The document provides calculations for the cathodic protection system design of Terminal A sheet piling. It includes calculations to determine the surface area of the sheet piling, current demand at initial, mean and final life, mass of anode required, selection of stand-off anode type, and number of anodes needed. The key results are that the initial current demand is 467 A, requiring 34,095 kg of anode material. 233 anodes would be needed for the existing sheet piling.
The document provides calculations for the cathodic protection system design of Terminal A sheet piling. It includes calculations to determine the surface area of the sheet piling, current demand at initial, mean and final life, mass of anode required, selection of stand-off anode type, and number of anodes needed. The key results are that the initial current demand is 467 A, requiring 34,095 kg of anode material. 233 anodes would be needed for the existing sheet piling.
The document provides calculations for the cathodic protection system design of Terminal A sheet piling. It includes calculations to determine the surface area of the sheet piling, current demand at initial, mean and final life, mass of anode required, selection of stand-off anode type, and number of anodes needed. The key results are that the initial current demand is 467 A, requiring 34,095 kg of anode material. 233 anodes would be needed for the existing sheet piling.
The document provides calculations for the cathodic protection system design of Terminal A sheet piling. It includes calculations to determine the surface area of the sheet piling, current demand at initial, mean and final life, mass of anode required, selection of stand-off anode type, and number of anodes needed. The key results are that the initial current demand is 467 A, requiring 34,095 kg of anode material. 233 anodes would be needed for the existing sheet piling.
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Design Calculation
Of
TERMINAL A
CODE
CALCULATIONS
RESUL
TERMINAL A SURFACE AREA OF STRUCTURE Total Length of the terminal A = 475m Width of a sheet piling = 1.4m Actual width of a unfolded sheet piling = 1.6m Correction factor for metre length of a sheet piling: = 1.6 1.4 = 1.14
DNVRP-
a. Surface area of newly installed sheet piling, A1, 2.5m depth
DESIGN PARAMETERS The following parameters have been considered in the design of Cathodic Protection System for Tin can Port Terminal A and adequate values or categories have also been selected for these parameters to ensure that a protective CP potentials would be maintained for the sheet piling spanning the terminal. DNVRP-
BS 7361DNVRP-
DNVRP-
a.
Current density for area below high tide level (initial) = 150 mA/m 2
b.
Current density for area below high tide level (mean) = 70 mA/m 2
c.
Current density for area below high tide level (final) = 100 mA/m2
d.
Driving potential (initial life) = 250 mV
e.
Driving potential (mid life) = 150 mV
f.
Design life = 15years
g.
Cathodic protection method: Sacrificial anodes
h.
Coating conditions: Category I
i.
Anode Material: GALVALUM-III
j.
Anode Utilization factor = 0.9
k.
Electrochemical capacity of Anode material (seawater) = 2000 AH/Kg (min.)
l.
CODES
Seawater resistivity = 0.25 ohm-m
CALCULATIONS
COATING BREAKDOWN FACTOR, FC
DNVRP-
Fci = Coating Breakdown factor at initial life of anode
RESUL
Fci = Coating Breakdown factor at mean life of anode
Fci = Coating Breakdown factor at final life of anode Components 1 A1, newly installed sheet piling 2 A2, existing sheet piling
CODES
DNVRP-
Status
Fci
Fcf
Remarks
0.1
Fc m 0.6
Mild
1.0
Category; a= 0.1, b= 0.1
Severe
1.0
1.0
1.0
CALCULATIONS
RESUL
CURRENT DEMAND (INITIAL)
The following calculations would consider appropriate current density stated above with other parameters for the initial current demand of the structure for initial polarisation to a protective volt.
Current Demand, Ic = Ac ic fc Where Ac = Surface Area of indicated components. ici = Initial Current Density fci = Coating Breakdown factor (initial) 1. Newly installed sheet piling, A1, 2.5m depth Current Demand = 1,353.75 * 150 * 0.1 1000 = 20.31A 20.31A 2. Existing sheet piling, A2, 5.5m depth Current Demand =
2,978.25 * 150 * 1.0
1000 = 446.74A
446.74A
CODES
DNVRP-
CALCULATIONS
RESUL
MASS OF ANODE REQUIRED (INITIAL)
The mass of anode required to maintain cathodic protection through out the design life of 15 years for individual component at initial current demand: Ma = Ici tf 8760
u where Ma = Mass of anode required. Ici = Current demand (initial) tf = Design life u = Electrochemical capacity of the anode = Anode utilization factor Assumptions 1. 15 years of design life with adequate cathodic protection is considered 2. Anode utilization factor of 0.9 is applied. 1. Newly installed sheet piling, A1, 2.5m depth Mass of anode required, Ma = 20.31 * 15 * 8760 0.9 * 2000 = 1,482.63kg 1,482.63kg 2. Existing sheet piling, A2, 5.5m depth Mass of anode required, Ma = 446.74 * 15 * 8760 0.9 * 2000 = 32,612.02kg 32,612.02kg s/ n
Components
Newly Installed sheet
piling Existing sheet piling
Total CODES
Initial Current Demand, A 20.31
Mass of Anode, kg
446.74
32,612.0 2 34,094. 65
467.05
CALCULATIONS
1,482.63
RESUL
CURRENT DEMAND (MEAN)
The following calculations would consider appropriate current density stated above with other parameters for the mean current demand of the structure. Current Demand, Ic = Ac ic fc Where Ac = Surface Area of indicated members. icm = Mean Current Density
The mass of anode required to maintain cathodic protection through out the design life of 15 years for individual component at mean current demand: Ma = Icm tf 8760 u where Ma = Mass of anode required. Icm = Current demand (mean)
tf = Design life u = Electrochemical capacity of the anode = Anode utilization factor Assumptions 3. 15 years of design life with adequate cathodic protection is considered 4. Anode utilization factor of 0.9 is applied. 1. Newly installed sheet piling, A1, 2.5m depth Mass of anode required, Ma = 56.86 * 15 * 8760 0.9 * 2000 = 4,150.78kg 4,150.78kg 2. Existing sheet piling, A2, 5.5m depth Mass of anode required, Ma =
208.48 * 15 * 8760 0.9 * 2000 = 15,219.04kg
15,219.04kg s/ n
Components
Newly Installed sheet
piling Existing sheet piling
Total CODES
Mean Current Demand, A 56.86
Mass of Anode, kg
208.48
15,219.0 4 19,369. 82
265.34
4,150.78
CALCULATIONS
RESUL
CURRENT DEMAND (FINAL)
The following calculations would consider appropriate current density stated above with other parameters for the final current demand of the structure. Current Demand, Ic = Ac ic fc Where Ac = Surface Area of indicated components. icf = final Current Density fcf = Coating Breakdown factor (final)
The mass of anode required to maintain cathodic protection through out the design life of 15 years for individual component at final current demand: Ma = Icm tf 8760 u where Ma = Mass of anode required. Icf = Current demand (final) tf = Design life u = Electrochemical capacity of the anode = Anode utilization factor
Assumptions 5. 15 years of design life with adequate cathodic protection is considered 6. Anode utilization factor of 0.9 is applied. 1. Newly installed sheet piling, A1, 2.5m depth Mass of anode required, Ma =
135.38 * 15 * 8760 0.9 * 2000 = 9,882.74kg
9,882.74kg 2. Existing sheet piling, A2, 5.5m depth Mass of anode required, Ma =
297.83 * 15 * 8760 0.9 * 2000 = 21,741.59kg
21,741.59kg s/ n
Components
Newly Installed sheet
piling Existing sheet piling
Total CODES
Final Current Demand, A 135.38
Mass of Anode, kg
297.83
21,741.5 9 31,624. 33
433.21
9,882.74
CALCULATIONS
RESUL
ELECTION OF ANODE TYPE
DNVRP-
The selection of anode type for Terminal A Sheet piling was
determined by the size, spatial uniformity in the geometrical configuration of the sheet piling and forces that would exert on the fabricated anodes during installation and operation Based on above criteria and several, The Stand-off Anode was selected with following specifications: Type
750NP
Net Wt, Kg
75
Width, mm
184
Height, mm
184
Length, mm
827
Overall Length, mm
1,469
Core Specificati on Flat bar
50 * 12mm
Maximum Current available
1.917
Complete anode schematic is shown in the attached drawings.
DNVRP-
CALCULATION OF ANODE RESISTANCE IN SEAWATER
To find the resistance of 750NP Manufacturer specification: Seawater resistivity = 0.25 ohm.m Driving potential = 250mV Current = 1.917A Ra = 2**L
CODES
4L In r
-1
CALCULATIONS
RESUL
where = seawater resistivity
L = Length of Anode material r = radius of Anode cross-section The cross-section of the selected anode is a rectangular, Thus, radius =
radius =
2(w + h) 2* 736 6.284
radius = 117.12mm
Rai
0.25 4 0.827 2 3.142 0.827
In
-1 0.117
= 0.048 2.34 = 0.112 ohm
Rai = 0.112 ohm
CALCULATION OF ANODE CURRENT OUTPUT DNVRP-
I a = E c - Ea Ra But Manufacturers specification states the following conditions Seawater resistivity = 0.25 ohm.m Driving voltage = 250mV Max available Current = 1.917 (Initial Life Current)
Iai = 1.917 A
Therefore Ra = 0.250 / 1.917
= 0.130 ohm The difference in resistance = 0.130 0.112 = 0.018 ohm can be attributed to resistive component of the anode insert. CODES
DNVRP-
CALCULATIONS
FINAL ANODE CURRENT OUTPUT
Mass of remaining Aluminium anodic material at the Final life is 10% of the total mass i.e. 90% anode efficiency. Mass (end-life) = Mass (initial life) (1 U) Mass (end life) = 75 kg * (1 0.9) Mass (end life) = 75 * 0.1 Mass (end life) = 7.5 kg Volume of remaining net mass of anode, V (end life)
RESUL
= Mass of Aluminium Density of Aluminium Volume (end life) = 7.5 kg 2678 kg / m3 = 0.0028 m3 Widt h mm 184
Initi al Life Final 0.00 Life 2
DNV-RPB401
Heigh t mm 184
Length Net mm Wgt kg 827 75
Volume m3
0.002
744.3
0.0028
7.5
0.0280
Assume the cross-section of the selected anode still remains rectangular
Thus, radius =
2(w + h) 2*
radius =
0.008 6.284
radius = 0.0012mm
CODES
CALCULATIONS
RESUL
Therefore, resistance of anode at end-life:
Rf
0.25 4 0.7443 2 3.142 0.7443
In
-1 0.0012
= 0.053 6.816 = 0.36 ohm Raf = 0.360 ohm I a = E c - Ea Ra
The current outputs as per the anode mass provided for respective members are being considered if it satisfies the acceptance criteria as stated below: Thus: i. Ca tot = N * Ca Icm * tf * 8760 ii. Iatot i = N * Iai Ici
iii. Iatot f = N * Iaf Icf
i. Ca tot = N * Ca Icm * tf * 8760 Ca = individual anode current capacity Ca = m a X X u ma = net mass per anode, kg = anode electrochemical capacity, AH / kg u = anode utilisation factor Ca = 75 kg X 2000 AH/kg X 0.9 Ca = 135,000 AH per anode Therefore; Ca tot = 135,000 AH per anode x 635 Icm * tf * 8760 = 85,725,000 AH 265.34 * 15 * 8760 = 85,725,000 AH 34,865,676 AH Accepted ii. Iatot i = N * Iai Ici Iatot i = 635 * 1.917 467.05 = 1,217.29 A 467.05 A Accepted
CODES
CALCULATIONS
RESUL
iii. Iatot f = N * Iaf Icf
Iatot f = N * Iaf Icf = 635 * 0.690 433.21 A = 438.15 A 433.21 A Accepted
The number of anodes on the members of Terminal A is
s/ n 1 2
Components
No of Anode, kg
Newly Installed sheet
piling
200
Existing sheet piling
435
TOTAL
635
Design Calculation Of
TERMINAL B
CODE
CALCULATIONS
RESUL
TERMINAL B SURFACE AREA OF STRUCTURE Total Length of the terminal B = 750m Width of a sheet piling = 1.4m Actual width of a unfolded sheet piling = 1.6m Correction factor for metre length of a sheet piling: = 1.6 1.4 = 1.14
DNV-
a. Surface area of newly installed sheet piling, B1, 2.5m depth
= 750 * 2.5* 1.14
= 2,137.50 m2 2,137.50 m2 b. Surface area of existing sheet piling, B2, 5.5m depth = 750 * 5.5 * 1.14 = 4,702.50 m2 4,702.50 m2
CODE
CALCULATIONS
RESUL
DESIGN PARAMETERS The following parameters have been considered in the design of Cathodic Protection System for Tin can Port Terminal B and adequate values or categories have also been selected for these parameters to ensure that a protective CP potentials would be maintained for the sheet piling spanning the terminal. DNVRP-
DNVRP-
a.
Current density for area below high tide level (initial) = 150 mA/m 2
b.
Current density for area below high tide level (mean) = 70 mA/m 2
c.
Current density for area below high tide level (final) = 100 mA/m2
d.
Driving potential (initial life & final life) = 250 mV
e.
Driving potential (mid life) = 150 mV
f.
Design life = 15years
DNVRP-
g.
Cathodic protection method: Sacrificial anodes
h.
Coating conditions: Category I
i.
Anode Material: GALVALUM-III
j.
Anode Utilization factor = 0.9
k.
Electrochemical capacity of Anode material (seawater) = 2000 AH/Kg (min.)
l.
CODES
Seawater resistivity = 0.25 ohm-m
CALCULATIONS
RESUL
COATING BREAKDOWN FACTOR, FC
DNVRP-
Fci = Coating Breakdown factor at initial life of anode
Fci = Coating Breakdown factor at mean life of anode Fci = Coating Breakdown factor at final life of anode Components 1 A1, newly installed sheet piling 2 A2, existing sheet piling
Status
Fci
Fcf
Remarks
0.1
Fc m 0.6
Mild
1.0
Category; a= 0.1, b= 0.1
Severe
1.0
1.0
1.0
CODES
DNVRP-
CALCULATIONS
RESUL
CURRENT DEMAND (INITIAL)
The following calculations would consider appropriate current density stated above with other parameters for the initial current demand of the structure for initial polarisation to a protective volt. Current Demand, Ic = Ac ic fc Where Ac = Surface Area of indicated components. ici = Initial Current Density fci = Coating Breakdown factor (initial) 1. Newly installed sheet piling, B1, 2.5m depth Current Demand = 2,137.50 * 150 * 0.1 1000 = 32.06A 32.06A 2. Existing sheet piling, B2, 5.5m depth Current Demand =
4,702.50 * 150 * 1.0
1000 = 705.38A 705.38A
CODES
DNVRP-
CALCULATIONS
RESUL
MASS OF ANODE REQUIRED (INITIAL)
The mass of anode required to maintain cathodic protection through out the design life of 15 years for individual component at initial current demand: Ma = Ici tf 8760 u where Ma = Mass of anode required. Ici = Current demand (initial) tf = Design life u = Electrochemical capacity of the anode = Anode utilization factor Assumptions 7. 15 years of design life with adequate cathodic protection is considered 8. Anode utilization factor of 0.9 is applied. 1. Newly installed sheet piling, B1, 2.5m depth Mass of anode required, Ma = 32.06 * 15 * 8760 0.9 * 2000
= 2,340.38kg 2,340.28kg 2. Existing sheet piling, B2, 5.5m depth Mass of anode required, Ma = 705.38 * 15 * 8760 0.9 * 2000 = 51,492.74kg 51,492.74kg s/ n
Components
Newly Installed sheet
piling Existing sheet piling
Initial Current Demand, A 32.06
Mass of Anode, kg
705.38
51,492.7 4 53,833. 02
Total CODES
737.44
CALCULATIONS
2,340.28
RESUL
CURRENT DEMAND (MEAN)
The following calculations would consider appropriate current density stated above with other parameters for the mean current demand of the structure. Current Demand, Ic = Ac ic fc Where Ac = Surface Area of indicated components. icm = Mean Current Density fcm = Coating Breakdown factor (mean) 1. Newly installed sheet piling, B1, 2.5m depth Current Demand = 2,137.50 * 70 * 0.6 1000 = 89.78A 89.78A 2. Existing sheet piling, B2, 5.5m depth Current Demand =
4,702.50 * 70 * 1.0 1000 = 329.18A
329.18A
CODES
CALCULATIONS
RESUL
MASS OF ANODE REQUIRED (MEAN)
The mass of anode required to maintain cathodic protection through out the design life of 15 years for individual component at mean current demand: Ma = Icm tf 8760 u where Ma = Mass of anode required. Icm = Current demand (mean) tf = Design life u = Electrochemical capacity of the anode = Anode utilization factor Assumptions 9. 15 years of design life with adequate cathodic protection is considered 10. Anode utilization factor of 0.9 is applied. 1. Newly installed sheet piling, B1, 2.5m depth Mass of anode required, Ma = 89.78 * 15 * 8760 0.9 * 2000 = 6,553.94 kg 6,553.94kg
2. Existing sheet piling, B2, 5.5m depth
Mass of anode required, Ma =
329.18 * 15 * 8760 0.9 * 2000 = 24,030.14kg
24,030.14kg s/ n
Components
Newly Installed sheet
piling Existing sheet piling
Mean Current Demand, A 89.78
Mass of Anode, kg
329.18
24,030.1 4 30,564. 08
Total CODES
418.96
6,553.94
CALCULATIONS
RESUL
CURRENT DEMAND (FINAL)
The following calculations would consider appropriate current density stated above with other parameters for the final current demand of the structure. Current Demand, Ic = Ac ic fc Where Ac = Surface Area of indicated components. icf = final Current Density fcf = Coating Breakdown factor (final) 1. Newly installed sheet piling, B1, 2.5m depth Current Demand = 2,137.50 * 100 * 1.0 1000 = 213.75A 213.75A 2. Existing sheet piling, B2, 5.5m depth Current Demand =
4,702.50 * 100 * 1.0
1000 = 470.25A
470.25A
CODES
DNVRP-
CALCULATIONS
RESUL
MASS OF ANODE REQUIRED (FINAL)
The mass of anode required to maintain cathodic protection through out the design life of 15 years for individual component at final current demand: Ma = Icm tf 8760 u where Ma = Mass of anode required. Icf = Current demand (final) tf = Design life u = Electrochemical capacity of the anode = Anode utilization factor Assumptions 11.
15 years of design life with adequate cathodic protection
is considered 12. Anode utilization factor of 0.9 is applied. 1. Newly installed sheet piling, B1, 2.5m depth Mass of anode required, Ma =
213.75 * 15 * 8760 0.9 * 2000 = 15,603.75kg
15,603.75kg 2. Existing sheet piling, B2, 5.5m depth Mass of anode required, Ma =
470.25 * 15 * 8760
0.9 * 2000 = 34,328.25kg 34,328.25kg s/ n
Components
Newly Installed sheet
piling Existing sheet piling
Total CODES
Final Current Demand, A 213.75 470.25 684.00
Mass of Anode, kg 15,603.7 5 34,328.2 5 49,932. 00
CALCULATIONS
RESUL
ELECTION OF ANODE TYPE
DNVRP-
The selection of anode type for Terminal B Sheet piling was
determined by the size, spatial uniformity in the geometrical configuration of the sheet piling and forces that would exert on the fabricated anodes during installation and operation Based on above criteria and several, The Stand-off Anode was selected with following specifications: Type
750NP
Net Wt, Kg
75
Width, mm
184
Height, mm
184
Length, mm
827
Overall Length, mm
1,469
Core Specificati on Flat bar Maximum Current available
50 * 12mm
1.917
Complete anode schematic is shown in the attached drawings.
DNV-
CALCULATION OF ANODE RESISTANCE IN SEAWATER
To find the resistance of 750NP Manufacturer specification: Seawater resistivity = 0.25 ohm.m Driving potential = 250mV Current = 1.917A Ra = 2**L
CODES
4L In r
-1
CALCULATIONS
RESUL
where = seawater resistivity
L = Length of Anode material r = radius of Anode cross-section The cross-section of the selected anode is a rectangular, Thus, radius =
2(w + h) 2*
radius =
736 6.284
radius = 117.12mm
Rai
0.25 4 0.827 2 3.142 0.827
In
-1 0.117
= 0.048 2.34 = 0.112 ohm
Rai = 0.112 ohm
CALCULATION OF ANODE CURRENT OUTPUT DNVRP-
I a = E c - Ea
Ra But Manufacturers specification states the following conditions Seawater resistivity = 0.25 ohm.m Driving voltage = 250mV Max available Current = 1.917 (Initial Life Current)
Iai = 1.917
A Therefore Ra = 0.250 / 1.917 = 0.130 ohm The difference in resistance = 0.130 0.112 = 0.018 ohm can be attributed to resistive component of the anode insert. CODES
DNVRP-
CALCULATIONS
RESUL
FINAL ANODE CURRENT OUTPUT
Mass of remaining Aluminium anodic material at the Final life is 10% of the total mass i.e. 90% anode efficiency. Mass (end-life) = Mass (initial life) (1 U) Mass (end life) = 75 kg * (1 0.9) Mass (end life) = 75 * 0.1 Mass (end life) = 7.5 kg Volume of remaining net mass of anode, V (end life) = Mass of Aluminium Density of Aluminium Volume (end life) = 7.5 kg 2678 kg / m3 = 0.0028 m3
DNV-RPB401
Widt h mm 184
Initi al Life Final 0.00 Life 2
Heigh t mm 184
Length Net mm Wgt kg 827 75
Volume m3
0.002
744.3
0.0028
7.5
0.0280
Assume the cross-section of the selected anode still remains rectangular
Thus, radius =
2(w + h) 2*
radius =
0.008 6.284
radius = 0.0012mm
CODES
CALCULATIONS
RESUL
Therefore, resistance of anode at end-life:
Rf
0.25 4 0.7443 2 3.142 0.7443
In
-1 0.0012
= 0.053 6.816 = 0.36 ohm Raf = 0.360 ohm I a = E c - Ea Ra
The current outputs as per the anode mass provided for respective members are being considered if it satisfies the acceptance criteria as stated below: Thus: i. Ca tot = N * Ca Icm * tf * 8760 ii. Iatot i = N * Iai Ici iii. Iatot f = N * Iaf Icf i. Ca tot = N * Ca Icm * tf * 8760 Ca = individual anode current capacity Ca = m a X X u ma = net mass per anode, kg = anode electrochemical capacity, AH / kg u = anode utilisation factor Ca = 75 kg X 2000 AH/kg X 0.9 Ca = 135,000 AH per anode Therefore; Ca tot = 135,000 AH per anode x 1010 Icm * tf * 8760 = 136,350,000 AH 418.96 * 15 * 8760
= 136,350,000 AH 55,051,344 AH Accepted ii. Iatot i = N * Iai Ici Iatot i = 1010 * 1.917 737.44 = 1,936.17 A 737.44 A Accepted
CODES
CALCULATIONS
RESUL
iii. Iatot f = N * Iaf Icf
Iatot f = N * Iaf Icf = 1010 * 0.690 684.00 A = 696.90 A 684.00 A Accepted
The number of anodes on the members of Terminal B is
