ENI – IRAQ

ZUBAIR OIL FIELD DEVELOPMENT PROJECT

Temporary CP system calculation and sizing

methodology

EX-DE 00 19/11/16 Issue for Approval M.HIJAZI H.HAMMAMI C. IALENTI M.SHAKER R. Dellacecca
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ZUBAIR OIL FIELD
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00250600DECID0134
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ZUBAIR OIL FIELD - GENERAL ONSHORE n.a. 1 of 11
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Temporary CP system calculation and sizing methodology Superseded by N.

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REVISION HISTORY

Rev. Date Nr. of sheets Description

EXDE-00 19/11/2016 11 Issue for Approval

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INDEX

1 General.......................................................................................................................................... 4
1.1 Scope of work........................................................................................................................ 4
1.2 Acronyms and abbreviations.................................................................................................. 4
2 Reference documents................................................................................................................. 5
2.1 Project documents................................................................................................................. 5
2.2 Company Standards.............................................................................................................. 5
2.3 International rules, codes and standards...............................................................................5
3. Temporary CP system calculation and sizing..............................................................................5
3.1.TCP Selected philosophy......................................................................................................... 5
4. Secondary TCP system sizing............................................................................................... 8
4.2. Anode resistance versus soil and current available...............................................................9

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1 General

1.1 Scope of work

This document, in conjunction with its ANNEX, reports the calculations performed in order to design the Temporary Cathodic Protection
system for the water injection flowlines inside well head.

1.2 Acronyms and abbreviations

3LPE: 3-layer Extruded High Density Polyethylene

CP: Cathodic Protection
CPS: Cathodic Protection Station
DC: Direct Current
DGS: Degassing Station
FEED: Front End Engineering and Design
FL: Flowline
GB: GroundBed
IC: Impressed Current
IJ: Insulating Joint/Device
OTL: Oil Transfer Line
PJB: Positive Junction Box
RP: To be RePlaced
RWP: River Water Pipeline
TCP: Temporary Cathodic Protection
TGB: Temporary GroundBed
Ti/MMO: Activated Titanium / Mixed Metal Oxides
TP: Test Point
T/R: Transformer / Rectifier
UMCS: Upper Medial Complex Satellite
WIT: Water Injection Trunkline.

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2 Reference documents

2.1 Project documents

00250600DEDQD0136 Water injection flowlines CP test point installation drawings

250600DEDQD0196 CP Temporary Installation Drawings Water Injection flowlines

2.2 Company Standards

27589.VAR.COR.PRG Guidelines for design and construction of cathodic protection systems.

2.3 International rules, codes and standards

EN 12954 Cathodic protection of buried or immersed metallic structures – General principles and application for pipelines.
ISO 15589-1(2001) Petroleum and natural gas industries – Cathodic protection of pipeline transportation system – On land
pipelines.
NACE SP0169 Control of external corrosion on underground or submerged metallic piping systems.
NACE SP0177 Mitigation of alternating current and lightning effects on metallic structures and corrosion control systems.

3. Temporary CP system calculation and sizing

3.1.TCP Selected philosophy

Because of the great variability of soil resistivity, even inside the same DGS area, an impressed current CP system has been chosen as
primary solution in order to guarantee the correct temporary cathodic Protection to the pipelines, while sacrificial anodes CP system
choice remains as a secondary solution only for short, remote or isolated trunks of pipeline, with length inferior to 200 m (for example,
remote tie-in, isolated road crossings etc.), where impressed current system becomes unpractical (See Ref. Doc. N.
002506TQSDSENIL012).
In our case inside well heads 75m distance from the filter requires the use of magnesium sacrificial anode buried at both sides of pipe.

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3.1 General aspects

All the pipelines are made of API 5L X60 carbon steel and are coated by means of three layer of extruded high density polyethylene
(3LPE).

As per FEED resistivity measurement reports shows that Zubair area has been divided into four ranges of values:

Low resistivity areas: 1 - 10 Ω∙m

Medium resistivity areas: 10 - 100 Ω∙m
High resistivity areas: 100 - 1,000 Ω∙m
Very high resistivity areas: > 1,000 Ω∙m

Nevertheless, design life for temporary CP system will be 3 years.

CPS Soil resistivity

T/R Location
Nos. range
7 South Complex Satellite Medium
8 Lower Medial Complex Satellite Medium
9 Upper Medial Complex Satellite Low
10 North Complex Satellite low

3.2. CBF and Protection current density

According to ISO 15589-1, paragraph 5.8, table 2, the CBF for the oil transfer will be 0,001 (value assumed for 10 years of service life).
The protection current densities for bare steel surface (from ISO 15589-1, paragraph 5.8, Table 1) are:

Low resistivity areas: 20 mA/m2

Medium resistivity areas: 10 mA/m2
High resistivity areas: 5 mA/m2

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Very high resistivity areas: 1 mA/m2.

For three-layer epoxy-polypropylene coated steel surface at 30°C (from ISO 15589-1, paragraph 5.8, Table 2) are:

Low resistivity areas: 0.020 mA/m2

Medium resistivity areas: 0.010 mA/m2
High resistivity areas: 0.005 mA/m2
Very high resistivity areas: 0.001 mA/m2.

Because the maximum operating temperature is 77°C, the values reported above change into these final protection current density
values for TCP:

Low resistivity areas: 0.044 mA/m2

Medium resistivity areas: 0.022 mA/m2
High resistivity areas: 0.011 mA/m2
Very high resistivity areas: 0.002 mA/m2.

3.3. Current requirement calculation

For each CPS, total required current is determined as follows:

(1)

Where:
Ir = total required current (A);
i = protective current density (mA/m 2);
Dj = external diameter of pipeline (or FOC corrugated steel tape reinforcement) “j” (m);

Lj = length of pipeline “j” (m).

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For 10’’ water injection of length 75m:

Ir=0.044*3.14*0.273*75=0.003A (current density for low resistive area has been taken into consideration 0.044 mA/m2 )

4. Secondary TCP system sizing

4.2. Anode quantity

(2)

Where:
W = required anodic mass (kg);
Y = design life (year);
U = utilization factor (%);
C = consumption rate (kg/Ayear);
I = DC feeder actual current output (A).

the weight of anodic material to be installed for the temporary CP system is:
kg

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Number of anodes due to weight is:

so one anode due weight is required

4.1. Anode resistance versus soil and current available

Calculation has been carried out considering each pipeline nominal diameter and a single pipeline span of 75 m.

As for primary TCP, resistivity values taken into account are the following:

low resistivity case: 10 m

Using Equation:

(3)

Where:
Da = Anode diameter, including pre-packaged backfill (m).
La = Anode length, including pre-packaged backfill (m).
H = Anode laying depth, bottom of trench (m).

resistance vs. soil of a single magnesium anode, horizontally buried into the soil at pipeline laying depth (1.5 m), is calculated:

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= 2.7 

The current available from each anode is calculated by means of Equation

(4)

Where:
Ia = Current from anode (V).
k = Correction factor accounting for other resistances in the circuit i.e. cables resistance, pipeline to earth resistance, soil resistance,
usually 0.85.
V = Driving voltage (V).
Pa = Closed circuit potential of anode (V).
P = Protective potential (V).

= 0.205 A

Hence,

hence one magnesium anode is required

Where N is the total number of anodes to be installed

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Summary:

Pipeline nominal diameter [inch] 10

Note: (*) eacch sacrificial anodes cathodic
protection system minimum
Current demand for 75 m of pipeline [A] 0.015 installation consists of nos. 2
magnesium anodes, each buried at one
Anodes number due to weight requirements 1 side of the pipeline.

Anodes number due to current requirement (current

1
demand / Ia)

Number of anodes chosen for a single battery 1

Current available for the whole anodes installation [A]
0.410
(2Ia  I)

Total anodes number required for 75 m of pipeline (*) 2

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