CA04!04!33 P SP 030 - X2 Cathodic Protection

SINCOR
Project Title: SINCOR, C. A. Document: CA04-04-33-P-SP-030

UPSTREAM SURFACE FACILITIES PROJECT Page /File: 1/CA04-04-33-P-SP-030_X2.doc
Rev./Date: X2 / Oct,10-05
SINCOR, C.A.
UPSTREAM SURFACE FACILITIES PROJECT
ELECTRICAL CATHODIC PROTECTION
REVISION INDEX:
This document consist of the following number of pages: 31
APPROVAL REGISTER
Prepared By/ Checked By/ Project SINCOR

No. Date Date Approved By/ Approved By/ Reason for Revision
Date Date
X0 JAN 22, 2004 JAN 22, 2004 JAN 22, 2004 JAN 22, 2004 Issue as built by
SINCOR
X1 A. Avila A. Avila/ S. Cuesta J. Riera/ Update 2004 by
Oct 27, 2004 Oct 27, 2004 Oct 27, 2004 Oct 27, 2004 SINCOR
X2 J.Menendez A. Avila/ S. Cuesta J. Riera/ Update 2005 by
Oct 10, 2005 Oct 10, 2005 Oct 10, 2005 Oct 10, 2005 SINCOR
SINCOR
CONTENTS
SECTION N PAGE
1. SCOPE 4
2. CODES AND STANDARDS 4
3. DEFINITIONS 4
4. ELECTROCHEMICAL CORROSION 5
5. APPLICATION OF CATHODIC PROTECTION TO OIL & GAS PRODUCTION EQUIPMENT

6
5.1. Pipelines 6
5.2. Aboveground Storage Tank Bottoms 7
5.3. Well Casings 8
6. CATHODIC PROTECTION PRINCIPLES 9
7. PIPE TO SOIL POTENTIALS 9
8. COATING SELECTION 12
9. RECTIFIERS 14
10. INFLUENCE OF FOREIGN PIPELINES 15
11. ANODE GROUND BEDS 15

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11.1. Impressed current anodes 15

11.2. Sacrificial Anode Beds 17
12. CABLE SELECTION 18
13. ELECTRICAL ISOLATION 18
14. BOND DESIGNS 19
15. SURVEY METHODS USED IN CATHODIC PROTECTION WORK 19
15.1. Type of Survey 19
16. CATHODIC PROTECTION CALCULATIONS AND DESIGN 29
17. CATHODIC PROTECTION MONITORING 30

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1. SCOPE
This document describes and specify the Cathodic Protection Basis and Design Criteria
involved in the corrosion control through the use of coatings and cathodic protection on oil
production, above ground storage tanks, pipelines etc. to be used in the design of the
SINCOR UPSTREAM SURFACE FACILITIES.
2. CODES AND STANDARDS
The following codes and standards will be used for the Cathodic Protection designs.
a) NACE RP0169, Control of External Corrosion on Underground or Submerged

Metallic Piping Systems.
b) NACE RP0286, The Electrical Isolation of Cathodically Protected Pipelines.
c) BSI-CP 1021, Code of Practice for Cathodic Protection (latest edition).
d) NACE Standard MR0175, Standard Material Requirements, Sulfide Stress Cracking

Resistant Metallic Materials for Oil field Equipment.
e) Steel Structures Painting Council Specifications.
3. DEFINITIONS
Corrosion of a buried or submerged metallic structure, in this case steel, occurs when
several components exist forming the basic corrosion circuit, with an anode or part of the
structure (where there is loss of steel into the electrolyte, corrosion), a cathode (where no
corrosion occurs), an electrolyte in which both the anode and cathode are located, and an
electrical pass for the electrons involved in the corrosion circuit to go from the anodic
areas to the cathodic ones. Basically if one or more of these components are missing no
corrosion will occur.
Cathodic Protection (CP) is a technique applied to underground and submerged

structures to reduce or mitigate the corrosion of the metal surfaces, by passing the
adequate amount of cathodic current to cause the anodic dissolution rate to become
negligible. In other terms, it is the use of corrosion current from anodic areas of a metallic
structure immersed in the electrolyte or conductive medium, such as soils and water.
These anodic areas are usually other elements, metallic or metal oxides, outside of the
corrosion circuits and will be consumed instead of the structure steel (pipe, tank bottom,
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steel sheetpile, etc.). These elements themselves form part of a similar system, consisting
of anodic and cathodic areas, electrolyte and collecting conductors (copper wires, steel of
the structure, etc..). When a CP system is properly designed and installed, all portions of
the protected structure collect current from the surrounding electrolyte and the entire
exposed surface becomes one large cathodic area. CP current is the type denominated
direct current, such as found in a battery.
CP is applicable only to control the corrosion resulting from flow of measurable direct
currents from portions of a structure (anodic areas), through an electrolyte to other parts of
the same structure (cathodic areas). This type of corrosion is called electrochemical
corrosion, and where current is discharged from the anodic areas, metal loss or corrosion
will occur; conversely, the cathodic areas will collect the current and no corrosion will occur
at that part of the structure, i.e. it is cathodically protected.
4. ELECTROCHEMICAL CORROSION
Electrochemical corrosion can occur naturally or artificially. The first case was discussed
previously and the second is referred to as Electrolysis or Interference. This term is
sometimes erroneously used to refer to both types of corrosion. Electrolysis or
interference results when direct current is discharged into the soil or water, the electrolyte.
These currents are also known as stray or erratic currents. Seifert1 defines Interference
Currents as manmade electrical currents, performing work on one grounded plant, which
flow on other grounded plant(s) using electrolytic paths of earth for interconnection. These
manmade currents can be separated into two main categories, static, generated in
foreign CP systems, electrolytic cells, or dynamic, continuously varying in amplitude and/or
continually changing their geographic paths, such as in DC generating equipment in
underground mines and electrical railway generating equipment (Subways).
When these currents are picked up from the electrolyte on areas of a structure, not
connected to the CP system, and discharged in other areas of the same structure,
corrosion occurs in the discharge zones and some cathodic protection results at the
collecting areas of the structure. This type of corrosion can be found widely where
pipelines cross each other, or there are several pipes paralleling at short separations in
the same corridor, some protected and others not. This phenomenon is also found in
underground structures in industrial plants, with CP systems for some structures, and in
cities along the Metro or Subway lines, specifically near the Stations.
1
PRACTICAL INTERFERENCE CURRENT TESTING ON UNDERGROUND METALLIC STRUCTURES, RICHARD L. SEIFERT.
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In petroleum production and transmission, it is the naturally occurring electrochemical

corrosion which is more universal and of everyday concern and which is prevented or
mitigated through the use of CP in its different forms of application.
5. APPLICATION OF CATHODIC PROTECTION TO OIL & GAS PRODUCTION

EQUIPMENT
5.1. Pipelines
The pipelines to be protected in UPSTREAM SURFACE FACILITIES PROJECT

are the lines between the Main Station and Zuata, the trunklines if buried and those
short stretches of flowlines, where it is considered worthwhile to protect them.
Crossings of rivers, swamps or areas considered potentially corrosive by flowlines
might indicate the control of their corrosion by means of sacrificial magnesium
anodes in backfill.
Short underground pipelines in the Main Station, considered of importance, that

might be subject to corrosion, due to the soil resistivities or galvanic action
(connections to copper grounding systems) should be cathodically protected.
Isolation must be considered in the case of buried lines connected to grounded
equipment.
Flowlines that might be connected to protected trunklines should be electrically

isolated at the wellheads, using monolithic isolation joints or insulating flange kits,
composed of a dielectric gasket, full length sleeve and two dielectric and carbon
steel washers per bolt. Trunklines should also be isolated at their arrival to the Main
Station, even if cathodically protected.
When cathodically protected well coated lines with a high electrical resistance to
soil arrive at an industrial plant it has been proven that their potentials suffer a large
fall, due to the connection of the lines with a large amount of unprotected steel and
other metals, with a very low resistance to soil. NACE RP0286 and other
Standards indicate that the proper way to avoid this loss of protection is by
isolating these pipes at the point of entrance to the plants.
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5.2. Aboveground Storage Tank Bottoms
5.2.1. External Protection
The external bottom of the tanks are prone to developing corrosion

conditions, between the center part of the tank bottom and the outer ring,
due to differential corrosion cells (aeration, resistivity) and also to
connection of the steel bottom to grounding system and/or steel of the
concrete ring foundation.
Due to the high resistivity of the soils in that part of the country, impressed
current CP systems with conventional anode groundbeds distributed
around the tank perimeter will not work properly. Other anode configuration
and types should be considered in this case, e.g. distributed titanium
ribbon in a grid or MMO anodes located immediately below the tank
separated around one foot from the steel plates is a proper solution to
control the corrosion of the bottoms. Electrical isolation of the tanks at
incoming and outgoing pipes should be analyzed.
5.2.2. Internal Protection
Because of the layer of conducting bottom sediment and water (BS&W) in

the tank is quite shallow, CP of an internal tank bottom is much more
difficult than if the tank was partially filled with water. For this reason internal
cathodic protection of oil field production tanks is not frequently used,
unless the water is corrosive. When deemed necessary galvanic anodes,
usually aluminum or zinc are used, distributing them along the bottom,
standing away from it. Magnesium anodes are not recommended due to
possibility of sparks produc ed when falling parts of the anode contact the
bottom.
Permanent reference electrodes can be designed crossing the tank walls,

located in the lower part of the tank, to be able to measure the potentials of
the internal part in contact with the water.
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5.3. Well Casings
First of all information should be recollected to find out if corrosion has occurred in
well casings in that part of the country where the installations will be located. If no
reports are available concerning this matter, oil production engineers or well
operators should be contacted, working in the area or other states in the east of
Venezuela, with similar formations, such as Monagas.
Well casing require amounts of current falling in the range of 1 to 25 A DC for

cathodic protection to be achieved. Some engineers have designed galvanic
anode systems when the amount of current required is in lower ranges, however in
many instances soil resistivities are too high for galvanic anodes, even for small
current demands, and impressed current systems become necessary.
The case of well casings can be of interest when CP systems are designed in oil
fields, where there are flow- and trunklines and pipeline corridors going towards
other installations. In many cases these casings suffer corrosion processes and
one of the forms of preventing this phenomenon is by impressed current CP
installations. To determine their effectively the behavior of the well casing potential
should be known when going downwards, to determine in this way the most
adequate current demand.
In countries like the States and Canada this problem has been detected and
studied, and there is literature about the ways to measure the potentials downhole
and the actions that have been taken to control the problem.
One of the problems occurring is the presence of corrosion by interference

currents. Several ways of measuring potentials and current to prepare the E-log I
curve, the instruments and cathodic protection systems used, and interference due
to CP for the lines connected at the wells or in the corridors are available in
literature extending more than 30 years.
External corrosion of the well casing can result in the loss of a well, the loss of
production, environmental dangers and human safety considerations. The only way
to prevent external corrosion of the casings effectively is by means of cathodic
protection.
Information should be recollected concerning the corrosion or not of the existing

wells in the area or of similar characteristics, prior to embarking in designs of
cathodic protection for the wells. One of the forms of avoiding problems is by
isolating the pipes at the wellheads.
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Should it be decided to protect the well casings, NACE Recommended Practice

concerning this matter should be consulted for the design.
6. CATHODIC PROTECTION PRINCIPLES
Electrochemical corrosion can be mitigated by the proper application of cathodic

protection, impressing cathodic current on the surface of the entire structure involved in the
process, making it cathodic, overriding the naturally occurring anodic areas with this
impressed current from an external, more powerful or active anode.
CP does not necessarily eliminate all the corrosion, but transfers it from the structure to be
protected and concentrates it on another structures, such as galvanic or inert anodes
which will be consumed instead of the structure itself. Proper design procedures and
selection of the right material will give these anodes a long life and easy replacement.
CP is only of value to the surface of the metal exposed to the same electrolyte (soil or
water) as the anode.
Coating buried structures and applying cathodic protection is the proper approach to
corrosion control.
7. PIPE TO SOIL POTENTIALS
Pipe to soil potentials is one of the most important measurements in Corrosion Control
and Cathodic Protection as the value of this parameter indicates if there is active
corrosion going on, the magnitude of it and also if CP has been achieved according to the
Criteria given in NACE RP0169, Section 6, Criteria and other Considerations for
Cathodic Protection. Section on SURVEY METHODS USED IN CATHODIC
PROTECTION WORK, elaborates on the different ways to measure structure to soil
potentials, and the equipment used for this purpose.
This section will list criteria and other considerations that will indicate, when used either
separately or in combination, whether adequate cathodic protection of a metallic structure
(buried piping system, aboveground or underground storage tank) has been achieved.
The effectiveness of CP or other corrosion control measures can be reaffirmed by visual

observation, measurement of pipe wall thickness, or by use of internal inspection devices.
Because such methods are not always practical, meeting any criterion or a combination of
various criteria in this section is evidence that adequate CP has been achieved. When
excavations are made for any purpose, the pipe should be inspected for evidence of
corrosion and/or coating condition.
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Sound engineering practices shall be used to determine the methods and frequency of
testing required to satisfy these criteria.
It is not intended that persons responsible for corrosion control be limited to the criteria
listed below. Criteria that have been successfully applied on existing piping systems can
continue to be used on those piping systems. Any other criteria used must achieve
corrosion control comparable to that attained with the criteria herein. The criteria in more
common use involve measurements of voltage (differences in potential) between the
protected structure and the electrolyte.
The most widely used criterion in the oil business involves the use of a copper/copper
sulfate electrode as a reference half cell. The electrode consists of a copper rod
immersed in a saturated copper sulfate solution, both housed in a plastic cylinder with a
porous plug (wood or ceramic) on the bottom end, to make contact with the soil, and the
copper rod extending out of the top (for connection to the measuring high-resistance
voltmeter or multimeter). The means to measure this potential shall be designed, so as to
be able to compare the values with those given in NACE RP0169-96, Section 6. All
potential mentioned are measured with respect to a saturated copper/copper sulfate
(stable) electrode (Cu/CuSO4 ) in contact with the electrolyte.
Normal values of potentials for buried steel without any CP applied and not receiving any
stray currents is in the order of -500 to -600 mV Cu/CuSO4 . This potential is called Native
Potential (Pnat).
Corrosion control can be achieved at various levels of cathodic polarization2 , with

protective current applied, and potentials called Active Potentials (Pact) such as:
A negative potential (cathodic) potential of at least 850 mV with CP applied. This

potential is measured with respect to a saturated Cu/CuSO4 ) contacting the
electrolyte. Voltage drops other than those across the structure-to-electrolyte
boundary must be considered for valid interpretation of this voltage measurement (IR
drop-electrolytic voltage drop).
A negative polarized potential of at least 850 mV to a saturated copper/copper sulfate

electrode.
2
Cathodic polarization: The change of electrode potential in the electronegative direction resulting from the flow of current between the
electrolyte and electrode.
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A minimum of 100 mV of cathodic polarization between the structure surface and a

stable reference electrode contacting the electrolyte. The formation or decay of
polarization can be measured to satisfy this criterion.
Overprotection of steel structures, i.e. generation of polarized potentials much more

negative than -850 mV Cu/Cu CuSO4 is normally not harmful, but wasteful, however too
negative values may damage certain coatings due to formation of nascent hydrogen, by
disbonding them from the steel substratum.
In some situations, such as the presence of sulfides, bacteria, elevated temperatures,

acid environments and dissimilar metals, the above mentioned criteria may not be
sufficient.
When a pipeline is buried in dry or aerated high resistivity soil, values less negative than
the criteria listed above may be sufficient.
In general the maximum protection for well coated pipes shall be Pact = -2.000 mV
Cu/CuSO4
Situations involving stray currents and stray electrical gradients may exist that require
special analysis.
Where experience has shown that a certain current density has been effective in
protecting steel in a given relatively uniform environment, this current density, applied
uniformly, may be considered an indirect protection criterion. A value used commonly for
protection of bare steel pipe is a current density of 1 mA/sqft. This value will be higher for
structures in sea water or for special considerations in buried steel, such as the case of
presence of SRB (Sulfate Reducing Bacteria), where the current density might be as high
as 25 mA/sqft. When the CP are functioning continuously, polarization and ampere -hour
effects tend to reduce the current demand required for protection of the same structure.
The reduction in this current density will depend on the type of electrolyte and the
magnitude of the current amperage.
In the case of external tank bottoms, a current density of around 3 mA/sqft has been
regarded as, specially when the rebars in the ring foundation might accidentally contact
the steel bottom, and to take account of the loss of protective current towards the
grounding rebars or bare copper wire.
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8. COATING SELECTION
According to the general practice nowadays and also to standards concerning pipelines,
all new buried pipes, conducting products such as oil or diluent will be coated. No bare
pipe is considered in the project for its corrosion control.
Dielectric coatings are used to control electrochemical corrosion by acting as a barrier,

with varying degrees of success. If a coating were available at reasonable cost, which
could constitute a good electrical insulating barrier between the surface of the structure
and the electrolyte, and this coating could be applied and stay in perfect conditions without
any damage, breaks or Holidays, then no other form of corrosion control would be
needed. The corrosion cells would in effect be disconnected, as no metal could dissolve
into the electrolyte.
The fundamental role of a protective pipe line coating is to provide and electrical and
electrochemical barrier isolating steel from the corrosive soil, halting corrosion by
breaking the continuity of the electrical circuit by insulating anode and cathode areas. It
follows that a coatings fundamental property must be moisture uptake resistance,
guarding against further disbondment promoted by moisture penetration to the steel-
coating interface.
No coating system can be guaranteed to completely fulfill the basic requirements of

separating anode and cathode areas on a steel pipe from the corroding environment for
the lines design life. All coatings develop imperfections, and corrosion will occur at some
of these breaks in the insulating barrier, most often at an accelerated rate due to the small
area of metal exposed. When coatings are used in conjunction with cathodic protection,
complete control can be obtained with a minimum of applied current. CP acts as a
supplementary technique to contain corrosion processes at coating defects.
The coatings moisture resistance is one of the properties that really matters Moisture
uptake can markedly reduce coating mechanical properties, making it much easier for soil
stresses to damage the coating.
Coating defects determine CP need and it is the distribution of defect sizes and locations
that determines the potential profile along a pipe line. Interaction between the competing
processes of corrosion to dissolve metal and CP to prevent metal dissolution results in the
steel surface exposed at organic coating defects being covered with a layer of corrosion
products that provides a form of protection. This corrosion-product layer is called the
inorganic coating.
Fault causes in a buried pipe lines protective coating are mainly the following:
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Mechanical damage during construction that was not repaired.
Stone damage, particularly if there is pipe movement after construction.
Coating damage caused by tree root ingress.
Moisture uptake by the coating causing blistering and general decay.
Soil stress effects assisted by high operating temperatures and moisture uptake by
the coating.
Wrong coating choice for the lines operating conditions.
Poor parent coating repair techniques.
For a 20 year design life of the CP system, a current density of 1 mA/sqft will be adopted,
applied on an estimated 4 % percentage of the whole outer surface of the pipe. This value
also takes into account future damages due to aging of the coating, taken from the
technical literature and accumulated experience in other pipelines CP designs. Thus for
the design a density current of 0,04 mA/sqft of the total external surface shall be applied to
the total external surface of the pipes.
Electric isolation of the pipeline steel surface and soil surrounding it shall be achieved with
a coating of optimum quality such as FBE (Fusion Bonded Epoxy) or similar, applied in
Plant with a controlled procedure and inspected through several methods in all its steps,
through several methods, by Holiday Detection, in the field before laying the pipe in the
trench, and backfilling it. Experience from other pipelines for projects in areas in the
eastern part of the country with similar conditions (Monagas and Anzotegui States) have
been considered for the coating selection. However literature has indicated that FBE can
absorb water with the aging of the coating.
Another excellent coating is Coal Tar Urethane 1, a 100% solid high structure, auto -
adhesive and of high effectivity has a rapid curing time, excellent resistance to corrosion
and abrasion, and can be buried or covered in a short time after its application. It can be
applied in plant, field and also on the welds, being compatible with FBE and Trilayer FBE
system with polyethylene or polypropylene on the outside.
Other coatings such as Polyethylene tape/butyl adhesive coatings have been proposed for
buried pipelines, however the application of these tapes should be inspected thoroughly,
and done with machines. Moisture resistance of these coatings is determined by the tape
application procedure and the type and amount of adhesive mastic used to stick the tape
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to the pipe. In the case of expansive clays, special types of adhesive tapes should be
applied. Tree root penetration has a larger probability to occur than in the case of the thin
film epoxy coatings.
Sufficiency shall be considered for possible protection current loss to other existing or
future pipelines, of different diameters and older, buried in corridors to be shared or which
will be crossed, increasing the areas to be protected or the rectifier capacity.
Information should be recollected regarding the characteristics of the soil, such as pH,
Chloride Content, soil stresses (presence of expansive clays), and presence of Sulfate
Reducing Bacteria along the route, for the coating selection.
To evaluate the pipe coating behavior, -specially for critical pipes due to their high
pressure, or passing through different resistivity zones-, IR Drop Stations shall be
designed to measure the coating resistance and its behavior over the time. When several
pipelines parallel each other, the most critical shall be considered for the IR Drop station
installation. These IR Drop stations shall be designed at 3 to 5 mile distance between
each other.
9. RECTIFIERS
The selection of the transformer rectifier (T/R) or rectifier will be based on the current
demand required to protect the pipelines, with and adequate margin for pipe coating
damaging, during handling, transportation, laying in the trench, backfilling with excavation
material, the natural aging of the coating and future enlargement of the pipe systems.
Besides these considerations, the presence of possible Sulfate Reducing Bacteria

(SRB) shall be accounted for as these microorganisms can increase the current demand
up to 25 times that required for normal soils.
Rectifiers shall meet the latest applicable NEMA, ANSI, NFPA, Mil-C-456662 and T-M
Standards. Rectifiers shall be designed to operate continuously with a variation in DC
current and voltage output, to adapt to the deviations of the subsoil humidity, addition
protection current requirement, and maintaining the CP potentials. This is normally
achieved with the full rated DC output voltage by not less than 20 equal steps or with
proper dimensioned rheostats.
Rectifiers shall be air-cooled, Wayne Broyles, Good-All or similar, single or three phase,
manually adjustable with tap studs and link bars, 120/240 AC V input, with sufficiency in
DC current and tension for the CP systems.
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Similar rectifiers have been used for many years with good results for the Oil Industry
installations in the country.
The output ranges should permit, by simple adjustment means, an efficient equipment
operation, according to the yearly seasons and the anode beds resistance variations.
The CP design should be done, locating the required rectifiers, when possible, near the
zones of electrical energy availability o with nearby electrical lines, e.g. in the existing or
projected Plants.
10. INFLUENCE OF FOREIGN PIPELINES
The project pipelines can accidentally come in contact with other existing lines, some
quite old, with regular coating, while the new pipe would be well protected, e.g. in the
connection at the existing Plants. This should be considered to design isolation between
the different pipes.
11. ANODE GROUND BEDS
11.1. Impressed current anodes
The impressed current groundbeds selected to protect the project buried pipelines,
must correspond to a type of design wherein the header or positive cable of the
rectifier arrives at a junction box where the output current is distributed through a
common copper bus bar to an individual cable per pair or group of anodes, till their
location in the terrain. This consists in a layout where there is a positive (+) cable
coming from the rectifier to the box. Anodes are separated between 15 ft (5 m) to
22 ft (7 m) one from the other. During the design the position of the groundbeds
and anode separations will be defined. In the case of groundbeds with few anodes,
each anode will be connected to an individual cable.
The anode beds will be designed in a perpendicular position to the axis of the
pipeline, with the first anode separated 330 ft (100 m) from the first pipe
encountered in the corridor. This distance may change during the design, if
difficulties are found due to conditions and terrain characteristics or other
particularities. If there exist conditions that should require it, the groundbeds could
be designed in an angle with the pipeline axis or in a T distribution, parallel to the
pipe.
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The beds will be designed in such a way to locate them in zones with lower
resistivities, and thus during the fieldwork possible locations for the groundbeds will
be pre-selected, to take resistivity measurements a higher depths [up to 25 ft (8
m))] in a grid of 66 ft by 66 ft (20 m x 20 m).
In some cases in the area, such as Monagas, the soils have very high resistivities
and lower values are found at depths of up to 50 or 60 ft, and measurements
should be taken up to that depth, at separations of 6 ft (2 m), in order to determine
the resistivities by the Layer or Barnes Method. As the area of Zuata seems to be
similar to Monagas, possibly anode groundbeds might have to be designed up to
that depth.
In the case of soils with very variable resistivities, with some very high values,
where the highest resistivities can be a 100 or more times the lowest ones, the
groundbeds shouldnt however be located in the sites with very low resistivities,
because it might be very difficult to get an adequate distribution of the current
towards the pipes in the highest resistivities soils.
The design shall meet the general Criteria of designing the anode beds with a
minimum of eight (8) and a maximum of thirty (30) anodes, trying to obtain low bed
resistance.
According to the design results, sufficient capacity shunts and a variable resistor
shall be designed in the junction boxes, to permit the calibration of the output
current of each individual anode or group of anodes. The advantage of a design
with a variable resistor is that it permits control of each individual anode or group of
anodes output current, achieving a uniform attenuation curve along the header
cable and the adjustment of the current output per anode.
High Silicon Cast Iron 3 anodes will be designed for a maximum current output
of 5 A/anode, with a 1,2 A/sqft density current. For 2 the output will be less,
around 3 A/anode, with a 1,1 A/sqft discharge. In the case of MMO anodes a
higher output is permitted, according to the manufacturers technical sheets.
The anodes will be designed for vertical installation in a low value metallurgical
coke breeze column, not larger than 25 Ohm-cm, guaranteeing a good current
drainage. However as the national metallurgical coke breeze has some impurities,
it is wise to use imported coke breeze, of low resistivity, of the fluidified petroleum.
In the case where particular conditions so requires, the anode beds shall be
designed with the anodes installed in a horizontal way in a coke breeze bed.
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Where the soil is of very high resistivities, beds will be designed with petroleum or
metallurgical coke breeze of very low resistivities (1 Ohm-cm) and/or with treatment
around the anodes with low resistivity electrolytic mixes to reduce the groundbed-
to-soil resistance.
11.2. Sacrificial Anode Beds
Due to the high existing resistivities in the area, only in extreme cases sacrificial
Magnesium (Magnesium) anode beds will be adopted, to protect very short pipe
lengths buried in the Plants and road crossings, where the pipe length in contact
with the soil is 150 ft (50 m.) or less.
The Magnesium anode beds will be designed with the negative cable welded to
the pipe arriving at a box or test point, where the anode cable is connected,
intercalating a shunt to measure the current output and permit the calculation of the
remaining anode life. The cable terminals and the shunt will be fixed on a bakelite
sheet, to isolate them from the metallic box, unless weather resistant plastic test
points are designed. The number of anodes per bed will depend on the amount of
current output required.
Anode beds will be designed in a perpendicular position to the pipe axis, with the
first anode separated 10 ft (3 m.) from the pipe. This distance might be
reconsidered during the design, if difficulties are encountered due to the terrain
conditions or characteristics or other particularities. In the case of conditions found
that thus require it, the anode beds could be designed in a position slanting to the
pipe axis or in a T form, parallel to the pipe.
The beds will be designed in such a way to locate them in the zones of lower
resistivities (up to 10.000 Ohm-cm), and thus during the fieldwork possible sites for
the anodes will be preselected, in order to take resistivity measurements at depths
of 1 to 2 m.
This anode selection will be implemented, designing a shunt of 0,1 Ohm and 2 A
capacity (MCM Miller, Cott Mfg.) or similar characteristics in the test point, to
measure the small current output of the sacrificial anodes.
The current output of the anodes will be calculated as a function of the soil
resistivities, the geometric characteristics of the anode and the desired potential of
the pipe (-900 mV -1000 mV Cu/CuSO4 ).
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The magnesium anodes will be designed in a selected backfill of Gypsum,

Bentonite and Sodium Sulfate, in proportions according to the soil resistivities. In
sites with very high resistivities, the mixture will be designed increasing the
proportion of Bentonite and Sodium Sulfate, to reduce the resistance to soil of the
groundbeds.
12. CABLE SELECTION
The positive, negative and bonding cables shall be selected of stranded copper, Class B,
Type HMWPE (CP cable, High Molecular Weight Polyethylene) or TTU (Polyethylene
covered with PVC) for direct burial.
The cable gages will be selected for the maximum current capacity, e.g. # 8 AWG (max.
cap. 45 A DC) for the anode cables. The bonding cables between pipes will be Type
HMWPE or TTU # 8 AWG (max. cap. 45 A DC) for mechanical resistance.
The negative copper cables shall be HMWPE or TTU # 2 AWG (max. cap. 115 A DC). In
the case of parallel pipes in corridors, or joint systems, the negative cables will be taken to
a common copper bus bar in the junction box for negative cables, were adjustable power
resistors or rheostats, rated for the respective cable current will be inserted. From this
place a single # 2 AWG THW will connect the bar to the rectifier negative terminal.
Some cables for the monitoring system will be stranded Class B copper THW, properly
rated for each situation as detailed in the Project drawings.
13. ELECTRICAL ISOLATION
The CP system shall be designed restricting the current on the project pipe stretches and
trying as much as possible to avoid current loss towards other structures connected
mechanically to them, such as the arrival or outgoing of the pipes at Plants or any lateral
pipe. In the project the pipes will be isolated at the Wellheads, Main Plant and Zuata.
This purpose will be achieved designing monolithic joints or isolating flanges at these
points, to avoid the passing of the current further on from the pipe. In order to protect the
insulating components of those isolation flange kits or monolithic joints from possible
atmospheric electric discharges that could fall on the pipeline aboveground parts or
valves, polarization cells shall be designed of the type consisting of plastic containers with
pure Nickel plates in KOH solution, or direct current isolation capacitors, located in
outdoors steel enclosures near the joints.
SINCOR
Contacts will be avoided as much as possible, between the reinforcing bars of concrete
pipe supports or crossing elements and the pipe or casings under road crossings.
14. BOND DESIGNS
In order to avoid possible failures on foreign lines by interference of the CP system

currents of the project buried pipelines and to achieve a better current distribution
electrical bonds will be designed in those principal crossings with foreign pipes in the
pipe corridors. Those electrical bonds will be executed, where feasible in negative
junction boxes or designed for that purpose.
All pipeline that should appear during the construction and that was not detected
beforehand or during the field work, of 8 size or larger should be electrically bonded.
When lesser diameter gas lines or high pressure lines are found, the need for their bond
should be studied during the Commissioning of the CP, based on the pipe to soil potential
measurements. Under no circumstances direct burial pipe crossings will be permitted,
without a test point, even if the bond is identified.
15. SURVEY METHODS USED IN CATHODIC PROTECTION WORK
15.1. Type of Survey
To determine the need for and applicability of cathodic protection, special

instrumentation and experience are required. As both corrosion and CP are
electrochemical in nature, the corrosion-CP surveys consist essentially of a well
organized and correlated series of electrical measurements. The most important of
these are:
Electrolyte resistance or resistivity measurement.
Structure-to-electrolyte potential measurement of existing structures. In the case
of SINCOR UPSTREAM these would pipe-to-soil (P/S) and tank-to-soil (T/S)
potential measurements.
Current requirement surveys for existing structures.
IR drop (current flow) measurements, either in the structure itself or in the
surrounding electrolyte. In the first case this would be done on existing
structures.
15.1.1.Soil Resistivity Measurements
Soil resistivity or the resistance of the earth to current passing through it, is
very important to obtain values which will indicate the aggressiveness of
SINCOR
the electrolyte. Soils with low resistivities will be corrosive to buried steel,
but will also be adequate to design corrosion control procedures. Soils with
high resistivities will not be corrosive, but at the same time offer a high
resistance to pass current through them for any CP system to be designed.
Even though high soil resistivities are not corrosive, the presence along a
pipeline of areas with low and high resistivities might generate corrosion
currents, that have to be taken into account. The same might happen under
tank bottoms with soils of different resistivities in contact with the steel
plates.
Soil resistivity values are important for CP designs in the case of buried
structures as they will give values to design the sacrificial anode system or
where to select the most adequate location for the impressed current
ground beds.
In Table I prepared by Gummow3 , values of aggressiveness of the soils are

given for different resistivities.
The corrosivity of an electrolyte can be categorized by its respective

electrical resistivity. Soils exhibiting electrical resistivities of less than
1,000 Ohm-cm are usually classified as severely corrosive. The soil
resistivity does not change with respect to moisture content where this is
above 15 to 20%. As most soils at pipe depth are above this figure, the
resistivity of the soil is a function of the number of conducting ions in
solution. For instance sea water which has approximately 3% sodium
chloride, has a very low resistivity (20 to 30 Ohm -cm, depending on the
geographical location) and hence is a very corrosive electrolyte.
3
CORROSION AND CATHODIC PROTECTION OF UNDERGROUND METALLIC WATER PIPING SYSTEMS, R.A. Gummow, presented at the
A.W.W.A., ONTARIO SECTION MEETING, HAMILTON, ONTARIO, MAY 30th, 1979
SINCOR
TABLE I
ANTICIPATED CORROSION OF STEEL EXPOSED TO SOILS
IN VARYING RESISTIVITY
Resistivity Range Classification Normal Life

Ohm-cm Expectancy, Years
AFM 88-9 (1) Corrosion Activity
0 - 2,000 Severe --
2,000 - 10,000 Moderate --
10,000 - 30,000 Mild --
> 30,000 Unlikely --
Senatoroff (2) Corrosion Activity
0 - 749 Extremely Corrosive --
750 - 2,599 Corrosive --
2,600 - 9,999 Moderately Corrosive --
10,000 and more Non-Corrosive --
Ewing (3) Corrosion Activity
0 - 2,000 Bad 0 - 10
2,000 - 4,500 Fair 10 - 17
4,500 - 6,000 Good 17 - 25
6,000 - 10,000 Excellent 25
Romanoff (4) Corrosion
700 Very Corrosive --
700 - 2,000 Corrosive --
2,000 - 5,000 Moderately Corrosive --
Greater than 5,000 Mildly to Non-Corrosive --
Husock (5) Soil Resistivity
Less than 1,000 Very Low Possibly 5 years (6)
1,000 - 5,000 Low Possibly 10 years (6)
5,000 - 10,000 Medium Difficult to predict
Greater than 10,000 High Depends on
homogeneity of soil
1) AFM-88-9, Chapter 4, page 27, 1 August 1962.

2) N.K. Senatoroff, Journal A.W.W.A., Vol. 43, pp. 1017-1020 (1951).
3) S.P. Ewing, Soil Corrosion and Pipe Line Protections, American Gas Association, York
(1938).
SINCOR
4) M. Romanoff , Results of National Bureau of Standards Corrosion Investigations in Disturbed

Bed and Undisturbed Soils, Proceedings of the Fourteenth Annual Appalachian Underground
Corrosion Short Course, 1969, pp. 433-456.
5) B. Husock, Harco Corp., Cleveland, Ohio, 21 August 1970.
6) Means one would be lucky if no corrosion failures occurred in the structure within this time
period. It does not infer that the structure would be corroded beyond repair.
SINCOR
15.1.2.Potential Measurements
The potential measurements are usually given in milliVolts or Volts. As the

voltage is really a difference of two potentials, the potential is a voltage
reading between the structure under study and a convenient reference
electrode, placed in contact to the electrolyte as near as possible to the
structure. For underground structures and tank bottoms a copper/copper
sulfate half cell is widely used.
Typical potential values for different metals in neutral soil or water,

measured with respect to a copper/copper sulfate reference electrode, of
more practical value for the Corrosion Engineer are presented in the
Galvanic Series, Table II, which is the listing of the relative electrical
potentials of some common metals in a sea water environment using a
copper/copper sulfate electrode. This same galvanic series is also found
for soil and other environments, but the relative position is always similar to
the one shown. In this series the more negative potentials denote the most
active elements which are the ones with the largest corrosion tendency.
TABLE II
GALVANIC SERIES
METAL Millivolts
MAGNESIUM (COMMERCIALLY PURE) -1750 - active
ZINC
ALUMINUM ALLOY (5% ZINC) -1100
COMMERCIALLY PURE ALUMINUM -1050
MILD STEEL (CLEAN AND SHINY) -800
MILD STEEL (RUSTED) -500 to -800
CAST IRON (NOT GRAPHITIZED) -200 to -500
LEAD -500
MILD STEEL IN CONCRETE -500
COPPER, BRASS, BRONZE -200
HIGH SILICON CAST IRON -200
MILL SCALE ON STEEL -200
CARBON, GRAPHITE, COKE -200
+400 - noble
The meaning of structure is any steel buried or in contact with the soil or
immersed in water. In general the structures referred to in this document
SINCOR
are buried coated pipelines or tank bottoms, however the discussion is

applicable to any other structure in its environment, such as grounding
copper bars or bare cable.
The potentials measured in corrosion control usually range from a few

milliVolts to several volts, and to obtain accurate measurements against
the reference cell, an instrument of high internal resistance is required. In
general a digital multimeter complies with this requisite.
For most of the measurements taken during potential surveys this

instrument, a reference electrode and the necessary test leads, one
connected to the reference half-cell and the other to the contacting device
make up the minimum required equipment. A spare reference electrode
and a water jar are very useful to complete the measurement.
In high resistivity soils, such as the probable case of the pipelines between
Main Station and Zuata, some measuring stations with buried probes
and/or permanent reference electrodes will be designed, to eliminate IR
drops in the P/S potentials. Permanent copper/copper sulfate electrodes
for 15 years or of the gel type for a longer life are desirable. Nowadays
electrodes of the copper sulfate gel type for a long life are available with a
guaranteed thirty (30) years of operation.
In the case of tank bottoms, where it would be impossible once erected, to

access underneath the bottom steel plates to measure tank-to-soil (T/S)
potential values at the center and the outer ring of the tank, permanent
reference electrodes are usually designed, selecting copper/copper sulfate
permanent electrodes of the gel type for a long life. Nowadays electrodes
of this type are available with a guaranteed thirty (30) years of life.
In making the survey, the structure is contacted through a device such as an

icepick or other instrument with a point, connected to a test lead finishing at
the positive terminal of the multimeter. It is extremely important that a good
low-resistance contact is established with the metal of the structure,
piercing through the paint if the steel is coated. The other lead will be
connected at the negative terminal, ending at the portable half-cell,
contacting the electrolyte or soil during the test. If the soil is dry it should be
wetted in order to reduce the resistance for the measuring procedure. If a
copper/copper sulfate is used the pipe will exhibit a negative polarity on the
multimeter. In the case of buried structures, when making measurements
SINCOR
with the Cu/CuSO4 half cell, and in absence of stray currents, the polarity
will not be of a large concern, as the potentials will in general have a
negative value. However, when a zinc reference cell is used, as in the case
of permanent electrodes, and measurements are done in sea water, the
polarity of the potential is of utmost importance, as the result has to be
converted into Cu/CuSO4 values, for comparison with standardized
potentials.
The values of potentials are measured, indicating the conditions of the

weather at the moment of the test, and the location of the structure where
the potentials were taken. Fixed or well identified test points are very
convenient in order to compare the values of measurements taken at the
different times and have a trend of the behavior of the structure under
different conditions.
Under native conditions, areas of more negative potentials on the structure

such as pipelines, indicate anodic or corroding areas. However, when
protective current is applied, the more negative potentials due to
polarization by the protective current will indicate if CP has been achieved
according to standards.
15.1.3.IR Drop (Current Flow)
The direction of the flow of direct current involved in corrosion and CP,
specially in the case of pipelines, can be determined using a multimeter. In
the case of a pipeline without any CP applied, the area or location where
current flows from the structure to the earth indicates an anodic zone where
corrosion is occurring. This can be detected by noting direction and
magnitude of current flow in the pipe. The point along the pipe, where the
value reaches its maximum and reverses the direction of flow is the point
where corrosion is occurring.
Because the same current flowing along the pipe must also be flowing in
the adjacent soil, where the larger soil resistance produces millivolt
readings of greater magnitude than in the pipe, the measuring procedure is
usually modified. This is called the surface potential or two electrode
survey, requiring a multimeter (or high resistance voltmeter) with polarity
reversal indication, two Cu/CuSO4 electrodes, and suitable test leads
connected to the instrument. For more accurate results, the crew should
SINCOR
have a pipe detector and a soil resistivity meter, so as to stay immediately

over the pipe and to know the soil resistivities at the anodic areas.
The two electrodes, calibrated to read within two milliVolts of each other,
are placed over the pipe at a suitable distance apart, usually 20 ft and the
potential difference and electrode polarity is read on the multimeter and
recorded. The electrodes are then leapfrogged down the line maintaining
the same separation, and the millivolt readings and polarity recorded over
the full length of the line under survey. Pipe-to-soil potentials are not
necessary, but it may be desirable to have their values.
Anodic and cathodic areas on the unprotected pipe are identified as points
of potential reversal. The anodic areas are identified during the survey, and
soil resistivities are measured at those locations. Direct current volt
gradients, also called side drains with the two electrodes positioned
perpendicularly to the pipeline are obtained at these spots and also on
cathodic areas.
The corrosion engineer will analyze the different results and use them for
the CP designs, with sacrificial or impressed current anodes.
15.1.4.Current Demand Tests
The actual amount of current required for cathodic protection of a given

structure can be determined in different ways. Cathodic protection in this
section is meant complete corrosion control, according to the Criteria
given in Standard NACE RP0169.
If the pipeline or other structure, lies in soil or water of known general

characteristics, the experienced corrosion engineer can design the
cathodic protection system applying a selected current density (mA/sqft) to
the structure, provided he is careful to distribute the current properly. This
protective current density will be applied to the defects of the coating.
Current density is however the unit most widely used and is defined as
the current applied divided by the total surface of the structure surface to be
protected. In the case of a coated pipeline thi s means dividing the current
demand by the whole surface, including the defects or Holidays in the
coating.
SINCOR
The bottoms of the above ground storage tanks (ASTs) shall be bare
metal in contact with the electrolyte, as very seldom the underpart of the
steel tank plates are coated before erecting the tank. All pipes carrying
products will be coated with an appropriate dielectric revetment.
In most of the cases when new installations are considered, the corrosion
engineer will have to use his best judgment to select the current density
during his design to dimension the cathodic protection system. When
cathodic protection has to be designed for existing steel structures, such
as bare or coated pipelines, or tank bottoms, it is advisable to install a
temporary cathodic protection system and measure potentials till the
structure has been protected according to NACE standards. This
temporary installation consists of a current source, impressing current
through temporary anodes, and positive and negative cables. If possible in
existing installations the structure being studied should be isolated
temporary, so as to restrict the protective current on its surface. If this is not
possible, measurements should be taken to determine the spread or loss
of cathodic protection current towards other structures.
The current source used might be a battery for small amounts of currents, a
generator or welding machine, or an existing rectifier, for larger amounts of
current (up to 100 A DC). The temporary anodes should be located
strategically, around or near the structure to be protected. The anodes
might be steel rods or steel pipes (carbon or galvanized) driven in the soil,
abandoned lines or well casings, the vertical pipes of cyclone fences driven
in the soil, and even aluminum foil has been used, covered with earth to get
a better contact. A good practice is to wet the soil around the temporary
anodes, and in some cases add some salt, to lower the resistance of the
anode to soil. If the location for the anode beds has been predetermined, it
is advisable to locate the temporary anodes near these places.
Before applying the test current P/S natural potentials should be measured,
and afterwards when the current has been applied for a certain time, about
2 to 4 hours, depending on the characteristics of the electrolyte (soil or
water). In sea water the polarization of the protected structures can be
observed in a short time, but in high resistivity soils, the current should
sometimes be applied for a whole night prior to making the final
measurements. The time of all measurement should be recorded to
appreciate the electrical polarization of the structure. Besides de Pnat
measured before the test, active potentials (Pact) should be measured at
SINCOR
different times. Besides the Pact, measurements should be done

interrupting the current, recording the value of the potential before the
interruption and immediately after cutting the current. These potentials are
called Pon and Poff values, and they are of extreme importance to
determine if CP has been obtained.
Poff values with a value of -850 mV Cu/CuSO4 or more negative indicates

cathodic protection has been achieved. If a depolarization or loss of
potential is equal or larger than 100 mV this also indicates cathodic
protection of the structure at the site the measurement was taken. Anyone
of these two criteria can indicate cathodic protection of the structure under
study.
In the case of ASTs, the measurements should be done using the

measuring points on the circumference of the tank to locate the portable
half-cell, and the permanent reference electrodes buried underneath the
tank. With a portable cell inserted along the perforated PVC pipe located
along a diameter of the tankbottom, a profile of the tank-to-soil
measurements can be drawn.
If The only measurements that can be taken are those of the circumference,
than other approaches should be used to estimate the T/S potentials
towards the center of the tank.
If its not possible to obtain full cathodic protection, the measured values of
potentials and the DC current output can be used to estimate the values of
the electrical parameters, such as amperage and voltage of the rectifier or
the number of galvanic anodes if the current demand is low.
SINCOR
16. CATHODIC PROTECTION CALCULATIONS AND DESIGN
The calculation and design of the CP Systems will cover the following subjects:
Analysis of the resistivity values along the routes of the different sections of the project
pipes.
Current demand calculated with the data of the different sections of the project pipes.
Interpretation of the P/S potential data of existing pipeline (with test points and
available), that cross or go parallel to the project pipelines.
Analysis of the behavior of the existing CP systems along the proposed pipe routes.
Analysis of the current demand and the CP levels achieved by other existing pipelines
crossing or paralleling the project lines. The current demand should consider a certain
amount of current that might be lost to other structures in the vicinity, if accidental b onds
might occur during construction of the installations (grounding systems attached to
tanks, pumps connected to pipelines, etc..).
Rectifier dimensioning.
CP groundbed designs with tubular Mixed Metal Oxide (MMO), cylindrical High
Chromium Cast Iron (FeSiCr) or other proven type of anodes for the pipelines between
the Main Station and Petrozuata.
CP groundbed designs for the tank bottoms, taking into account the probable high
resistivity of the soil in the area, to select a system with ribbon titanium anodes and
conductor bars located underneath the tank bottoms in the fill of the foundation.
Dimensioning of the positive and negative cables, and variable resistors in the junction
boxes.
Calculation of the electrical grounds for the CP equipment, rectifier and junction boxes.
Calculation of CP with sacrificial magnesium anodes in short stretches of pipes inside

the Plants, if resistivity values permit the use of these sacrificial anodes.
Calculation of Polarization Cells in isolation flanges or insulating joints, for their

protection or where there are High Voltage Electric Power Transmission Lines (HVL)
nearby or there is a danger of electric discharges.
SINCOR
Calculation of Polarization Cells in places where the towers of the HVL are at less than
30 m away from the project pipelines, and where the pipelines parallel the electrical
transmission lines.
Calculation of the influence of the HVL crossing the proposed pipelines.
17. CATHODIC PROTECTION MONITORING
The criteria for CP monitoring is based on the need to know if the CP systems are
working properly or not, if CP has been met according to NACE RP0169-96 or other
applicable Standards, and the necessity of their continuous operation and maintenance.
For this reason the following CP monitoring controls have been designed for the buried
sections of the project, pipelines or tank bottoms of the ASTs:
Standard Pipe to Soil (P/S) potential test points (N) along the pipe route.
Critical Areas P/S potential test points (ACR), at sites such as asphalt covered roads,
rivers, mayor creeks or sudden changes of the terrain topography or geology, along the
proposed pipe route.
P/S potential test points, at other pipe crossings or where the pipes parallel foreign
lines along the proposed route.
P/S potential test points, with buried probes and/or coupons, where the pipes parallel
other lines in corridors, specially in high resistivity soils.
P/S potential and sacrificial (magnesium) anodes test points, where special conditions
might require this type of anode, and the resistivity of the soil permits their use.
P/S potential test points, at monolithic isolation joints or insulating flanges, at both ends
of the different pipes (Main Station and Zuata), to observe the behavior of this electric
parameter on both sides of the isolating piece.
Tank bottom to soil potential measurements with portable electrodes at fixed

measuring points along the perimeter of the tanks.
Tank bottom to soil potential measurements with permanent reference electrodes

buried underneath the tank bottom at different locations and along the buried perforated
PVC pipe located along the diameter of the tank bottom, to obtain a profile of the T/S
potentials.
SINCOR
Inclusion in the distribution or junction boxes of shunts to measure current output going
to the CP impressed current system anodes and variable resistors to adjust this current
output if required. This will be used both on the CP systems for the buried pipelines as
well as for the anodes underneath the tank bottoms.
IR drop test stations for the pipe lines, to monitor coating and resistance to soil.
For the Monitoring and Commissioning Phase, as well as for the Operation and
Maintenance, a Manual should be prepared at the Detailed Engineering Level for the
pipelines and tankbottoms cathodic protection.

CA04!04!33 P SP 030 - X2 Cathodic Protection

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SINCOR

Project Title: SINCOR, C. A. Document: CA04-04-33-P-SP-030

ELECTRICAL CATHODIC PROTECTION

This document consist of the following number of pages: 31

Prepared By/ Checked By/ Project SINCOR

2. CODES AND STANDARDS 4

5. APPLICATION OF CATHODIC PROTECTION TO OIL & GAS PRODUCTION EQUIPMENT

6. CATHODIC PROTECTION PRINCIPLES 9

7. PIPE TO SOIL POTENTIALS 9

10. INFLUENCE OF FOREIGN PIPELINES 15

11. ANODE GROUND BEDS 15

11.1. Impressed current anodes 15

12. CABLE SELECTION 18

13. ELECTRICAL ISOLATION 18

14. BOND DESIGNS 19

15. SURVEY METHODS USED IN CATHODIC PROTECTION WORK 19

15.1. Type of Survey 19

16. CATHODIC PROTECTION CALCULATIONS AND DESIGN 29

17. CATHODIC PROTECTION MONITORING 30

2. CODES AND STANDARDS

a) NACE RP0169, Control of External Corrosion on Underground or Submerged

b) NACE RP0286, The Electrical Isolation of Cathodically Protected Pipelines.

c) BSI-CP 1021, Code of Practice for Cathodic Protection (latest edition).

d) NACE Standard MR0175, Standard Material Requirements, Sulfide Stress Cracking

e) Steel Structures Painting Council Specifications.

Cathodic Protection (CP) is a technique applied to underground and submerged

In petroleum production and transmission, it is the naturally occurring electrochemical

5. APPLICATION OF CATHODIC PROTECTION TO OIL & GAS PRODUCTION

The pipelines to be protected in UPSTREAM SURFACE FACILITIES PROJECT

Short underground pipelines in the Main Station, considered of importance, that

Flowlines that might be connected to protected trunklines should be electrically

5.2. Aboveground Storage Tank Bottoms

5.2.1. External Protection

The external bottom of the tanks are prone to developing corrosion

5.2.2. Internal Protection

Because of the layer of conducting bottom sediment and water (BS&W) in

Permanent reference electrodes can be designed crossing the tank walls,

5.3. Well Casings

Well casing require amounts of current falling in the range of 1 to 25 A DC for

One of the problems occurring is the presence of corrosion by interference

Information should be recollected concerning the corrosion or not of the existing

Should it be decided to protect the well casings, NACE Recommended Practice

6. CATHODIC PROTECTION PRINCIPLES

Electrochemical corrosion can be mitigated by the proper application of cathodic

7. PIPE TO SOIL POTENTIALS

The effectiveness of CP or other corrosion control measures can be reaffirmed by visual

Corrosion control can be achieved at various levels of cathodic polarization2 , with

A negative potential (cathodic) potential of at least 850 mV with CP applied. This

A negative polarized potential of at least 850 mV to a saturated copper/copper sulfate

A minimum of 100 mV of cathodic polarization between the structure surface and a

Overprotection of steel structures, i.e. generation of polarized potentials much more

In some situations, such as the presence of sulfides, bacteria, elevated temperatures,

Dielectric coatings are used to control electrochemical corrosion by acting as a barrier,

No coating system can be guaranteed to completely fulfill the basic requirements of

Mechanical damage during construction that was not repaired.

Stone damage, particularly if there is pipe movement after construction.

Coating damage caused by tree root ingress.

Moisture uptake by the coating causing blistering and general decay.

Wrong coating choice for the lines operating conditions.

Poor parent coating repair techniques.

Besides these considerations, the presence of possible Sulfate Reducing Bacteria

10. INFLUENCE OF FOREIGN PIPELINES

11. ANODE GROUND BEDS