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Pipeline Cathodic Protection Design Report


Document Number: D6316-141-RP-PL-0005, Rev. 1 Page 2 of 19

TABLE OF CONTENTS
Revision History .......................................................................................................................................................................... 3
1 Introduction ............................................................................................................................................................... 4
1.1 Scope of Work ............................................................................................................................................................ 4
1.2 Abbreviations ............................................................................................................................................................ 6
1.3 Definitions .................................................................................................................................................................. 6
1.4 Units ........................................................................................................................................................................... 6
2 Codes, Standards and Specifications ....................................................................................................................... 7
2.1 Supplementary Design Codes and Standards ......................................................................................................... 7
2.2 Project Specifications ................................................................................................................................................ 7
2.3 Project Documents .................................................................................................................................................... 7
3 Summary & Conclusions .......................................................................................................................................... 8
4 Design Data .............................................................................................................................................................. 10
4.1 Pipeline Data ............................................................................................................................................................ 10
4.2 Anode Data .............................................................................................................................................................. 10
4.3 Environment Data ................................................................................................................................................... 10
5 Pipeline Cathodic Protection Design Methodology .............................................................................................. 11
5.1 Current Demands .................................................................................................................................................... 11
5.2 Anode Net Mass ....................................................................................................................................................... 12
5.3 Anode Current Output ........................................................................................................................................... 12
6 Results ...................................................................................................................................................................... 14
6.1 Base Scope ................................................................................................................................................................ 14
6.1.1 24 Inch Production Line from I to ZB ................................................................................................................... 14
6.1.2 12 Inch Water Injection Line from HH to FA ...................................................................................................... 14
6.1.3 12 Inch Water Injection Line from LL to CC ...................................................................................................... 15
6.1.4 12 Inch Water Injection Line from KK to FF ...................................................................................................... 15
6.1.5 12 Inch Water Injection Line from II to GG ........................................................................................................ 16
6.2 Optional Scope ......................................................................................................................................................... 17
6.2.1 14 Inch Water Injection Line from U to ZA ......................................................................................................... 17
6.2.2 20 Inch Water Injection Line from WF-1 to M .................................................................................................... 17
6.2.3 14 Inch Water Injection Line from WF-1 to U ..................................................................................................... 18
6.2.4 18 Inch Water Injection Line from WF-1 to ZC .................................................................................................. 18
Appendix A: CP Design Calculation Sheet (Typical) ............................................................................................................ 19



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Document Number: D6316-141-RP-PL-0005, Rev. 1 Page 3 of 19

Revision History
Revision Description
A1 Issued for IDC
A Issued for Approval
0 Approved for Design







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Document Number: D6316-141-RP-PL-0005, Rev. 1 Page 4 of 19
1 Introduction
Dubai Petroleum Establishment is planning to replace existing pipelines and also install new pipelines in
the Fateh and South West Fateh Fields as part of the 2014 Pipelay Campaign. The 2014 Pipelay Campaign
covers the following base scope and optional scope pipelines.
Base Scope Pipelines:
New 24 production line with an approximate length of 2.1 km from platform I to ZB in Fateh field
New 12 water injection line with an approximate length of 2.3 km from platform LL to CC in SWF
field
New 12 water injection line with an approximate length of 2.5 km from platform KK to FF in SWF
field
Replacement of existing 12 water injection line with an approximate length of 12.7 km from
platform HH to FA in SWF field
Replacement of existing 12 water injection line with an approximate length of 0.9 km from
platform II to GG in SWF field
Existing risers at platforms HH and FA will not be replaced. Subsea tie-in to the existing risers will be
performed by using smart flanges.
Replacement of Optional Scope Pipelines:
Existing 14 water injection line with an approximate length of 0.7 km from platform U to ZA in
Fateh field
Existing 20 water injection line with an approximate length of 3.5 km from platform WF-1 to M in
Fateh field
Existing 14 water injection line with an approximate length of 2.9 km from platform WF-1 to U in
Fateh field
Existing 18 water injection line with an approximate length of 3.3 km from platform WF-1 to ZC in
Fateh field
Existing 14inch risers at platforms U, ZA and WF-1 will not be replaced. Also existing 20inch risers at
platforms WF-1 and M will not be replaced.
1.1 Scope of Work
The objective of this document is to present the analysis carried out to calculate the cathodic protection
design requirement for the pipeline and risers under the Base and Optional scope against external corrosion
during their design life of 25 years.
The pipeline and risers will be coated and will have sacrificial aluminum anodes attached to provide
sufficient cathodic protection for the exposed surface area.
The CP calculation have been performed for the following pipelines under Base and Optional scope

1
1

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Document Number: D6316-141-RP-PL-0005, Rev. 1 Page 5 of 19
Base Scope
24inch Production Pipeline from I to ZB
12inch Water Injection Pipeline from HH to FA
12inch Water Injection Pipeline from LL to CC
12inch Water Injection Pipeline from KK to FF
12inch Water Injection Pipeline from II to GG

Optional Scope
14inch Water Injection Pipeline from U to ZA
12inch Water Injection Pipeline from WF-1 to M
12inch Water Injection Pipeline from WF-1 to U
12inch Water Injection Pipeline from WF-1 to ZC
CP requirements for risers and spools in Base and Optional scope are also presented in this report.




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Pipeline Cathodic Protection Design Report


Document Number: D6316-141-RP-PL-0005, Rev. 1 Page 6 of 19

1.2 Abbreviations
3LPP Three Layer Polypropylene
DNV Det Norske Veritas
DPE Dubai Petroleum Establishment
FEED Front End Engineering Design
SCFD Standard Cubic Feet per Day
NPS Nominal Pipe Size
OD Outside Diameter
SMLS Seamless
SMTS Specified Minimum Tensile Strength
SMYS Specified Minimum Yield Stress
TBC To Be Confirmed

1.3 Definitions
COMPANY : Dubai Petroleum Establishment (DPE)
PROJECT : 2014 Pipelay Campaign
CONTRACTOR : EPC Contractor
SUPPLIER : The party which manufactures and/or supplies goods or System and services to
perform the duties specified by CONTRACTOR
1.4 Units
Data presented in this document are expressed in the System International (SI) units of measurements.
Other units for Standard flow rate (SCFD), pipe and piping component size (in), temperature (
o
C), force
(T), pressure (psig or barg) and combinations of the compass directional bases (N,E,S,W) may be
displayed in addition to the SI units.



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Pipeline Cathodic Protection Design Report


Document Number: D6316-141-RP-PL-0005, Rev. 1 Page 7 of 19
2 Codes, Standards and Specifications
This section specifies the regulations, codes and standards applicable to the FEED of the pipelines and
subsea facilities. The subsea pipelines system will be designed to meet the Companys requirements and to
satisfy applicable industry standards. Latest edition of the standards and specifications shall be used unless
noted otherwise.
The FEED of the pipeline systems shall be performed as per Det Norske Veritas (DNV standards in
conjunction with DPE). DNV OS F101 Rules for Submarine Pipeline Systems will be used as a primary
design codes in this study.
2.1 Supplementary Design Codes and Standards
The supplementary international codes that will be used where applicable and required are listed here
below:
Table 2.1: Supplementary Design Codes and Standards
Ref No. Code/Std. No. Title
[1] API 5L Specification for Line Pipe, 44
th
edition, 2008
[2] ANSI/ASME B36.10 Welded and Seamless Wrought Steel Pipe, 2004
[3] DNV OS F101 Rules for Submarine Pipeline Systems, 2012
[4] DNV-RP-F103 Cathodic Protection of Submarine Pipelines by Galvanic Anodes
2.2 Project Specifications
In addition to the applicable standards/codes referred in Section 2.1, the design of the pipeline system shall
comply with the COMPANY codes and standards specified in Table 2.2
Table 2.2: DPE Design Codes and Standards
Ref No. Code/Std. No. Title
[5] DP-PL-1 Submarine Pipeline Design
2.3 Project Documents
The relevant project documents are presented in Table 2.3.
Table 2.3: Project Documents
Ref No. Doc. No. Title
[6] D6316-141-DB-PL-0001 Pipeline and Riser Design Basis


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Pipeline Cathodic Protection Design Report


Document Number: D6316-141-RP-PL-0005, Rev. 1 Page 8 of 19
3 Summary & Conclusions
The cathodic protection design for the subsea pipelines has been performed in accordance with
DNV RP F103 [Ref. 4]. CP design has been carried out by assuming constant design temperature profile
throughout the length of the pipelines both in Base and Optional Scope
The detailed results of the CP design for Base and Optional Scope of pipelines are presented in section 6
of this document and the summary of the results of CP design for Base and Optional Scope of pipelines are
presented in Table 3.1 and Table 3.2 respectively.

Table 3.1: CP Design Summary [Base Scope]
Pipelines
OD
(mm)
Pipeline
Segment
Proposed Anode Details
Anode
Type
Anode
Length
(2)

Anode
Material
Anode
Thickness
Anode
Spacing
(joints)
(3)

Net mass
per each
Anode
(kg)
24 Production Line
from I to ZB
609.6 Pipeline
Half Shell
Bracelet
Type
200 Al-Zn-In 40 6 38
12 Water Injection
Line from HH to FA
323.9 Pipeline
Half Shell
Bracelet
Type
200 Al-Zn-In 40 6 21
12 Water Injection
Line from LL to CC
323.9 Pipeline
Half Shell
Bracelet
Type
200 Al-Zn-In 40 6 21
12 Water Injection
Line from KK to FF
323.9 Pipeline
Half Shell
Bracelet
Type
200 Al-Zn-In 40 6 21
12 Water Injection
Line from II to GG
323.9 Pipeline
Half Shell
Bracelet
Type
200 Al-Zn-In 40 6 21
Notes:
1. The length of riser and spool is approximate and subject to verification in detail engineering stage
2. A minimum length of 200mm has been selected to minimize fabrication and installation issues with anode
manufacturing
3. Anode spacing has been selected as per DP-PL-1





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Pipeline Cathodic Protection Design Report


Document Number: D6316-141-RP-PL-0005, Rev. 1 Page 9 of 19

Table 3.2: CP Design Summary [Optional Scope]
Pipelines
OD
(mm)
Pipeline
Segment
Proposed Anode Details
Anode
Type
Anode
Length
(2)

Anode
Material
Anode
Thickness
Anode
Spacing
(joints)
(3)

Net mass
per each
Anode
(kg)
14 Water Injection
Line from U to ZA
355.6 Pipeline
Half Shell
Bracelet
Type
200 Al-Zn-In 40 6 23
20 Water Injection
Line from WF-1 to M
508 Pipeline
Half Shell
Bracelet
Type
200 Al-Zn-In 40 6 32
14 Water Injection
Line from WF-1 to U
355.6 Pipeline
Half Shell
Bracelet
Type
200 Al-Zn-In 40 6 23
18 Water Injection
Line from WF-1 to ZC
457.2 Pipeline
Half Shell
Bracelet
Type
200 Al-Zn-In 40 6 29
Notes:
1. The length of riser and spool is approximate and subject to verification in detail engineering stage
2. A minimum length of 200mm has been selected to minimize fabrication and installation issues with anode
manufacturing
3. Anode spacing has been selected as per DP-PL-1













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Pipeline Cathodic Protection Design Report


Document Number: D6316-141-RP-PL-0005, Rev. 1 Page 10 of 19

4 Design Data
4.1 Pipeline Data
The pipeline design and operation data, pipeline material properties, design temperature profile and design
pressure profiles are presented in Section 3 of [6].
4.2 Anode Data
The anode is Half Shell Bracelet Type made of Aluminium, Zinc and Indium Alloy.
4.3 Environment Data
The environmental data including sea water properties, water depth, tide, sea water temperature, wave and
current data is presented in Section 4.1 to 4.7 of [6].

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Pipeline Cathodic Protection Design Report


Document Number: D6316-141-RP-PL-0005, Rev. 1 Page 11 of 19
5 Pipeline Cathodic Protection Design Methodology
The size and the dimension of anodes will be determined by the cathodic protection design.The cathodic
protection design consists of calculating anodes spacing, as function of anode length, required to satisfy
mean current requirement based on mass consumption rate and final current requirements based on current
output of the consumed anode. The mean and final current demands are checked to ensure that the anodes
can provide sufficient current output to polarize the pipeline throughout its entire life.
The pipeline cathodic protection will be carried out using MathCAD. The key of the analysis are as
following:
Current Demand Analysis for Mean and Final Life (Section 5.1)
Anode Net Mass Analysis (Section 5.2)
Anode Current Output Analysis based on Ohms law (Section 5.3)
5.1 Current Demands
In order to determine the mass of anode required for the cathodic protection system, it is necessary to
calculate the current demand to achieve polarization during the design life of the system as follows:
c c c c
f i A I
where:
I
c
is the current demand for a specific surface area (mean I
cm
, final I
cf
), A
A
c
is the cathode surface area, m
2

i
c
is the design current density (mean i
cm
, final i
cf
), A/m
2

f
c
is the coating breakdown factor (mean, final)
a, b is the constant values depend on coating properties and the environment
t is the coating life time, min

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Document Number: D6316-141-RP-PL-0005, Rev. 1 Page 12 of 19
5.2 Anode Net Mass
The total mass of anode required to maintain cathodic protection for the design life can be calculated as
follows:

u
t I
M
f cm
a
8760

where:
M
a
is the total net anode mass required, kg
I
cm
is the mean current demand, A/m
2

t
f
is the design life, yr
u is the anode utilization factor, 0.8 for bracelet anode
is the electrochemical capacity, A-hr/kg
The total net anode mass provided must be more than or equal to that required for cathodic protection to be
sustained throughout the design life.
5.3 Anode Current Output
The individual anode current output, required to meet the current demand, is calculated from Ohms law.
af
o
a
o
c
af cf
R
E E
N I N I


final
af
A
R
315 . 0

where:
I
cf
is the final current demand, A
I
af
is the final anode current output, A
N is the number of anodes required
E
c
o
is the design closed circuit potential of the anode, V
E
a
o
is the design protective potential, V
R
af
is the final anode resistance, Ohm
is the environmental resistivity, Ohm-m
A
final
is the final anode exposed surface area, m
2

The final anode resistance is determined from the initial anode dimensions by assuming that the anode is
consumed to its utilization factor, which would give a final exposed surface area and corresponding anode
resistance.

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Document Number: D6316-141-RP-PL-0005, Rev. 1 Page 13 of 19
The following will be applied in defining anode spacing :
Anode production constraints dictate that the half-shell bracelet length should not be longer than
1000 mm. above this value, difficulties of excessive alloy cooling during casting occurs.
For very thin anodes (thickness lower than 50 mm), this length shall be reduced to about 600 mm.
The anode thickness of all pipelines in base and optional scope is 40mm.
Anodes shorter than 200 mm present difficulties in core design.
The maximum anode spacing shall be 4 joints for 8 and less diameter pipelines as well as 6 joints
for greater than 8 diameter pipelines as per DP-PL-1
Anode spacing should not be too short to avoid excessive anode fittings and particular anode fitted
pipe handling precautions.
No anodes shall be placed on risers, anode designed to protect the riser shall be installed at the
spool piece/ pipeline after the last riser bend.

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Document Number: D6316-141-RP-PL-0005, Rev. 1 Page 14 of 19
6 Results
This section present the results of cathodic protection design of pipelines under Base and Optional scope.
The example of the cathodic protection design calculation is presented in Appendix A.
6.1 Base Scope
The results of cathodic protection design of pipelines under Base scope are mentioned below
6.1.1 24 Inch Production Line from I to ZB
The result of cathodic protection design of 24 inch production line from I to ZB is presented in Table
6.1.1
Table 6.1.1: Cathodic Protection Design Results for 24 Inch Production Line from I to ZB
OD
(mm)
Location
Segment
length
(m)
Design
Temp.
(
o
C)
Anode Details
Length

(mm)
(2)

Thickness
(mm)
Approx.
Mass
(kg)
Spacing as per
DNV-RP-F103
(joints)
Recommended
Spacing
(3)

609.6
Riser & Spool at I
(1)
<146 115.6 200 40 38 8 6
KP 0.0 to KP 2.1 2100 115.6 200 40 38 17 6
Riser & Spool at ZB
(1)
<146 115.6 200 40 38 8 6
Notes:
1. The length of riser and spool is approximate and subject to verification in detail engineering stage
2. A minimum length of 200mm has been selected to minimize fabrication and installation issues with anode
manufacturing
3. Anode spacing has been selected as per DP-PL-1
4. Two anodes for each riser and two anodes for each spool is recommended.
6.1.2 12 Inch Water Injection Line from HH to FA
The result of cathodic protection design of 12 inch water injection line from HH to FA is presented in
Table 6.1.2
Table 6.1.2: Cathodic Protection Design Results for 12 Inch Water Injection Line from HH to FA
OD
(mm)
Location
Segment
length
(m)
Design
Temp.
(
o
C)
Anode Details
Length

(mm)
(2)

Thickness
(mm)
Approx.
Mass
(kg)
Spacing as per
DNV-RP-F103
(joints)
Recommended
Spacing
(3)

323.9
Riser & Spool at HH
(1)
<146 35 200 40 21 8 6
KP 0.0 to KP 12.7 12700 35 200 40 21 24 6
Riser & Spool at FA
(1)
<146 35 200 40 21 8 6
Notes:
1. The length of riser and spool is approximate and subject to verification in detail engineering stage

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Document Number: D6316-141-RP-PL-0005, Rev. 1 Page 15 of 19
2. A minimum length of 200mm has been selected to minimize fabrication and installation issues with anode
manufacturing
3. Anode spacing has been selected as per DP-PL-1
4. Two anodes for each riser and two anodes for each spool is recommended
6.1.3 12 Inch Water Injection Line from LL to CC
The result of cathodic protection design of 12 inch water injection line from LL to CC is presented in Table
6.1.3
Table 6.1.3: Cathodic Protection Design Results for 12 Inch Water Injection Line from LL to CC
OD
(mm)
Location
Segment
length
(m)
Design
Temp.
(
o
C)
Anode Details
Length

(mm)
(2)

Thickness
(mm)
Approx.
Mass
(kg)
Spacing as per
DNV-RP-F103
(joints)
Recommended
Spacing
(3)

323.9
Riser & Spool at LL
(1)
<146 35 200 40 21 8 6
KP 0.0 to KP 2.3 2300 35 200 40 21 24 6
Riser & Spool at CC
(1)
<146 35 200 40 21 8 6
Notes:
1. The length of riser and spool is approximate and subject to verification in detail engineering stage
2. A minimum length of 200mm has been selected to minimize fabrication and installation issues with anode
manufacturing
3. Anode spacing has been selected as per DP-PL-1
4. Two anodes for each riser and two anodes for each spool is recommended

6.1.4 12 Inch Water Injection Line from KK to FF
The result of cathodic protection design of 12 inch water injection line from KK to FF is presented in
Table 6.1.4
Table 6.1.4: Cathodic Protection Design Results for 12 Inch Water Injection Line from KK to FF
OD
(mm)
Location
Segment
length
(m)
Design
Temp.
(
o
C)
Anode Details
Length

(mm)
(2)

Thickness
(mm)
Approx.
Mass
(kg)
Spacing as per
DNV-RP-F103
(joints)
Recommended
Spacing
(3)

323.9
Riser & Spool at KK
(1)
<146 35 200 40 21 8 6
KP 0.0 to KP 2.5 2500 35 200 40 21 24 6
Riser & Spool at FF
(1)
<146 35 200 40 21 8 6
Notes:
1. The length of riser and spool is approximate and subject to verification in detail engineering stage
2. A minimum length of 200mm has been selected to minimize fabrication and installation issues with anode
manufacturing.
3. Anode spacing has been selected as per DP-PL-1.

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Document Number: D6316-141-RP-PL-0005, Rev. 1 Page 16 of 19
4. Two anodes for each riser and two anodes for each spool is recommended.
6.1.5 12 Inch Water Injection Line from II to GG
The result of cathodic protection design of 12 inch water injection line from II to GG is presented in
Table 6.1.5
Table 6.1.5: Cathodic Protection Design Results for 12 Inch Water Injection Line from II toGG
OD
(mm)
Location
Segment
length
(m)
Design
Temp.
(
o
C)
Anode Details
Length

(mm)
(2)

Thickness
(mm)
Approx.
Mass
(kg)
Spacing as per
DNV-RP-F103
(joints)
Recommended
Spacing
(3)

323.9
Riser & Spool at II
(1)
<146 35 200 40 21 8 6
KP 0.0 to KP 0.9 900 35 200 40 21 24 6
Riser & Spool at GG
(1)
<146 35 200 40 21 8 6
Notes:
1. The length of riser and spool is approximate and subject to verification in detail engineering stage.
2. A minimum length of 200mm has been selected to minimize fabrication and installation issues with anode
manufacturing.
3. Anode spacing has been selected as per DP-PL-1.
4. Two anodes for each riser and two anodes for each spool is recommended













































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Document Number: D6316-141-RP-PL-0005, Rev. 1 Page 17 of 19
6.2 Optional Scope
The results of cathodic protection design for Optional scope of pipelines are mentioned below
6.2.1 14 Inch Water Injection Line from U to ZA
The result of cathodic protection design of 14 inch water injection line from U to ZA is presented in
Table 6.2.1
Table 6.2.1: Cathodic Protection Design Results for 14 Inch Water Injection Line from U to ZA
OD
(mm)
Location
Segment
length
(m)
Design
Temp.
(
o
C)
Anode Details
Length

(mm)
(2)

Thickness
(mm)
Approx.
Mass
(kg)
Spacing as per
DNV-RP-F103
(joints)
Recommended
Spacing
(3)

355.6
Riser & Spool at U
(1)
<146 37.78 200 40 23 8 6
KP 0.0 to KP 0.7 700 37.78 200 40 23 24 6
Riser & Spool at ZA
(1)
<146 37.78 200 40 23 8 6
Notes:
1. The length of riser and spool is approximate and subject to verification in detail engineering stage
2. A minimum length of 200mm has been selected to minimize fabrication and installation issues with anode
manufacturing
3. Anode spacing has been selected as per DP-PL-1
4. Two anodes for each riser and two anodes for each spool is recommended

6.2.2 20 Inch Water Injection Line from WF-1 to M
The result of cathodic protection design of 20 inch water injection line from WF-1 to M is presented in
Table 6.2.2
Table 6.2.2: Cathodic Protection Design Results for 20 Inch Water Injection Line from WF-1 to M
OD
(mm)
Location
Segment
length
(m)
Design
Temp.
(
o
C)
Anode Details
Length

(mm)
(2)

Thickness
(mm)
Approx.
Mass
(kg)
Spacing as per
DNV-RP-F103
(joints)
Recommended
Spacing
(3)

508
Riser & Spool at WF-1
(1)
<146 37.78 200 40 32 8 6
KP 0.0 to KP 3.5 3500 37.78 200 40 32 24 6
Riser & Spool at M
(1)
<146 37.78 200 40 32 8 6
Notes:
1. The length of riser and spool is approximate and subject to verification in detail engineering stage
2. A minimum length of 200mm has been selected to minimize fabrication and installation issues with anode
manufacturing
3. Anode spacing has been selected as per DP-PL-1
4. Two anodes for each riser and two anodes for each spool is recommended

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Document Number: D6316-141-RP-PL-0005, Rev. 1 Page 18 of 19


6.2.3 14 Inch Water Injection Line from WF-1 to U
The result of cathodic protection design of 14 inch water injection line from WF-1 to U is presented in Table
6.2.3
Table 6.2.3: Cathodic Protection Design Results for 14 Inch Water Injection Line from WF-1 to U
OD
(mm)
Location
Segment
length
(m)
Design
Temp.
(
o
C)
Anode Details
Length

(mm)
(2)

Thickness
(mm)
Approx.
Mass
(kg)
Spacing as per
DNV-RP-F103
(joints)
Recommended
Spacing
(3)

355.6
Riser & Spool at WF-1
(1)
<146 37.78 200 40 23 8 6
KP 0.0 to KP 2.9 2900 37.78 200 40 23 24 6
Riser & Spool at U
(1)
<146 37.78 200 40 23 8 6
Notes:
1. The length of riser and spool is approximate and subject to verification in detail engineering stage
2. A minimum length of 200mm has been selected to minimize fabrication and installation issues with anode
manufacturing
3. Anode spacing has been selected as per DP-PL-1
4. Two anodes for each riser and two anodes for each spool is recommended


6.2.4 18 Inch Water Injection Line from WF-1 to ZC
The result of cathodic protection design of 18 inch water injection line from WF-1 to ZC is presented in
Table 6.2.4
Table 6.2.4: Cathodic Protection Design Results for 18 Inch Water Injection Line from WF-1 to ZC
OD
(mm)
Location
Segment
length
(m)
Design
Temp.
(
o
C)
Anode Details
Length

(mm)
(2)

Thickness
(mm)
Approx.
Mass
(kg)
Spacing as per
DNV-RP-F103
(joints)
\

Recommended
Spacing
(3)

457.2
Riser & Spool at WF-1
(1)
<146 37.78 200 40 29 8 6
KP 0.0 to KP 2.5 2500 37.78 200 40 29 24 6
Riser & Spool at ZC
(1)
<146 37.78 200 40 29 8 6
Notes:
1. The length of riser and spool is approximate and subject to verification in detail engineering stage
2. A minimum length of 200mm has been selected to minimize fabrication and installation issues with anode
manufacturing
3. Anode Spacing has been selected as per DP-PL-1
4. Two anodes for each riser and two anodes for each spool is recommended



DUBAI PETROLEUM ESTABLISHMENT
Engineering Consultancy Service Contract

Pipeline Cathodic Protection Design Report


Document Number: D6316-141-RP-PL-0005, Rev. 1 Page 19 of 19

Appendix A: CP Design Calculation Sheet (Typical)

[1] API, Specification for American Petroleum, API Spec 5L
[2] ANSI/ASME, Welded and Seamless Wrought Steel Pipe, 2004, ANSI/ASME B36.10
[3] DNV-OS-F101, Rules for Submarine Pipeline Systems, 2012
[4] DNV, Cathodic Protection of Submarine Pipelines by Galvanic Anodes, DNV RP F103, 2010
SUBSEA ENGINEERING
DUBAI PETROLEUM ESTABLISHMENT
2014 PIPELAY CAMPAIGN
24 inch Production Line from I to ZB
Cathodic Protection - Bracelet, Half-shell Type Anode Design (KP0.0 to KP0.1)
DocTitle:CPDESIGNOFFSHORE
PIPELINE
Pre.By:SC Date:11/09/2013 Rev
Doc.No:D6316141RPPL005 Chk.By:NJ Date: 0

Table of Content
I. Introduction 2
2. Units 2
3. Codes, Standards and References 2
4. Design Data 2
5. Design of Cathodic Protection 4
6. Summary of Design 7
CP design (KP 0.0-KP 0.1).xmcd 1 of 8
SUBSEA ENGINEERING
1. Introduction
Cathodic Protection of 8" Gas Lift line from CI to PC20 by using Bracelet Half shell Type Anode Based on
DNV-RP-F103,2010 and ISO 15589-2
User Manual
Guidlines: This Mathcad sheet is based on DNV-RP-F103, 2010 and ISO 15598-2. If any changes are
required in the values taken form the above codes because of Client specific requirement , in that case
the Input values need to checked and revised as per the same.
2. Units
ORIGIN 1 c K joint 12.2 m
3. Codes, Standards and References:
Codes: DNV-RP-F103, 2010 (Cathodic Protection of Submarine Pipelines by Galvanic
Anodes
Standards: ISO 15589-2 (Petroleum and Natural Gas Industries-Cathodic Protection of
Pipeline Transportation system- Part 2 -Offshore Pipeline)

4. Design Data
4.1 Pipeline Material and Process Data
D 609.6 mm := _ outside diameter of the pipe_including pipe OD tolerances
t
w
20.6 mm :=
_ Pipeline wall thickness thickness
t
c
2.5 mm := _ corrossion coating thickness

mt
0.2 10
6
ohmm := _Specific Electrical resistivity Based on Linepipe
Material-extracted from Clause 5.6.10 of DNV-RP-F103
PLM "CM" := _pipeine material type; CM for CMn steel linepipe
CR for Type 13 Cr linepipe
DX for duplex stainless steel pipe
L
p
100 m := _total length of the pipeline (including corridor spool length)
L
cp
100 m := _ equivalent length of the coated pipeline or spool
L
ncp
0m := _equivalent length of the bare pipeline or spool
T 115.6 c := _ anode design temperature in degree centigrade
T
sea
19 c := _sea water temperature
PCPE 100% := _ percentage of pipeline exposed to sea water
PCAE 100% := _ percentage of anode exposed to sea water
t
fD
1 := _ design factor for design life of pipeline (DNV-RP-F103
Guidance note of Clause 1.2.1)(if not given then use t
fD
equal
to 1)
CP design (KP 0.0-KP 0.1).xmcd 2 of 8
SUBSEA ENGINEERING
t
fg
25 := _ design life of cathodic protection system given
t
f
t
fg
t
fD
yr := _ design life of cathodic protection system
L
cut
0mm := _cutback length or FJ length
4.2 Sacrificial Anode Data (Bracelet, half-shell type)

a
2750 kg m
3
:= _density of the anode material
u 0.8 = _anode utilisation factor (From ISO15589-2, Sec 7.4)
o 25 mm := _gap between the half shells
n
ac
2 := _no of anode cores
w
ac
50 mm := _width of the anode cores
t
ac
6 mm := _thickness of the anode cores
n
ar
12 := _no of reinforcement bars
d
ar
6 mm := _diameter of the reinforcement bars
o
r
25 mm := _end cover for the reinforcements
o
ac
10 mm := _distance of anode core from pipe outer surface

s
7850 kg m
3
:= _density of the steel
t
r
3.mm := _thickness of rubber sheet between anode and coated pipeline
ATY "AL" := _anode type " AL" for Aluminium and " ZN" for Zinc anodes
4.3 Cathodic Protection requirment Parameters
S
amax
24 joint := _maximum spacing of anodes
4.4. Code Defi ned CP desi gn Parameters
i
cm_e_cp
70mA m
2
= _ average current density for fully
exposed coated pipeline (taken from
Table 5-1 of DNV-RP-F103)
E
c
( )
.8 V := _ protective potential wrt Ag / AgCl /
Seawater as per Saudi Aramco
requirements
_ closed circuit anode potential for
exposed pipeline wrt Ag / AgCl /
Seawater Table 4 of ISO 15589-2:2004(E)
E
a
1.05 V =
CP design (KP 0.0-KP 0.1).xmcd 3 of 8
SUBSEA ENGINEERING
f
cmp
3.25 10
3
= _mean breakdown factor for pipeline
Table A1 of DNV RP F 103
_final breakdown factor for pipeline
Table A1 of DNV RP F 103
f
cfp
4.5 10
3
=
_environmental seawater resistivity for
fully exposed pipeline (As recommended
by Clause 5.5.2 of DNV RP F103 andas
perSeconA.8ofAnnexure8of
ISO155892)
0.3
kg m
3

s
3
A
2

=
_ electrochemical efficiency for exposed
pipeline wrt Ag / AgCl / Seawater As
specified by the saudi armaco standards
17-SAMSS-006 material system spec
c 2.592 10
6

s A
kg
=
5. Design of Cathodic Protection
5.1 Surface Area and Weight of the Anode
x 0.001 0.002 , 1.50 .. :=
_dimensionless variable for defining
functions
L
amin
n
ac
3 +
( )
w
ac
:=
L
amin
0.25m = _minimum anode width required
L
a
x ( ) L
amin
x m + := _function defining length of the anode
D
i
D 2 t
c
+ 2 t
r
+ := D
i
0.621m = _inside diameter of the anode shell
D
o
D
i
2 t
a
+ := _outside diameter of the anode shell
D
o
0.701m =
V
ac
t
4
D
i
2 o
ac
t
ac
+
( )
+

2
D
i
2 o
ac
+
( )
2

w
ac
n
ac
:= _Volume of the anode core
V
ac
1.219L =
V
ar
x ( ) n
ar
t
4
d
ar
2
L
a
x ( ) 2 o
r

( )
:= _Volume of the anode reinforcement
M
1
x ( )
t
4
D
o
2
D
i
2

|
\
|
.
2 o t
a

(
(

L
a
x ( ) V
ac
V
ar
x ( ) +
( )

(
(


a
:= _net mass of the anode without bolt
holes
M x ( ) M
1
x ( ) 0.07M
1
x ( ) :=
_net mass of anode(assuming 7%
reduction for bolt holes)
M
g
x ( ) M x ( ) V
ac
V
ar
x ( ) +
( )

s
+ := _gross mass of the anodes
CP design (KP 0.0-KP 0.1).xmcd 4 of 8
SUBSEA ENGINEERING
A
f
x ( ) t D
i
2 1 u ( ) t
a
+

2 o

L
a
x ( ) := _final surface area of the anode at the
end of life
5.2 Current Demand Calculations
_total number of joints
n
j
ceil
L
cp
joint
|

\
|
|
.
:= n
j
9 =
L
j
2 L
cut
n
j
:= _total joint length
L
j
0 =
I
cm_cp
tD L
cp
f
cmp
i
cm_cp
:= I
cm_cp
0.044A = _mean current demand for coated pipeline
I
cm_ncp
tD L
ncp
i
cm_ncp
:= I
cm_ncp
0 = _mean current demand for non-coated
pipeline
I
cm
I
cm_cp
I
cm_ncp
+ := I
cm
0.044A = _total mean current demand
I
cf_cp
tD L
cp
f
cfp
i
cm_cp
:= I
cf_cp
0.06A = _final current demand for coated pipeline
I
cf_ncp
tD L
ncp
i
cm_ncp
:= I
cf_ncp
0 = _final current demand for non-coated
pipeline
I
cf
I
cf_cp
I
cf_ncp
+ := I
cf
0.06A = _total final current demand
5.3 Total Anode Mass and Number of Anodes Calculation
M
t
I
cm
t
f

u c
:= M
t
16.576kg = _total anode net mass
n x ( )
M
t
M x ( )
:= _total number of the anodes
I
f
x ( )
I
cf
n x ( )
:= _required final anode current output
R
af
x ( ) 0.315

A
f
x ( )
:= _final anode resistance
I
af
x ( )
E
c
E
a

R
af
x ( )
:= _available final anode current
CP design (KP 0.0-KP 0.1).xmcd 5 of 8
SUBSEA ENGINEERING
1
.
10
4
0.36 0.72 1.08 1.44 1.8
0
5
10
15
Length of Anode (m)
C
u
r
r
e
n
t

(
A
)
I
af
x ( )
I
f
x ( )
L
a
x ( )
Number of Anodes Based on Sel ected Anode Length
x La
sel
L
amin

( )
m
1
:= _selected x value x 0.05 =
n
ar
n x ( ) := _total no of anodes required n
ar
0.434 =
S
ar
L
p
ceil n
ar
( )
:= _required spacing of
anodes
S
ar
8.197joint =
S
ap
S
sel
:= _spacting of anodes to be provided S
ap
97.6m =
Check for Spaci ng
Check_sp if S
ap
S
amax
> "Anode spacing exceeds 12 joints" , "OK" ,
( )
:= Check_sp "OK" =
n
ap
ceil
L
p
S
ap
|

\
|
|
|
.
:= _total number of anodes provided
n
ap
2 =
M
a
n
ap
M x ( ) := _total net mass of anode M
a
76.382kg =
CP design (KP 0.0-KP 0.1).xmcd 6 of 8
SUBSEA ENGINEERING
Check for mean current:
I
cm
0.044A = _average current required
I
acm
c u M
a

t
f
:= _average current output I
acm
0.201A =
Check_mc "OK" I
cm
I
acm
< if
"Required current is greater than output current" otherwise
:= Check_mc "OK" =
Check for fi nal current:
I
cf
0.06A =
_final current required
I
acf
E
c
E
a

R
af
x ( )
n
ap
:=
_final current output I
acf
3.304A =
Check_fc "OK" I
cf
I
acf
< if
"Required current is greater than output current" otherwise
:=
Check_fc "OK" =
6. Summary of Design
t
a
40mm = _thickness of anode
o 25mm = _gap between half shells
S
ap
8joint = _spacing of anodes (assuming 12.2 m
joints)
n
ap
2 = _no of anode
M x ( ) 38.191kg = _net mass of each anode
M
g
x ( ) 48.158kg = _gross mass of each anode
M
a
0.076tonne = _total net mass of anode
M
gr
M
g
x ( ) n
ap
:= M
gr
0.096tonne = _total gross mass of anodes
n
ac
2 = _no of anode cores
w
ac
50mm = _width of anode cores
t
ac
6mm = _thickness of anode cores
n
ar
0.434 = _no of reinforcement bars
d
ar
6mm = _diameter of reinforcement bars
o
r
25mm = _end cover for reinforcements
CP design (KP 0.0-KP 0.1).xmcd 7 of 8
SUBSEA ENGINEERING
I
cm
0.044A = _average current required
I
acm
0.201A = _average current output
I
cf
0.06A = _final current required
I
acf
3.304A =
_final current output
Check_sp "OK" = _check for spacing
Check_mc "OK" = _check for mean current
Check_fc "OK" = _check for final current
u 0.8 _anode utilisation factor
S
ar
8.197joint = _required anode spacing
La
sel
0.2m _selected length of each anode effective
tapered
Note: if selected anode length is not same as calculated length then the above parameter will be calculated
based on the selected anode length and Lasel value will change as per selected anode length.
S
sel
8 joint _selected anode spacing
t
a
40 mm _thickness of the anode
CP design (KP 0.0-KP 0.1).xmcd 8 of 8