FUNCTIONAL Spec. No.

FS 4001
Offshore Design Section Rev. No. 9
SPECIFICATION FOR
Engineering Services Discipline Electrical
ISO 9001:2008 CP System for Offshore
Structure Page: 1 OF 9

FUNCTIONAL SPECIFICATION

FOR

CP System for Offshore Structure

Prepared / Total No. of

Reviewed By Approved By Date Rev. No.
Revised By Pages

S. Kumar K. Rajamouly A. Sezhian 09 22.09.2017 9

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 FUNCTIONAL Spec. No. FS 4001
Offshore Design Section Rev. No. 9
SPECIFICATION FOR
Engineering Services Discipline Electrical
ISO 9001:2008 CP System for Offshore
Structure Page: 2 OF 9

1. SCOPE

This specification defines the minimum requirements for the material selection, design,
manufacture, supply and installation of a sacrificial type cathodic protection system with
monitoring facilities (wherever required) for offshore structures. The structures include all
offshore structures like platform jackets, clamp-on structures on existing platforms, flare or
bridge support tripods, SPM including PLEM and other appurtenances permanently attached to
any of the structure.

2. CODES & STANDARDS

2.1. Design and installation of the cathodic protection system shall be in accordance with
good marine engineering practice in corrosion protection and compliance with the latest
revisions of following Codes & Standards:

Det Norske Veritas: DNVGL RP B 401, 2017

National Association of Corrosion Engineers:

NACE STANDARD SP 0176-2007
NACE STANDARD SP 0387-2014

American Petroleum Institute: API RP 5L

American Society for Testing and Materials: ASTM A36

National Electrical Code: NEC

National Electrical Manufacturers Association: NEMA

3. SITE CONDITIONS:

As specified in the General Design Criteria enclosed in the bid package.

4. Deleted

5. TECHNICAL REQUIREMENTS

5.1. General

Cathodic protection system shall be made up of anodes with a configuration and anodic
material composition suitable for use in seawater. All raw materials finished products
and components of the CP system and monitoring assemblies specified herein shall be

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Offshore Design Section Rev. No. 9
SPECIFICATION FOR
Engineering Services Discipline Electrical
ISO 9001:2008 CP System for Offshore
Structure Page: 3 OF 9

new and unused, of current manufacture, of highest grade and free from all defects and
imperfections that could adversely affect the performance of the system.

5.2. Design:

5.2.1. The cathodic protection system for the Jacket structure shall be designed in
accordance with DNVGL RP B 401, 2017 and the requirements of this
Specification.

5.2.2. For C.P. System design following current density and driving potential shall be
considered irrespective of the values specified in Codes.
1. Current Density in sea water (initial) :150 mA/m2
2. Current Density in sea water (final) :100 mA /m2
3. Current Density in sea water (average) : 80 mA/m2
4. Current Density in sea mud : 20 mA/m2
5. Driving potentials (initial and near end life) : 250 mV

For calculation of Anode mass, electrochemical efficiency shall be taken

as 2000 AHr/Kg for sea water and 1500 AHr/Kg for sediments.

5.2.3. Design Life: same as the design of the platform specified elsewhere in the bid
package.

5.2.4. Cathodic protection method: sacrificial anodes

5.2.5. Coating breakdown factor shall be considered as per DNVGL RP B401 for
painted structures.

5.2.6. Anode Utilisation factor shall be considered as given in Table:

Anode Type Anode Utilisation Factor

Long slender stand-off L>=4r 0.90
Short slender stand-off L<4r 0.85

5.2.7. Surface Areas Definition for CP system design:

The system shall be adequately designed to protect all exposed steel surface of
the structure along with its various metallic components in the submerged zone
and in the splash zone area. The submerged zone and splash zone for CP system
design have been defined in Table 4 of structural design criteria Part-II
enclosed in the bid package.
In order to account for structural design variation during detailed engineering,
an allowance of 10% shall be added to jacket surface area including
appurtenance at the commencement of detailed engineering for cathodic

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 FUNCTIONAL Spec. No. FS 4001
Offshore Design Section Rev. No. 9
SPECIFICATION FOR
Engineering Services Discipline Electrical
ISO 9001:2008 CP System for Offshore
Structure Page: 4 OF 9

protection (anode calculation). The area shall be as per jacket drawing nearing
finalization & put up for the approval.
The zone wise anode distribution details shall be attached along with jacket
drawings at first instance.
The contractor shall, however, prepare a comprehensive list covering all
structural members/assemblies considered for cathodic protection along with
their individual surface area calculation and total surface area calculation and
submit it to Company, along with jacket drawings, for review and approval.

The following factors shall also be taken into consideration-

Piles from mud line up to a depth of 30 meters shall be considered.

Pile surface areas are to be calculated taking into account apparent
batter.
Internal surface area of the main pile is not required to be considered.

5.2.8. Current Drain

The current drain of structures that do not need protection but are still exposed
to sea water and electrically connected to the protected structure need to be
considered in the cathodic protection design.
For buried structures of mud mat, piles, etc., current drain shall be calculated as
per DNVGL RP B 401.

5.2.8.1 Current Load for Conductor casing

Wherever it exists, a current drain of 5A shall be included for each well to

account for protection of buried portion of well conductor casing/ false casing.
However, surface area of conductor and conductor guide in seawater shall be
included in total surface area of the structures to be protected by CP system.

5.2.9 Interference

Suitable arrangement to prevent interference in cathodic protection system from

structures protected through impressed current CP system shall be made by the
vendor.

5.2.10 Clamp-on structures:

Vendor shall calculate the exact surface area based on structural drawings and
furnish details of the same. The surface area of all the components as defined in
section 5.2.7 shall be considered for cathodic protection. External surface area
only shall be considered for conductors, conductor guide support framings,
clamps including stiffeners, stubs and anode clamps. Both external and internal
surface area shall be considered for conductor guides and conical plates. In

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Offshore Design Section Rev. No. 9
SPECIFICATION FOR
Engineering Services Discipline Electrical
ISO 9001:2008 CP System for Offshore
Structure Page: 5 OF 9

addition to the above, 10% contingency, especially for fasteners and other
fixtures of clamps, shall be included in total surface area to be protected.
5.2.11 The complete surface area of PLEM shall be considered for cathodic protection.
5.2.12 Submerged surface area and splash zone surface of SPM shall be considered for
cathodic protection.

5.3Anode Material

Anodes shall be GALVALUM-III or Equivalent (Al-Zn-In) alloy suitable for protection of

steel in submerged marine environment. They shall not have any mercury content. The
potential of the sacrificial alloy material shall be (-) 1.08V or more negative referred to a
silver/silver chloride reference electrode. The Electro-chemical efficiency of anode material
shall be minimum 2500 AH/Kg after four (4) days of operation as per DNVGL RP B 401.

6. TESTING AND INSPECTION

6.1 Anode Composition analysis:

Anode composition analysis shall be undertaken by methods agreed upon in advance. Two
samples from each melt shall be taken for chemical analysis. The samples shall be taken in
the beginning and at the end of casting from the pouring string. Checking of closed circuit
potential and practical mass consumption shall be done for each 15 ton produced anodes.
The test samples may be separately casted or cut directly from an anode. Ampere-hour
capacity test shall be carried out by weight loss method only.

6.2 After casting, the inspection of the anodes shall be done to ensure that:

6.2.1 AH capacity of anodes shall not be less than the figures considered for design i.e. no
negative tolerance shall be permitted.
6.2.2 Closed circuit potential shall be within (+) 10 mV and (-) 50mV of the guaranteed
value. For example, for design value of (-) 1.08 volts, anodes having closed circuit
potential less negative than (-) 1.07 Volts shall be rejected.
6.2.3 The anodes shall have minimum net weight (Gross weight minus core weight) within
a tolerance of + 2.0% to 1.0%. However, overall negative tolerance shall be 0% to
ensure that is no short fall in total alloy weight.
6.2.4 Dimensions shall be within tolerance limits indicated in the approved drawings. No
negative tolerance shall be allowed in standoff dimensions.
6.2.5 At least one anode per delivery or at least 0.5 percent of the anodes shall be subjected
to destructive testing to check that the casting is to an acceptable standard, each anode
shall be cut at 3 of the most relevant locations. The cut surface shall generally be free
from visible pores and slag/dross inclusions. The lack of bond or void between anode
core and anode material shall not exceed 5%.
As an alternate to a destructive testing, a non-destructive testing by radiography may
be used to check for lack of bond or slag/dross inclusions if so permitted by the
Company or its authorized representative.

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Offshore Design Section Rev. No. 9
SPECIFICATION FOR
Engineering Services Discipline Electrical
ISO 9001:2008 CP System for Offshore
Structure Page: 6 OF 9

6.2.6 Anode to steel insert shall be checked for electrical continuity. The resistance
between the connector and the body of the anode shall not exceed 0.005 ohm.
6.2.7 The anodes shall be free from mechanical defects like cracks, shrinkages, excessive
flash, surface projections, laminations, cold laps, surface slag etc. as consistent with
good casting practice. Criteria for accepting these shall be as per NACE STANDARD
SP 0387.
6.2.8 All the above Inspection / tests shall be witnessed by Company or its authorized
representative.
6.2.9 All anodes shall be delivered with material certificate from the Vendor stating batch
identification number and chemical analysis.

6.3 All work, materia to inspection by Company at all

reasonable times. However inspection by the Company shall not relieve the Vendor of
his responsibility under terms of contract.

6.4 The monitoring system shall be inspected after completion of fabrication and prior to
load out. These checks shall include:

Polarity checks on all monitored anodes.

Insulation and continuity test of all cables.
Calibration tests shall subsequently be carried out on all instrumentation and
reference electrodes.

7. ANODE DIMENSIONS AND PHYSICAL CHARACTERISTICS

Anode shall be standoff type. The steel core of the anode and stub pipes or brackets provided
for mounting the anode on the platform structure shall conform to ASTM-A36 (for structural
shapes) and API-5L Gr. B Seamless (for pipes) or equivalent.

7.1 The core shall be of nominal 4 inch schedule 80 seamless steel pipe or equivalent structural
shape. Anode material shall surround the core.
7.2 Stand off-legs shall be of nominal 4 inch schedule 80 size. Standoff separation between the
underside of the anode alloy and the cathode surface (member to be protected) should be in
the range of 250 to 450 mm. Distance between the two legs shall be less than the anode
length. The free ends of the legs shall be welded to the gusset plates superimposing the
member.

8. ANODE DISTRIBUTION:

8.1 Anode distribution on the structural members of new jacket structures shall be based on
advanced computer modeling techniques such as Boundary Element Method (BEM) to
ensure uniform current distribution. The contractor shall submit all relevant details of
the techniques used/ procedures adopted, datasheets, results, drawings etc., for

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Offshore Design Section Rev. No. 9
SPECIFICATION FOR
Engineering Services Discipline Electrical
ISO 9001:2008 CP System for Offshore
Structure Page: 7 OF 9

commencement of the installation of anodes over the structural members.

8.2 Anode locations shall ensure early polarization of structures to provide adequate
protection at node welds. Anode for SPM chains and piles shall be mounted on SPM
whereas those for PLEM piles shall be put on PLEM itself. Anode to be installed on
PLEM shall be suitable for saline mud as well.

8.3 Clamp-on structures:

Anode distribution for clamp-on structures shall be carried out taking into consideration
that current distribution is uniform without considering any contribution from the
existing CP System.

9 MONITORING SYSTEM

9.1 General
Monitoring system shall be required only for the cathodic protection of process
platform jackets and shall be designed to provide the following as minimum
requirements:
a) The measurement of the effectiveness of the cathodic protection system as
judged by potential measurements.
b) The performance of the sacrificial anodes as judged by measurements of current
output of monitored anodes.
c) Cathodic protection system for unmanned well platforms, clamp-on structures,
Flare tripod, SPM, PLEM shall be unmonitored.

9.2 Reference Electrodes

9.2.1 12 Nos. of reference electrodes shall be provided on the Jacket, out of which 4 will be
used for vertical plane potential measurement and 8 for horizontal plane potential
measurement. The electrodes shall be located in areas where the potential is expected
to be least negative. The vertical plane electrodes shall be installed at two different
planes with two electrodes in each plane and the horizontal plane electrodes shall be
installed in two different elevations with four electrodes in each elevation.

9.2.2 The electrodes shall be of high purity (99.99%) Zinc to ASTM B418 Type 2. Each
reference electrode shall be supplied with sufficient cable length to run between the
selected location and the junction box.

9.3 Monitored Anodes

9.3.1 The monitoring system shall also include four monitored anodes which shall be located
at two different elevations on the structure with two anodes at each elevation.

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Offshore Design Section Rev. No. 9
SPECIFICATION FOR
Engineering Services Discipline Electrical
ISO 9001:2008 CP System for Offshore
Structure Page: 8 OF 9

9.3.2 The monitored anodes shall be identical to those supplied for the structural protection
system and have the same physical characteristics but suitably modified so that current
outputs can be electrically measured at the monitoring panel. The anodic material of the
monitoring anodes shall be electrically insulated for those parts of the anode core to be
welded to the structure with an insulation resistance, of not less than one mega
ohm(when dry) and reducing to not less than one thousand ohms(when wet).
Prefabricated isolating joints with suitable mechanical properties shall be utilized.

9.4 Monitoring panel

The monitoring panel shall be located in the switchgear room or other suitable location
in safe area. The panel shall be of sheet steel (14 SWG) construction with an enclosure
protection equivalent of IP-51 or NEMA-12. The monitoring panel, as a minimum,
shall contain the following;

a) Selector Switches, manually operated, one for each reference electrode and monitoring
anode.
b) Voltmeter with capability to measure the potential difference between the structure and
each of the reference electrodes.
c) Ammeter with capability to measure the current output of each of the monitored
anodes.
d) Built in Meter calibration facility for checking the calibration and accuracy of the
instruments.
e) Mimic diagram showing the platform jackets to be cathodically protected shall be
included on the front of the panel. Positioning of all reference electrodes and monitored
anodes shall be marked distinctly on it. Different colors shall be used for marking
structures, monitored anodes and reference electrodes. The positions of reference
electrodes and monitoring anodes get illuminated when they are selected for voltage or
current readings respectively. LED displays may be used for this purpose.
f) Recording unit provisions
g) Painting in accordance to Spec no 2005

Power supply for the panel shall be provided by the contractor and the vendor shall
specify the total power required for the panel.

10 . CABLING

All cabling from each reference electrode and monitored anode shall be brought to a metallic
waterproof junction box, mastic filled and mounted on the jacket/walkway level in unclassified
area. The cables shall be double insulated, abrasion, ozone and weather resistant and suitable
for total immersion in sea-water. The cable shall be routed through a conduit and supported
from the jacket by welded bracket. The main raiser conduit shall be clamped at frequent
intervals for adequate supporting.

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Offshore Design Section Rev. No. 9
SPECIFICATION FOR
Engineering Services Discipline Electrical
ISO 9001:2008 CP System for Offshore
Structure Page: 9 OF 9

11 . SERVICE AFTER INSTALLATION

11.1 The vendor shall provide necessary test equipment, material and services of a corrosion
specialist and carryout performance tests at the site after jacket installation and verify
that required protection level has been achieved.
11.2 The contractor shall carry out CP survey to ascertain the effectiveness of the cathodic
protection system provided for the jacket structure. The survey shall be carried out after
60 days of the launching of jacket (and before 180 days maximum) to ensure that the
structures are sufficiently polarized. Survey can be conducted earlier also provided it is
established that structure is sufficiently polarized.
11.3 Post installation jacket Survey shall be carried out by either drop cell method or diver/ROV
assisted method. In case of insufficient polarization at any level, further survey shall be
carried out with diver/ROV assisted method to locate deficient area for corrective action.
During detailed engineering, the contractor shall develop and submit to ONGC for
approval the detailed procedure for carrying out CP survey.

12 VENDOR DATA REQUIREMENTS

Vendor shall furnish the following information related to the anodes:

12.1 Dimensional drawings of sacrificial anodes, monitored anodes and reference anodes and
supporting parts or accessories along with separate as well as assembled drawings for
their supporting parts and other accessories
12.2 Guaranteed minimum electrochemical value in ampere-hour per kg
12.3 Net, gross, and buoyant weight of anodes.
12.4 Minimum closed-circuit potential in volts.
12.5 Recommended means of anode support.
12.6 Anode alloying compositions (% age by weight and volume)
12.7 Testing method of anodes and details of the test procedure. The test shall establish the
guaranteed minimum electro-chemical value of the anode material and its potential w.r.t.
Ag/AgCl reference electrode under site conditions.
12.8 Analytical information regarding the location of reference electrode (which has to be
located in least negative potential area.).
12.9 Calculation of anode quantity and weight based on current and weight basis for the
designated design life
12.10 Cable type /specification along with routine and type test certificates.
12.11 Type test certificate for monitoring panel (IP-51)
12.12 Routine and type certificates for cable glands, junction boxes, pull boxes etc.
12.13 Vendor shall confirm and provide guarantee for the design life (minimum) for reference
anodes with necessary back up calculation and other relevant data.

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