.m.

SP-1128

32

December 2005

Specification for Cathodic Protection Design

Version 2.0

The design basis is as follows :

Tank wetted area (average), A
Water resistivity,
Operating Temperature, T
Coating breakdown, Cb
Design current density, Id
Anode electrochemical efficiency, ET (@ 20c)
Anode Utilisation factor, U
Design life, L (hours)

:
:
:
:
:
:
:
:

5,000 m
25 Ohm.cm
45C
10%
110 x 10-3 A/m (seeTable 3.3)
2000 Ah/kg
0.9
87660 hours (10 years)

Step 1
Calculate total current requirement, Ir,

Ir = Id x A x Cb
= 110 x 10-3 x 5,000 x 0.1
= 55A
Calculate anode resistance, Ra,
For long slender stand off anodes a minimum of 300mm from the protected structure surface,
anode resistance is given by the Dwight Formula.

Ra

4L
1
log e
2L
r

Where,

L
R

= length of anode (cm)

= radius of anode (cm)

For non-cylindrical anodes,

C
2

Where,

= cross-section periphery of anode (m).

Therefore, utilising a commercially available anode size, weight 54.4kg, with dimensions.

SP-1128

L
W

= 61.0cm
= 17.8cm

= 17.8cm

= 11.3 cm

2 x (17.8 17.8)
2

33

December 2005

Specification for Cathodic protection Design

Version 2.0

Therefore,

25
4 x 61.0

1
log e
2 xx 61.0
11.3

Ra

Anode current output (per anode), La, using Ohms Law:

Ia

Ec Ea
Ra

Where,

Ec = design protective potential = -0.80V (vs Ag/AgCl)

Ea = design closed circuit potential of anode = -1.00V (vs Ag/AgCl)
Ra = Anode Resistance
Ia

0.80 {1.0}
0.135

= 1.481 Amps
Therefore, 37 No. anodes will satisfy the current requirement.
Step 2
Calculate anode weight requirement, W, where,

LxI r
ExU

From Section 5,

=ET - 27 (T-20)

=2000 - 27 (45 - 20)

= 1325 Ah/kg

Therefore,

87660 5
kg
1325 0.9

W = 4,043 kg
Therefore, 75 anodes (54.4 kg) would be required to satisfy both the weight and current
requirements.

SP-1128

34

December 2005

Specification for Cathodic Protection Design

Version 2.0

8 References
PDO Standards
SP-1246

Specification for Painting and Coating of Oil & Gas

Production Facilities.

SP-1129

Specification for Construction, Installation &

Commissioning of Cathodic Protection Systems.

SP-1102

Design of 33kV Overhead Lines

SP-1114A

Design of 132kV Overhead Lines

SP-1283

Standard Drawings
Sunshades

SP-1136

Specification for Cathodic Protection Standard

Drawings

SP-1099

Electrical Installation Practice.

SP-1130

Specification for Cathodic Protection Materials and

Equipment

PR-1234

Procedures for Safe Working on Cathodically

Protected Structures.

DEP-31.40.30.31

External Polyethylene and Polypropylene Coating

for Line Pipe

DEP-31.40.30.32

External Fusion-Bonded Epoxy Powder Coating for

Line Pipe

DEP 33.64.10.10-Gen

Electrical Engineering Guidelines

DEP 31.40.21.31

Pipeline Isolating Joints (Amendments to MSS

SP75)

DEP 31.10.73.10

Cathodic Protection

and

Requirements

for

International Standards
BS 7361 Part 1: 1991

Cathodic Protection Code of Practice for Land and

Marine Operations

BS 1377

Methods of Test For Soils for Civil Engineering

Purposes

MSS SP75

Specification for High Test Wrought Butt Welding

Fittings.

SP-1128

35

December 2005

Specification for Cathodic protection Design

Version 2.0

9 User Comment Form

User Comment Form
If you find something that is incorrect, ambiguous or could be better in this Procedure, write your comments
and suggestions on this form. Send the form to the Document Control Section (DCS). They make a record of
your comment and send the form to the correct CFDH. The form has spaces for your personal details. This lets
DCS or the CFDH ask you about your comments and tell you about the decision.
Issue Date:
Procedure Title:
Details
Number:
Page Number:

Heading Number:

Figure Number:

Comments:

Suggestions:

Users personal details

Name:

Ref
.

Signature:

Date:

Ind.
:
Phone:
Document Control Section Actions

SP-1128

36

December 2005

Specification for Cathodic Protection Design

Comment

Version 2.0

Date:

CFDH

Number:

Ref. Ind.:

Recd.:

To CFDH:

CFDH Actions
recd.
Date:

Inits.:

Decision:

Ref.

Reject:
Accept, revise at next issue:

Date:

Ind.

Accept, issue temporary amendment

Comments:

Originator
Advised:

Date:

Inits.:

Document

Date:

Inits.:

Control
Advised.

SP-1128

37

December 2005