Document Review - CP System - Hamriyah Pipeline, Rev. C

CN/14/523-SUPPLY &
INSTALLATION OF GAS & AIR

LINES - HAMRIYAH
PROJECT
COMPANY
Document Title QCP : BSST-TECH-
CP CONTRACTOR
CPJ14449-001~DES
Specialized in Corrosion Control &
Cathodic Protection Detailed Design Package For Rev :C
Cathodic Protection System For
Date 07.03.2015
Lamprell Hamriyah Facility
Page : 3 of 13
PROJECT : CN/14/523 - SUPPLY & INSTALLATION OF GAS &

AIR LINES - HAMRIYAH
COMPANY : LAMPRELL ENERGY LTD.
BSST PROJECT No : BSST-CPJ14449
LAMPRELL PROJECT No : CN/14/523

CN/14/523-SUPPLY &
LINES - HAMRIYAH
PROJECT
COMPANY
CP CONTRACTOR
CPJ14449-001~DES
Date 07.03.2015
Page : 4 of 13
Index
1. Scope
2. Purpose
3. Applicable Documents
4. Abbreviations
5. Design Criteria
6. Design
7. System Configuration
8. Appendices
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CPJ14449-001~DES
Date 07.03.2015
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1.0 SCOPE
Bin Sari Specialized Technologies has been awarded the contract by M/S LAMPRELL
ENERGY LTD. to carry out Impressed current Cathodic Protection works, which include,
Cathodic Protection Field Survey, Design, Engineering, Material supply, Installation Supervision
and Commissioning for “CN/14/523 - Supply & installation of Gas & Air lines - Hamriyah”
project. This report is prepared with the objective of providing a design for Permanent and
Temporary Cathodic Protection System for the underground pipelines listed in Table-1.
2.0 PURPOSE
This Document discusses – Permanent and Temporary Cathodic Protection System for
underground pipelines.
This design report covers Permanent Cathodic Protection system for the Pipelines by using
Impressed Current Cathodic Protection System and Temporary Cathodic Protection system for
the Pipelines by using Sacrificial Cathodic Protection System. The system is to be based on
selected anodes, power supplies at selected location, which shall be designed to protect
external surface of under ground portion of the entire Pipeline listed below.
PIPE DIA LENGTH SURFACE

LINE DESCRIPTION
SL NO (M) (M) AREA (M²)
0.0762 4800 1149.069
1 Oxygen carrying line(O2) 0.0508 230 36.70637
0.0254 120 9.575574
0.0762 4180 1000.648
Carbon Di Oxide carrying
2 0.0508 230 36.70637
line(CO2)
0.0254 100 7.979645
0.0762 4900 1173.008
3 Cutting Edge 0.0508 230 36.70637
0.0254 100 7.979645
0.2032 4800 3064.184
0.1524 600 287.2672
4 Air Utility Line 0.1016 40 12.76743
0.0508 90 14.36336
0.0254 120 9.575574
0.0508 230 36.70637
5 AR/AR + CO2
0.0254 120 9.575574
Table#1
This report provides the design for Permanent and Temporary Cathodic Protection of the
Pipeline based on the actual survey, measured parameters on site, guidelines from tender
documents, specification, references stated and the actual construction practices. This report
CN/14/523-SUPPLY &
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CPJ14449-001~DES
Date 07.03.2015
Page : 6 of 13
also includes pipeline crossings, permanent monitoring facilities and any other Cathodic
Protection requirements for the 30 years of operation.
3.0 APPLICABLE DOCUMENTS
Doc. No. Description

NACE SP-0169 Control of external corrosion on under ground or submerged metallic
piping system
NACE SP-0177 Mitigation of alternating current and lightning effects on metallic
structures and corrosion control systems
NACE SP-0286 The electric isolation of cathodically protected pipelines
NACE SP-0572 Design, installation, operation and maintenance of Impressed current
deep ground beds
BS 7361: Part 1, Cathodic protection part 1 land and marine application
1991
DEP 30.10.73.10 Technical specification – Design for CP system for Onshore buried
GEN pipelines
4.0 ABBREVIATIONS
CP : Cathodic Protection
ICCP : Impressed current Cathodic protection system
SACP : Sacrificial Cathodic protection system
mA : Milli amperes
KM : Kilometer
AC : Alternate Current
AJB : Anode junction box
NDB: Negative distribution box
TR: Transformer Rectifier
mV: Milli-volt
UV : Ultraviolet
NACE: National association of corrosion engineers
5.0 DESIGN CRITERIA
The Cathodic Protection System is designed to provide the protection criteria as detailed in the
above references. Most commonly accepted criteria out of these can be summarized as “a
structure can be said as Cathodically protected, if a negative (Cathodic) voltage of at least 850
mV has measured between the structure surface and a saturated Copper/Copper Sulphate
(Cu/CuSO4) reference electrode contacting the electrolyte”.
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5.1 DESIGN PARAMETERS (PERMANENT CP SYSTEM)
a) Design Life - 30 years

b) Coating - Densopol 60HT or BC Petro Tape
c) Current Density - 0.20mA/m2 (specified per DEP, Refer appendix E)
d) Soil resistivity - 2.51 Ωm (Actual measured)
e) System - Impressed current Cathodic protection system
using mixed metal oxide coated Titanium tubular anodes
f) Isolation - Isolation shall be provided to isolate the under
ground & above ground sections of the pipeline.
5.2 CONSIDERATIONS
The design of Cathodic Protection system is based on the site conditions. In determining the
type of Cathodic Protection system, consideration has to be given to all the aspects like,
surrounding structures, soil conditions, space availability, power availability, O/H power lines in
the vicinity, foreign pipelines and any other steel structures connected to the pipeline or
crossing the pipelines.
Further considerations must be the location accessibility, both in terms of positioning any
proposed Cathodic protection system (anode beds, test stations, etc.) and the economics.
These considerations may limit design and placement of any groundbed installation.
Considering all these, it is proposed to install deep well type impressed current
Cathodic Protection system for the permanent protection of pipelines.
5.3 SOIL RESISTIVITY SURVEY
To enable a satisfactory Cathodic Protection system design, it is necessary to determine the

resistivity of any electrolyte (soil). This resistivity is used to calculate anode to earth resistance
and thus has an effect on the sizing, number of anodes and anode placement. The resistivity is
also an indication of the aggressiveness of the environment. i.e., in general, lower the resistivity
the more aggressive and more corrosive nature of the environment.
It is practical to install anode ground beds in low resistivity areas of the environment. The
resistivity measurements were taken using a Wenner 4-Pin Instrument. The Wenner method
provides an average resistivity of the environment from 0 metres to any depth, means, the
resistivity measured at 1m depth is the average resistivity for 0 to 1m, and that measured at 2m
depth is the average from 0 to 2m and so on. Soil resistivity values have been attached as an
appendix (BSST-QAQC-CPJ14449-022-FR) to this document.
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6.0 DESIGN
This design report explains different calculations, which led to the Permanent Cathodic
Protection requirement for the Corrosion Protection of pipelines listed in Table#1. Basically a
new CP system is designed to accommodate the power requirement of the pipeline.
6.1 DESIGN SUMMARY (PERMANENT CP SYSTEM)
Calculation sheets to identify and quantify the CP requirements are included in Appendix
A The following section discusses each result.
6.1.1 CURRENT REQUIREMENTS
Calculations are carried out to find the current requirements and the results are as follows.
1. Oxygen carrying line (O2)
Surface area of 3" Oxygen carrying line 1,149.07 m2
Surface area of 2" Oxygen carrying line 36.71 m2
Surface area of 1" Oxygen carrying line 9.58 m2
2. Carbon Di Oxide carrying line (CO2)

Surface area of 3" Carbon Di Oxide carrying line 1,000.65 m2
Surface area of 2" Carbon Di Oxide carrying line 36.71 m2
Surface area of 1" Carbon Di Oxide carrying line 7.98 m2
3. Cutting Edge
Surface area of 3" Cutting Edge line 1,173.01 m2
Surface area of 2" Cutting Edge line 36.71 m2
4. Air Utility line

Surface area of 8" Air Utility line 3,064.18 m2
Surface area of 6" Air Utility line 287.27 m2
Surface area of 2" Air Utility line 14.36 m2
5. CO2 + Air mix line
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CPJ14449-001~DES
Date 07.03.2015
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Surface area of 2" CO2 + Air mix line 36.71 m2

Surface area of 1" CO2 + Air mix line 9.58 m2
Total surface area of pipelines 6,892.82 m2
2
Minimum Current density for pipeline im = 0.2 mAmp/m (Specified per DEP)
Coating = Densopol 60HT or BC Petro Tape
Total current required I=α* im = 1.65 Amps
As a safe design, an extra current requirement of 20% considered. This current will be utilized
to cover any surface which is unforeseen and any other virtual metallic part which could utilise
the proposed cathodic protection system.
Refer Appendix A – Calculations for BSST-CALC-CPJ14449- 006D1 for Total area of

pipeline and BSST-CALC-CPJ14449-002D1 for Total current required to protect the
external surface of pipeline.
6.1.2 ANODE REQUIREMENTS
The minimum quantity of anode required is based on the current requirement, the life of the
system, and the anode material used. As we have chosen the most efficient and state of the art
anode material which is rare earth metal oxides coated on titanium substrate (MMO Tubular
anodes with cable tail), the quantity of anode purely depends on the current density and anode
surface area.
Total current required to protect the pipelines (I) = 1.65 Amp
Selected Anode = Mixed metal anode
2
Current density of selected anode material in coke back fill (χ) = 100.00Amp/m
Diameter of anode (δ) = 0.0250m
Length of anode (λ) = 1.0m
Surface area of Anode (α = Л λ δ) = 0.0785m2
Minimum Total surface area of anode material required (A=Ic/ χ)= 0.0165m2
Number of Anodes required based on Anode current density (Nc = A/α) = 0.2106Nos.
Theoretically 0.2106Nos (1) anode should be sufficient to deliver the current required to
protect the pipeline for the said design life. We have considered one ground bed with 3
nos of anodes based on the distribution and to compensate any additional requirement
that may arise due to the actual site conditions.
Refer Appendix A – Calculations sheet BSST-CALC-CPJ14449-013D1.

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6.1.3 ANODE RESISTANACE
Anodes are utilized for induction of current into the surrounding environment to allow the
current to reach the structure to be protected. The resistance of anode to the surrounding
environment has an overall effect on the size of the Cathodic protection system.
The anode resistance is calculated based on Dwight equation for vertical anodes in earth.
Soil resistivity at anode bed location ρ = 2.51 Ω-m (actual measured)
Resistance of Vertical anode to earth = Rv = /2L) (Ln(8L/D)-1)] Ohm

SOIL RESISTIVITY = r = 2.51 ohm-m
ANODE LENGTH = L = 11.000 m
ANODE DIAMETER = D = 0.254 m
ANODE RADIUS = r = 0.127 m
2L = 69.1240
/2L = 0.036
8L/D = 346.4567
Ln(8L/D) = 5.8478
Ln(8L/D)-1 = 4.8478
sum = 0.176
Calculated Resistance of single anode
groundbed = 0.176 Ohms
Refer Appendix A – Calculations for BSST-CALC-CPJ13414-042D1
6.1.4 TOTAL CIRCUIT RESISTANACE
Total circuit resistance is calculated based on anode to earth resistance and cable resistance.
Total circuit resistance Rc = Rv+Rlw
Where
Rc = Total circuit resistance
Rv = Anode resistance
Rlw = Lead wire resistance
Positive header cable size in mm2 = 50
Resistance/m = 0.0004Ω
2
Negative feeder cable size in mm = 50
2
Anode tail cable size in mm = 16
Resistance of cable = Cable length x resistance/meter
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Equivalent anode feeder and tail cable

resistance (3 anodes) = 0.0231Ω
Positive feeder cable resistance Rpf = 0.040Ω
Anode feeder & tail cable resistance Rt = 0.0231Ω
Resistance of negative circuit Rn = 0.0160Ω
Resistance of positive circuit Rp = Rt +Rpf = 0.063Ω
Lead wire resistance Rlw = Rp+Rn = 0.079Ω
Ground bed resistance Rv = 0.176Ω
Total Circuit Resistance Rc = Rv+Rlw = 0.255Ω
Total Circuit resistance = 0.255 
Refer Appendix A – Calculations sheets BSST-CALC-CPJ14449-017D1.
6.1.5 TRANSFORMER RECTIFIER SIZING
Considering all the above the power supply unit has been decided, which ultimately controls the
protection and cost. In this project we have 1 new Transformer Rectifier unit.
What ever be the power units, the sizing of the system depends on the current requirement and
the circuit resistance. The circuit resistance dictates the output voltage required to push the
design current.
Actual current required I = 1.3786A
Actual total circuit resistance Rc = 0.255Ω
Efficiency of transformer rectifier considered as 80%
Back voltage of system considered E = 2.00V
Rectifier output voltage (Ic*Rc/Efficiency)+2 = 2.45V
Selected T/R unit sizing for the system = 30V/15Amps *
* The rating has been chosen to standardize the unit.
Refer Appendix A – Calculations sheets BSST-CALC-CPJ14449-022 D1.

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7 SYSTEM CONFIGURATION
7.1 GROUND BED AND TRANSFORMER RECTIFIER INSTALLATION
Permanent Cathodic protection system has been designed based on the design provided in
section 6.0 above. Deepwell types of anodes are proposed based on the site conditions and
performance requirements.
Cathodic Protection shall be achieved by means of BTMO25X1000T type mixed metal oxide
anodes installed in ground bed 100m away from the pipeline. There is one anode ground bed
which consists of 3 nos of mixed metal oxide anodes and powered by a 30V/15A Transformer
Rectifier. Anode tail cable is 16mm2 HMWPE/KYNAR and terminated in to the anode junction
box. Anodes and transformer rectifier system is designed and sized to protect this pipeline.
Negative drain connection shall be taken from the pipeline and to be terminated at the
negative terminal of transformer rectifier.
7.2 ANODE JUNCTION BOX
Anode junction box shall be installed near the deep well ground bed location. Anode junction
box shall be of FRP IP55 with current measuring shunts. 3nos Anodes shall be terminated
inside the anode junction box. Positive header cable from the Transformer rectifier shall be
terminated inside the anode junction box.
7.3 NEGATIVE DISTRIBUTION BOX
Negative junction box shall be installed near the transformer rectifier. Negative distribution box
shall be of FRP IP55 with current measuring shunts and variable resistor. 4Nos of cables from
pipelines is terminated inside the negative distribution box.
7.4 BOND BOX
Bond box shall be installed as shown as the installation layout drawing. Bond box shall be of
FRP IP55. 1No of cable from each pipeline shall be terminated inside the Bond box and
connected in single bus bar.
7.5 SYSTEM MONITORING AND EVALUATION
To monitor the system performance test stations shall be installed at the locations as per the
installation drawings. Test station locations includes
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7.6 PIPE TO CABLE CONNECTIONS
All the pipe to cable connections shall be by thermit weld method except at drain points where
padded weld connection shall be used. Coating shall be reinstated using suitable (Interguard)
coating repair material after connections.
7.7 ISOLATION
Isolation flanges/mono-block isolation joint shall be provided at both ends of the pipeline/at all
above ground underground pipeline intersections to isolate the above ground and under ground
section of the pipeline. Isolation joints/flanges shall also be provided at Tie-in locations.
Isolation joint test stations shall be provided at the extreme main ends of the pipeline.
7.8 TEMPORARY CATHODIC PROTECTION
Temporary cathodic protection is provided for the pipeline in order protect from corrosion during
installation stage. Temporary anodes will be disconnected when energizing permanent cathodic
protection system.
7.9 EXECUTIVE SUMMARY
An impressed current cathodic protection system shall be installed for the protection of
pipelines and the system includes the following.
 Deepwell anode ground bed consists of 3nos. of mixed metal oxide anodes.
 Transformer rectifier
 Anode junction box
 Negative distribution box
 Insulation joint test stations
 Potential monitoring test station
 Mg Anode
8.0 APPENDICES
Appendix A: Calculation Sheets (Permanent CP System).

Appendix B: Calculation Sheets (Temporary CP System).
Appendix C: Bill of Materials.
Appendix D: BSST-QAQC-CPJ14449-022FR – Soil resistivity survey record.
Appendix E: DEP 30.10.73.31 – Gen – Page 18.
Appendix A: Calculation Sheets (Permanent CP System)
Design Calculations
CATHODIC PROTECTION SYSTEM FOR LAMPRELL HAMRIYAH FACILITY

Client:- Reference:- BSST-CPJ14449
Lamprell Energy Ltd (CN/14/523)
Total Area Calculations
Structure
Length of 3" Oxygen carrying line 4,800.00 m
Pipeline diameter 0.0762 m
a1
2
Surface area of 3" Oxygen carrying line 1,149.07 m
Length of 2" Oxygen carrying line 230.00 m

a2
2
Surface area of 2" Oxygen carrying line 36.71 m

a3
2

Length of 3" Carbon Di Oxide carrying line 4,180.00 m
2
Surface area of 3" Carbon Di Oxide carrying linea4 1,000.65 m
Length of 2" Carbon Di Oxide carrying line 230.00 m

2
Surface area of 2" Carbon Di Oxide carrying linea5 36.71 m

2
3. Cutting Edge
Length of 3" Cutting Edge line 4,900.00 m
a7
2
Surface area of 3" Cutting Edge line 1,173.01 m
Length of 2" Cutting Edge line 230.00 m

a8
2
Surface area of 2" Cutting Edge line 36.71 m
Prepared By:-Gafoor Date:- 07.03.15
Checked By:- Y.M Salim Date:- 07.03.15
Calculation Title:- Total Surface Area -sheet 1
DRAWING NUMBER
BSST CALC CPJ14449 006 D1 RevC
EXTAREA (1) 1 of 9 Design Perm Calc CPJ14449 - Rev C.xls

Design Calculations

Structure
a9
2
4. Air Utility line

Length of 8" Air Utility line 4,800.00 m
a10
2
Surface area of 8" Air Utility line 3,064.18 m
Length of 6" Air Utility line 600.00 m

a11
2
Surface area of 6" Air Utility line 287.27 m

a12
2

a13
2

a14
2
5. CO2 + Air mix line

Length of 2" CO2 + Air mix line 230.00 m
a15
2
Surface area of 2" CO2 + Air mix line 36.71 m
Length of 1" CO2 + Air mix line 120.00 m

a16
2
Surface area of 1" CO2 + Air mix line 9.58 m
2
Total surface area of pipelines 6,892.82 m
Calculation Title:- Total Surface Area - Sheet 2
DRAWING NUMBER
EXTAREA (2) 2 of 9 Design Perm Calc CPJ14449 - Rev C.xls

Design Calculations

Total Current Requirement Calculations
Structure
Total Surface area of the pipeline a 6892.82 m2
2
Minimum Current density im 0.20 mAmp/m *
Coating Densopol 60HT or BC Petro Tape
Actual current required I=a*im 1378.56 mAmps
1.379 Amps
As a safe design, an extra current requirement of 20% considered. This current will be
utilized to cover any surface which is unforeseen and any other virtual metallic part which
could utilise the proposed cathodic protection system.
Total current required 1.65 Amps
* Specified per DEP, Refer Appendix E.

Calculation Title:- Total Current Required
DRAWING NUMBER
current 3 of 9 Design Perm Calc CPJ14449 - Rev C.xls

Design Calculations

Total Anode Requirement Calculations
Structure
Total Current required to protect the

Pipeline I 1.654 Amp
Selected Anode Mixed Metal Oxide
Current Density of selected Anode Material
c
2
in coke back fill 100.00 Amp/m *
Diameter of Anode d 0.0250 m

Length of Anode l 1.0000 m
2
Surface Area of Anode a= pdl 0.0785 m
Minimum Total Surface Area of Anode

2
Material Required A= I/c 0.0165 m
Number of Anodes Required based on

Anode Current Density Nc= A/a 0.2106 Each
Final number of anodes N 3.00 Each **
* Manufacuture specified
** We have considered more number of anodes to compensate any additional requirement that may
arise due to the actual site conditions
Total Anodes required to Protect the External
Calculation Title:- Surface of Pipeline
DRAWING NUMBER
Extanod 4 of 9 Design Perm Calc CPJ14449 - Rev C.xls

Design Calculations

Ground bed resistance Calculations
Structure
Ground bed resistance

Calculated using Dwight's formula for single anode bed
Resistance of Vertical anode to earth = Rv = [(r/2pL) (Ln(8L/D)-1)] Ohm
SOIL RESISTIVITY = r = 2.51 ohm-m *

ANODE LENGTH = L = 11.000 m
ANODE DIAMETER = D = 0.254 m
ANODE RADIUS = r = 0.127 m
2pL = 69.1240
r/2pL = 0.0363
8L/D = 346.4567
Ln(8L/D) = 5.8478
Ln(8L/D)-1 = 4.8478
sum = 0.1760
Calculated Resistance of single anode

groundbed = = 0.1760 ohms
* Soil resistivity value based on actual site measurements

Checked By:- Y.M.Salim Date:- 07.03.15
Calculation Title:- Ground bed Resistance
DRAWING NUMBER
GB resistance 5 of 9 Design Perm Calc CPJ14449 - Rev C.xls

Design Calculations

Total Circuit Resistance

Location: KM0+100
Structure
Total Circuit Resistance Rc= Rv+Rlw Ohms
Positive Header Cable Size in mm2 50 Resistance/m 0.0004 Ohms
Negative Feeder Cable Size in mm2 50 Resistance/m 0.0004 Ohms
2
Anode Tail Cable Size in mm 16 Resistance/m 0.00161 Ohms
Resistance of Cable = Cable Length x Resistace/meter
Length of
anode tail Total 1/Total
Cable 16mm2 Resistance Resistance
Anode # in m in Ohm in Ohm
Anode #1 45 0.0725 13.7985
Anode #2 43 0.0693 14.4403
Anode #3 41 0.0660 15.1447
Equivalent Anode feader and Tail Cable Resistance 0.0231 Ohms

Positive Header Cable Resistance 100 0.0400 0.0400 Ohms
Equivalent Resistance for Negative feeder cable 40 0.0160 0.0160 Ohms
Positive Feeder Cable Resistance Rpf 0.0400 Ohms
Anode feeder and Tail Cable Resistance Rt 0.0231 Ohms
Resistance of Negative Circuit Rn 0.0160 Ohms
Resistance of Positive Circuit Rp = Rt+Rpf 0.063 Ohms
Lead Wire Resistance Rlw= Rp+Rn 0.079 Ohms
Ground bed resistance Rv 0.1760 Ohms
Total Circuit Resistance Rc= Rv+Rlw 0.255 Ohms
Calculation Title:- Total circuit resistance
DRAWING NUMBER
Total circuit Resistance 6 of 9 Design Perm Calc CPJ14449 - Rev C.xls

Design Calculations

Estmated life of system (Reverse Calculation)
Structure
Actual Current required 1.3786 Amp

Final number of anodes N 3 Each
Total Current Requirement I 1.3786 Amps
a
2
Surface area of a single anode 0.0785 m
Current Output of a single anode Is= I/a 0.4595 Amps
Actual maximum Current Density

based on anode output (Amps/m2) c= Is/a
2
5.85 Amps/m
Actual Life of the system Y=Log-1(2.3-(0.4Log Amp/m2)) 98.43 Years
Design Life 30.00 Years
Actual Life Expected 98.43 Years
Conclusion:- Actual Life Expected is more than the Designed.

Calculation Title:- Estimated life of Cathodic Protection System

DRAWING NUMBER
Extlife 7 of 9 Design Perm Calc CPJ14449 - Rev C.xls

Design Calculations

Transformer Rectifier Sizing Calculation
Structure
Actual Current Required I 1.3786 A

ActualTotal Circuit Resistance Rc = 0.255 Ohm
Efficiency of Transformer Rectifier
Considered as Efficiency 80.00 %
Back Voltage of System Considered 2.00 V
E=
Rectifier Output Voltage (Ic*Rc1/Efficiency)+2 2.44 Volt
Selected Trannsformer Rectifier Sizing for the system is 30V/15 Amps *
* This rating has been choosen to standardize the unit

Calculation Title:- Estimated life of Cathodic Protection System

DRAWING NUMBER
TR rating 8 of 9 Design Perm Calc CPJ14449 - Rev C.xls

Design Calculations

Calculation for the length of Anode Column and Quantity of Coke Breeze
Total Number of anodes 3 Each

Type of anode MMO anode
Anode Length 100 cm
Anode Diameter 2.54 cm
Diameter of Bore hole 25.4 cm
Radius of Bore Hole 12.7 cm
Spacing between anodes 200 cm
Length of Bottom Plug 20 cm
Length of surface Plug 0 cm
Length of top coke breeze column 200 cm
Length of Bottom coke breeze column 200 cm
Length of Native Backfill 28.8 m
Length of anode Column 11 m
Total length of Bore hole 40 m
Amount of Coke Breeze Required
3
Total Volume of Anode Column 0.557378227 m
3
Volume of Each anode 0.00051 m
3
Total Volume of Anodes 0.001520122 m
3
Total Volume of Coke breeze required 0.555858105 m
3
Density of Coke Breeze 1188 kg/m
Mass of Coke breeze Required 660.3594282 kg
Mass of Coke breeze per bag 22.5 kg/bag
No. of bags of coke breeze required 29.35 Bag

30 Bag

Checked By:-Y.M.Salim Date:- 07.03.15
Calculation Title:- Length of Anode Column and Quantity of Coke Breeze

DRAWING NUMBER
Anode columm 9 of 9 Design Perm Calc CPJ14449 - Rev C.xls

Appendix B: Calculation Sheets (Temporary CP System).
Design Calculations

Structure

a1
2

2
3. Cutting Edge

a3
2
4. Air Utility line

a4
2
2
Total surface area of pipelines 610.44 m

Calculation Title:- Total Surface Area
DRAWING NUMBER
EXTAREA 1 of 3 Design Temp Calc CPJ14449 - Copy.xls

Design Calculations

Total Current Requirement Calculations
Structure
Total Surface area of the pipeline a 610.44 m2
2
Minimum Current density im 0.040 mAmp/m *
Coating BC Petro Tape
Current required I=a*im 24.42 mAmps

0.024 Amps
As a safe design, an extra current requirement of 20% considered. This current will be
utilized to cover any surface which is unforeseen and any other virtual metallic part which
could utilise the proposed cathodic protection system.
Total Current required 0.00488 A
* Specified per DEP, Refer Appendix E.

Calculation Title:- Total Current Required
DRAWING NUMBER
current 2 of 3 Design Temp Calc CPJ14449 - Copy.xls

Design Calculations

Total Anode Requirement Calculations
Structure
Total Current required to protect the

Pipeline I 0.00488 Amp
Selected Anode Magnesium anode
Anode Capacity * k 1105.00 Amp. Hr/ Kg*
Anode utilization factor m 90.00 %

Design Life t 2 Years
Mass of anode required ** M = t * I * 8760 / k * m 0.09 Kg
Selected Anode Mass m 4.10 Kg
Number of anodes based on the above n=M/m 0.02 Each
Final Number of anodes N 3 Each **
* Manufacuture specified
** Considering the construction configaration ,we propose 3 anodes for temporary protection.
Total Anodes required to Protect the External
Calculation Title:- Surface of Pipeline
DRAWING NUMBER
Extanod 3 of 3 Design Temp Calc CPJ14449 - Copy.xls

Appendix C: Bill of Materials.
CN/14/523-SUPPLY &
LINES - HAMRIYAH
PROJECT
COMPANY
CP CONTRACTOR
CPJ14449-001BOM
Cathodic Protection Bill Of Materials For Cathodic Rev :C
Protection System For Lamprell
Date 07.03.2015
Hamriyah Facility
Page :
Sl.No. Item Description Qty Unit

Transformer/ Rectifier, oil cooled, 30V/15A, 415V, 50Hz,
1. 01 Ea.
3phase AC , painted steel enclosure ,sunshade, IP55
MMO coated Titanium Anodes BTMO 25x1000, c/w
2. 03 Ea.
16Sq.mm Kynar/HMWPE cable 45m.
3. Anode Centralizers 02 Ea
4. Low resistive carbonaceous back fill (50lb/bag) (Loresco) 30 Bags
Anode Junction box – FRP Enclosure, IP55,c/w shunts, 2”
5. 01 Ea.
dia hub, ‘C’ channel support frame & 2” dia PVC conduit
Negative Junction box – FRP Enclosure, IP55, c/w shunts,
6. 01 Ea.
2” dia hub, ‘C’ channel support frame & 2” dia PVC conduit
Bonding box – FRP Enclosure, IP55, c/w shunts, 2” dia hub,
7. 01 Ea.
‘C’ channel support frame & 2” dia PVC conduit
8. 1cx 50Sq.mm Cu XLPE/PVC positive and negative cable. 150 m
9. 1cx 10Sq.mm Cu XLPE/PVC monitoring cable. 200 m
10. Spark gap arrestor 6 Ea.
11. CAPTAIN Test Post type for potential monitoring 12 Ea.
12. Thermite weld materials 01 Lot
13. Coating repair material –Inter-guard 01 Lot
14. uPVC casing pipe 10” dia 6m c/w cap 01 Lot
15. 8” Steel casing pipe 40 m
16. Weld pad for Drain cable connection 04 Nos
Appendix D: Soil resistivity survey record
Soil Resistivity Measurements using Wenner
4-Pin Method
Client: Lamprell Date : 13/12/2014
Project: CN/14/523-SUPPLY & INSTALLATION OF GAS & AIR LINES IN HAMRIYAH DOC NO. BSST-QAQC-CPJ14449-022FR
Sl # Location Pin Spacing in cm Resistance in ohm Resistivity in ohm cm Remarks
100 2.57 1,614.78
1 Near to IVC1
200 0.34 427.26
300 0.11 207.35
100 2.01 1,262.92
2 Near to UVC1 & 2

200 0.47 590.62
300 0.13 245.04
100 2.6 1,633.63
3 Near to UVC86 & 82

200 0.39 490.09
300 0.14 263.89
100 2.01 1,262.92
200 0.47 590.62
300 0.13 245.04

Near to waste segregation
4 area
(Anode groundbed) 1000 0.076 477.52
2000 0.03 376.99
3000 0.01 188.50
4000 0.01 251.33
Contractor EngineerName: Pradap Sign: Date: 13/12/2014
Contracor QA/QC Name: Sign: Date:
Company Name: Sign: Date:
SOIL RESISTIVITY 1 of 1 Doc ref: BSST-QAQC-GEN-022FR

Appendix E: DEP 30.10.73.31 - Gen - Page 18.

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CN/14/523-SUPPLY &

INSTALLATION OF GAS & AIR

PROJECT : CN/14/523 - SUPPLY & INSTALLATION OF GAS &

COMPANY : LAMPRELL ENERGY LTD.

BSST PROJECT No : BSST-CPJ14449

LAMPRELL PROJECT No : CN/14/523

PIPE DIA LENGTH SURFACE

3.0 APPLICABLE DOCUMENTS

Doc. No. Description

5.0 DESIGN CRITERIA

5.1 DESIGN PARAMETERS (PERMANENT CP SYSTEM)

a) Design Life - 30 years

5.3 SOIL RESISTIVITY SURVEY

To enable a satisfactory Cathodic Protection system design, it is necessary to determine the

6.1 DESIGN SUMMARY (PERMANENT CP SYSTEM)

6.1.1 CURRENT REQUIREMENTS

2. Carbon Di Oxide carrying line (CO2)

4. Air Utility line

Surface area of 2" CO2 + Air mix line 36.71 m2

Total surface area of pipelines 6,892.82 m2

Refer Appendix A – Calculations for BSST-CALC-CPJ14449- 006D1 for Total area of

6.1.2 ANODE REQUIREMENTS

Refer Appendix A – Calculations sheet BSST-CALC-CPJ14449-013D1.

6.1.3 ANODE RESISTANACE

Soil resistivity at anode bed location ρ = 2.51 Ω-m (actual measured)

Resistance of Vertical anode to earth = Rv = /2L) (Ln(8L/D)-1)] Ohm

Refer Appendix A – Calculations for BSST-CALC-CPJ13414-042D1

6.1.4 TOTAL CIRCUIT RESISTANACE

Equivalent anode feeder and tail cable

Total Circuit resistance = 0.255 

Refer Appendix A – Calculations sheets BSST-CALC-CPJ14449-017D1.

6.1.5 TRANSFORMER RECTIFIER SIZING

Selected T/R unit sizing for the system = 30V/15Amps *

* The rating has been chosen to standardize the unit.

Refer Appendix A – Calculations sheets BSST-CALC-CPJ14449-022 D1.

7.1 GROUND BED AND TRANSFORMER RECTIFIER INSTALLATION

7.2 ANODE JUNCTION BOX

7.3 NEGATIVE DISTRIBUTION BOX

7.4 BOND BOX

7.5 SYSTEM MONITORING AND EVALUATION

7.6 PIPE TO CABLE CONNECTIONS

7.8 TEMPORARY CATHODIC PROTECTION

7.9 EXECUTIVE SUMMARY

Appendix A: Calculation Sheets (Permanent CP System).

CATHODIC PROTECTION SYSTEM FOR LAMPRELL HAMRIYAH FACILITY

Total Area Calculations

Length of 2" Oxygen carrying line 230.00 m

Length of 1" Oxygen carrying line 120.00 m

2. Carbon Di Oxide carrying line (CO2)

Length of 2" Carbon Di Oxide carrying line 230.00 m

Length of 1" Carbon Di Oxide carrying line 100.00 m

Length of 2" Cutting Edge line 230.00 m

EXTAREA (1) 1 of 9 Design Perm Calc CPJ14449 - Rev C.xls

CATHODIC PROTECTION SYSTEM FOR LAMPRELL HAMRIYAH FACILITY

Total Area Calculations

4. Air Utility line

Length of 6" Air Utility line 600.00 m

Length of 4" Air Utility line 40.00 m