Cathodic Protection Design

GAMBA EXPORT LOADING LINE (SHELL GABON)
Cathodic Protection Design

Issued
Date
10/12/13
Sht.
No.
2 of 19
PROJECT NUMBER: 13027

DOCUMENT NUMBER :
Z.205.1
REVISION CONTROL SHEET

REV.NO
DATE
SECTION NO.
SUMMARY OF CHANGES
Rev. No.
A

Issued
Date
10/12/13

DOCUMENT NUMBER :
Z.205.1
Sht.
No.
3 of 19
TABLE OF CONTENTS
1.0
INTRODUCTION .............................................................................. 4
General ......................................................................................... 4
Scope ............................................................................................ 4
2.0
UNITS AND ABBREVIATIONS ....................................................... 5

System of Units ............................................................................. 5
Abbreviations ................................................................................ 5
3.0
SUMMARY OF RESULTS & RECOMMENDATIONS ...................... 6

Results Summary .......................................................................... 6
Recommendations ........................................................................ 8
4.0
DESIGN DATA ................................................................................ 9

Pipeline Data ................................................................................. 9
Environmental Data ....................................................................... 9
Anode Data ................................................................................. 10
5.0
DESIGN METHODOLOGY ............................................................ 11

General ....................................................................................... 11
Current Demand Calculation ....................................................... 11
Anode Mass Calculation .............................................................. 13
Calculation of Number of Anodes ................................................ 13
Design Assumptions .................................................................... 15
6.0
RESULTS ...................................................................................... 16
Anode Properties......................................................................... 16
Cathodic Protection Requirement ................................................ 16
7.0
REFERENCES ............................................................................... 18
APPENDIX A SAMPLE OF CATHODIC PROTECTION CALCULATION .... 19
Rev. No.
A

Issued
Date
10/12/13
1.0

DOCUMENT NUMBER :
Z.205.1
Sht.
No.
4 of 19
Rev. No.
A
INTRODUCTION
General
Shell Gabon is operating and producing oils from numerous fields located in the western
part of Gabon. Crude is treated and exported from the Gamba Terminal to tankers through
a 30 inch offshore export line connected to a SBM via a PLEM and 2 x 16 inch floating
hose strings (risers).
The total length of the existing export line is about 10.7km from the export pump in Gamba
terminal to a PLEM (1.3km located onshore and 9.4km located offshore).
Figure 1-1 Project Location
Shell Gabon intends to replace the existing export pipeline. Zeetech B.V. has been
awarded by Shell to perform a concept replacement study and Front End Engineering
Design (FEED) for the selected concept.
Scope
This report presents cathodic protection design of new dual 22 inch Gamba export line for
onshore and offshore sections including its expansion spools in accordance with
Company Design Engineering Practices (Ref. 1 and Ref. 2).

Issued
Date
10/12/13
2.0

DOCUMENT NUMBER :
Z.205.1
Sht.
No.
5 of 19
Rev. No.
A
UNITS AND ABBREVIATIONS

System of Units
In accordance with Shell DEP 00.00.20.10, the International System (SI) of units is
adopted as the main system of units unless noted otherwise.
Abbreviations
CP
Cathodic Protection
DEP
Design Engineering Practices
DNV
Det Norsk Veritas
FEED
Front End Engineering Design
KP
Kilometer Post
ISO
International Standard Organisation
PLEM
Pipeline End Manifold
w.r.t.
With relation to

Issued
Date
10/12/13
3.0

DOCUMENT NUMBER :
Z.205.1
Sht.
No.
6 of 19
Rev. No.
A
SUMMARY OF RESULTS & RECOMMENDATIONS

Results Summary
The required cathodic protection of the dual 22 inch Gamba export line from onshore
Gamba terminal to offshore PLEM/SBM has been designed in accordance with Ref. 1
and Ref. 2 for onshore and offshore pipelines respectively.
The onshore pipeline will be buried from KP 0.0 to KP 1.1 outside Gamba Terminal area.
Based on the On-bottom Stability report (Ref. 7), for the onshore pipeline which is buried
underneath the water table will have a concrete coating of 50mm. Therefore, a bracelet
sacrificial anode is used in-line with the offshore pipeline cathodic protection system. The
offshore pipeline will be buried from KP 1.1 to KP 1.3 and the remaining section up to KP
10.6 will be laid on the seabed.
Anode quantities have been selected to satisfy the following criteria:
Total anode net mass shall meet the current demand over the design life of the
pipeline;
Anode current output shall meet the current demand at the end of design life;
Anode spacing shall not exceed the maximum value of 300m as specified by Sec.
7.1 of Ref. 4.
Table 3-1 below show the required anode quantities from the analysis to meet the design
criteria stated above.

Issued Date
10/12/13

DOCUMENT NUMBER : Z.205.1
Sht. No.
7 of 19
Rev. No.
A
Table 3-1 Summary of Cathodic Protection Design for a 22in Gamba Export Pipeline
Pipe
Section
Onshore
Pipeline
KP Range
Length
(m)
Mass of
Exposure
Condition
one
anode
(kg)
Total
Required
anode net
Final
mass to
Individual
meet
Anode
current
Current
demand
Output
(kg)
(A)
Actual
Individual
Final
Current
Output
(A)
Required
Required
number of
anode
anode to
spacing to
meet total
meet total
anode net
anode net
mass
mass
(ea)
(m)
Required
Required total
Recommended
number of
anode weight
Spacing of
anode based
based on
(1)
anode
(joints)
on
recommended
recommended
spacing
spacing (ea)
(kg)
0.20 1.07
1100
Buried
21
93
0.059
0.09
248
13
273
1.07 1.24
200
Buried
28
0.063
0.18
1050
24
28
1.24 10.6
9300
Un-buried
28
674
0.212
1.37
24
390
24
32
896
25
Un-buried
28
0.485
1.37
164
28
Offshore
Spool
Notes:
1. Anode spacing of 300m (24 joints) for offshore pipeline has been recommended in accordance with the requirements of Ref. 2.
2. Dual 22 in Gamba export pipeline will be routed parallel from Gamba terminal to the PLEM/SBM, hence the anode required above shall be applicable
to both pipelines.

Issued
Date
10/12/13

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Rev. No.
A
Recommendations
The following recommendations shall be addressed in the next design stage.
The individual anode mass is selected based on minimum required number of

anodes to meet total anode net mass. Anode dimension of the anode may be
adjusted during detailed design based on the anodes supplier data.
Onshore soil resistivity considered for the design is based on assumptions. It is

recommended to update the value once the actual survey data becomes
available.
To protect the un-buried onshore pipeline/piping section inside the Gamba

Terminal from the offshore cathodic protection system to interfere, an isolation
joint shall be introduced to separate these two systems.

Issued
Date
10/12/13
4.0
Sht.
No.
9 of 19

Rev. No.
A
DESIGN DATA
The following subsections presents design data used in the cathodic protection design.
Pipeline Data
The pipeline properties used in the design are presented in Table 4-1 below. This data
is applicable to both pipelines.
Table 4-1 Gamba 22in Pipeline Data
Descriptions
Units
Pipeline Design Life
22in Gamba
Export Lines
years
25
Onshore
1100
Offshore
9500
Spool
25
Outside Diameter
mm
558.8
Selected Pipeline Wall thickness
mm
10
Onshore
mm
50
Offshore
mm
65
Spool
mm
3LPE
mm
3.2
Pipeline Length
Selected Concrete
Coating thickness
Anti-Corrosion Coating Material

Anti-Corrosion Coating Thickness
Environmental Data
The seawater resistivity of 0.22m has been taken from Figure A.1 of Ref. 4. A salinity
of 3% and seawater temperature of 25oC has been assumed in the analysis.
A resistivity of the seabed sediments is considered as 1.5m in accordance with Sec.
A.9 of Ref. 2.
For onshore section, a soil resistivity of 3.4m has been assumed.

Issued
Date
10/12/13
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No.
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19

Rev. No.
A
Anode Data
Refer to Ref. 2, aluminum alloy anodes has been used for sacrificial anodes material. A
flush mounted bracelet anode has been selected.
Design values of the galvanic anode has been extracted from Table B of Ref. 2 and
shown in Table 4-2.
Table 4-2 Anode material properties
Immersed in Seawater
Anode
Buried in Seawater Sediments
Surface
Potential
Electrochemical
Potential
Electrochemical
Temperature
Ag/AgCl/Seawater
Capacity,
Ag/AgCl/Seawater
Capacity,
(mV)
(A.h/kg)
(mV)
(A.h/kg)
30
-1050
2000
-1025
1600
60
-1050
1600
-1025
680
80
-1000
720
-1000
320
( C)
For non-buried pipeline, the anodes surface temperature has been taken as the external
pipeline temperature, not the internal fluid temperature.
As per Sec. 7.4 of Ref. 2 a utilization factor of 0.85 has been used for the bracelet and
flush mounted anode.
Anode alloy density is assumed to be 2700kg/m3.

Issued
Date
10/12/13
5.0

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Rev. No.
A
DESIGN METHODOLOGY
General
Cathodic protection design for new dual 22in Gamba export line is in accordance with
the Shell DEP 30.10.73.31 (Ref. 1) and Shell DEP 30.10.73.32 (Ref. 2) for onshore and
offshore pipeline respectively.
Anode quantities are selected to satisfy the following criteria:
Total anode net mass shall meet the current demand over the design life of the
pipeline;
Anode current output shall meet the current demand at end of the design life;
For offshore section, anode spacing shall not exceed the maximum value of
300m as specified by Sec. 7.1 of Ref. 4.
Current Demand Calculation

The mean current demand, Icm, and final demand is calculated from:
=
Where:
current demand for specific pipeline section (A)
total surface area for specific pipeline section (m2)
coating breakdown factor, calculated for mean and final conditions
current density, selected for mean and final conditions (A)
The coating breakdown factor is calculated based on equation (1) and (2) of Ref. 4. For
mean coating breakdown factor is,
= (1.75 ) + (0.5 )
For final coating breakdown factor is,
= (1.75 ) + ( )

Issued
Date
10/12/13
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No.
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19

Rev. No.
A
Where:
initial coating breakdown factor at start of pipeline operation;
To account for coating damage during fabrication and installation or workmanship
damage, factor of 1.75 is used as recommended by Ref. 2 Sec. 6.5.
average yearly increase in the coating breakdown factor;
design life of the pipeline (years).
For offshore pipeline, the initial coating breakdown factor are extracted from Table 3 of
Ref. 4.
Table 5-1 Coating breakdown factor Offshore Section
Coating Type
Multilayer (incl. FBE primer) polyethylene

(PE) and polypropylene (PP) anti-corrosion
Multilayer
(incl.
FBE
primer)
PE/PP
corrosion + concrete
Factor
0.005
0.0002
0.002
0.0001
The coating breakdown factors given refer to both pipelines exposed to

seawater and pipelines buried in the seabed.
Recommended mean current density has been extracted from Figure 2 of Ref. 4 using
the upper conservative curve. Mean current density of 0.068 A/m2 for 25oC of seawater
temperature is used in the analysis.
For pipeline fully buried in sediments or artificially covered (e.g. rock dumping), a design
current density (mean and final) of 0.02 A/m2 is used.
For onshore pipelines, the current densities which has been multiplied by coating
breakdown factor is extracted from Table-1 of Ref. 3.

Issued
Date
10/12/13
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No.
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Rev. No.
A
Table 5-2 Design current density & coating breakdown factor for Onshore Pipeline ( * )
Design current density(1)

Pipeline coating
10-yr design
20-yr design
30-yr design
life
life
life
0.08
0.1
0.4
3-layer epoxy-polyethylene
3-layer epoxy polypropylene
(1) Refer to Ref. 3, for pipelines operating at elevated temperatures, the current density value shall be
increased by 25% for each 10oC rise in temperature above 30oC.
Based on Table 5-2 above, for fluid temperature of 55oC, design current density which
has been multiplied by coating breakdown factor is taken to be 0.000375 A/m2.
Anode Mass Calculation

The total net anode mass required to maintain cathodic protection throughout the design
life is calculated based on equation below.
=
8760
Where:
total net anode mass (kg)
mean current (Ampere)
design life (years)
electrochemical capacity of the anode material (A.h/kg)
utilization factor (0.85 for bracelet flush mounted anodes Sec. 7.4 of Ref. 4)
Calculation of Number of Anodes

The number of the anodes required can be derived from the following equation,
=
Where:
number of anode

Issued
Date
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Rev. No.
A
total net mass anodes (kg)

individual mass anode (kg)
A boundary on the number of anodes is given by the maximum allowable spacing. The
maximum spacing based on Ref. 4 is 300m.
To provide the required current, the actual anode current output shall be greater than or
equal to the required current output as given below,

Where:
=
required end of life individual anode current output (Ampere)
actual individual anode current output at the end of life (Ampere)
final current demand at the end of life (Ampere)

number of anodes to be installed
design closed-circuit potential of the anode from Table 4-2 of Sec. 4.3 (Volts)
design protection potential, minimum negative potential (-0.80 Volts, Table 1 of Ref.
4)
total circuit resistance (Ohms)
The anode resistance to be applied for pipeline bracelet, , is calculated based on
equation below.
= 0.315
Where:
environmental resistivity (ohm.m) see Sec. 4.2.
exposed surface area of the anode (m2).

Issued
Date
10/12/13

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Rev. No.
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Design Assumptions
The following assumptions have been considered in this cathodic protection analysis.
The coating breakdown factor, , and the electrochemical capacity, , used in
the CP design is assumed to be same over the life of the pipeline.
Attenuation of protection is considered not required to be performed as the
selected anode spacing does not exceed 300m in accordance with the Annex
A.10 of Ref. 4.
The coating breakdown factor on field joint coating is as per the requirements of
Shell DEP guideline.
As there is no data available, resistivity of the onshore soil is assumed to be
3.40m.

Issued
Date
10/12/13
6.0
Sht.
No.
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19

Rev. No.
A
RESULTS
Results of the cathodic protection design are presented in the following subsections.
Anode Properties
The anode dimension and density of the alloy used in cathodic protection design is
presented in Table 6-1.
Table 6-1 Anode dimension
Property
Anode thickness
(mm)
Value
Onshore
50
Offshore
65
Anode length (mm)
90
Half shell gap (mm)
100
Anode density (kg/m 3)
2700
Cathodic Protection Requirement

Table 6-2 shows the minimum anode mass required to meet the required total anode
net mass.

Issued
Date
10/12/13
Sht. No.
Rev. No.
17 of 19
Table 6-2 Summary of Cathodic Protection Design for a 22in Gamba Export Pipeline
Pipe
Section
Onshore
Pipeline
KP Range
Length
(m)
Mass of
Exposure
one
Condition
anode
(kg)
Total
Required
anode net
Final
mass to
Individual
meet
Anode
current
Current
demand
Output
(kg)
(A)
Actual
Individual
Final
Current
Output
(A)
Required
Required
number of
anode
anode to
spacing to
meet total
meet total
anode net
anode net
mass
mass
(ea)
(m)
Required
Required total
Recommended
number of
anode weight
Spacing of
anode based
based on
anode(1)
on
recommended
(joints)
recommended
spacing
spacing (ea)
(kg)
0.20 1.07
1100
Buried
21
93
0.059
0.09
248
13
273
1.07 1.24
200
Buried
28
0.063
0.18
1050
24
28
1.24 10.6
9300
Un-buried
28
674
0.212
1.37
24
390
24
32
896
25
Un-buried
28
0.485
1.37
164
28
Offshore
Spool
Notes:
1. Anode spacing of 300m (24 joints) for offshore pipeline has been recommended in accordance with requirements of Ref. 2.
2. Dual 22 in Gamba export pipeline will be routed parallel from Gamba terminal to the PLEM/SBM, hence the anode required above shall be applicable
to both pipelines.

Issued
Date

10/12/13
7.0
Sht.
No.
18 of
19
Rev. No.
A
REFERENCES
1.
2.
3.
4.
5.
6.
7.
Shell DEP 30.10.73.31-Gen, Design of Cathodic Protection Systems for Onshore

Buried Pipelines and Plot Piping (Amendments/Supplements to ISO 15589-1:2003).
Shell DEP 30.10.73.31-Gen, Design of Cathodic Protection Systems for Onshore
Buried Pipelines and Plot Piping (Amendments/Supplements to ISO 15589-1:2003).
ISO 15589-1, Petroleum and Natural Gas Industries Cathodic Protection of
Pipeline Transportation System Part 1: On-land Pipelines.
ISO 15589-2, Petroleum and Natural Gas Industries Cathodic Protection of
Pipeline Transportation System Part 2: Offshore Pipelines.
Z.100.0, Design Basis Report.
Z.202.1, Wall Thickness Report.
Z.203.1, On-Bottom Stability Analysis.

Issued
Date
10/12/13

APPENDIX A Sample of Cathodic Protection Calculation
Sht.
No.
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Rev. No.
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CP calculation Gamba
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GAMBA EXPORT LOADING LINE (SHELL GABON)