250611DECID1608 - EXDE02 - 27 (Update HH)
250611DECID1608 - EXDE02 - 27 (Update HH)
250611DECID1608 - EXDE02 - 27 (Update HH)
EX-DE 03 01/06/20 Issue for Approval A. Fumelli G. Renga H. Hammami H. Hammami V.Maurizio
EX-DE 02 13/05/19 Issue for Approval A. Fumelli G. Renga H. Hammami H. Hammami R. Dellacecca
EX-DE 01 25/09/18 Issue for Approval A. Fumelli G. Renga H. Hammami H. Hammami R. Dellacecca
EX-DE 00 30/06/18 Issue for Approval A. Fumelli G. Renga H. Hammami H. Hammami R. Dellacecca
Validity Rev.
Status number Prepared Checked Approved Contractor Company
Date Description
by by by Approval Approval
Revision Index
Company logo and business name Project name Company Identification
OGI002-CO-1608-01
Drake & Scull International PJSC
Contract N.
Vendor logo and business name Vendor Identification
Order N.
Facility Name Location Scale Sheet of Sheets
PPG INTERCONNECTING ONSHORE n.a. 1 of 25
Document Title Supersedes N.
REVISION HISTORY
INDEX
1 General ........................................................................................................................................... 4
1.1 Scope of work.......................................................................................................................... 4
1.2 Acronyms and abbreviations ................................................................................................... 4
2 Reference documents ................................................................................................................... 5
2.1 Project documents eni iraq b.v. ............................................................................................... 5
3 Permanent CP system calculation and sizing ............................................................................ 7
3.1 General data............................................................................................................................ 7
3.2 Protection potential ................................................................................................................. 9
3.3 Current requirement and evaluation of existing CP system utilization.................................... 9
3.4 Definitive CP system sizing ................................................................................................... 11
3.4.1 Calculation of characteristics resistance and attenuation constant .................................. 12
3.4.2 Pipeline potential shift ....................................................................................................... 13
3.4.3 Groundbed design ............................................................................................................. 21
3.5 Summary ............................................................................................................................... 24
4 Annex A ........................................................................................................................................ 25
1 General
This document, in conjunction with its ANNEX, reports the calculations performed
in order to design the Cathodic Protection system for the n.4 new 12” Raw Gas
Pipelines, being part of the PPG Interconnecting, in Zubair Oil Field, near Zubair
Mishrift, Iraq.
2 Reference documents
For the design, drawings and materials of the cathodic protection system,
reference will be done to the latest edition of the following Zubair Oil Field
Development Project documents, including all Codes and Standards
mentioned and adopted in them:
Project Specifications
According to project alignment sheets and P&I (see paragraph 2), structures to be
protected against electrochemical corrosion are the external surfaces of the
following buried steel pipelines.
Thickness Operating
DN Length
From To (bends) Temperature
[inch] [m]
[mm] [°C]
10.31
12 Hammar IPF L1 PPG 10141.13 60
(11.13)
10.31
12 Hammar IPF L2 PPG 10197.32 60
(11.13)
Reject Water
8 ZM NEW TRAP 2987 12.7 77
PPG
River Water ZM
8 ZM EXT TRAP 1399.38 12.7 77
NEW TRAP
Reject Water ZM
8 ZM EXT TRAP 1422.3 12.7 77
NEW TRAP
CONDESATE
8 PPG 2489 12.7 77
LINE ZM EXT
ZB-383
8 NWCS 3060.1 12.7 60
CORRIDOR
All the pipelines are made of API 5L X60 carbon steel and are coated by means
of three layers of extruded high density polyethylene (3LPE).
As per resistivity measurement reports (listed under paragraph 2), Zubair area has
been divided into four ranges of values:
The table below resumes the superficial resistivity (1.6 m depth) characteristic of
DGS areas:
According to ISO 15589-1, (2015), the CBF can be calculated with the following:
ff=fi + (∆f∙tdl ),
where fi and Δf, for three-layer polyethylene coated steel surface and from Table
2, are respectively 0.001 and 0.0003, so, for a design life tdl = 30 years, the CBF
at the end of life, ff, is:
ff =0.001+(0.0003∙30) = 0.01.
As per Paragraph 3.1, the current densities for bare steel buried in soil at 30°C
have been chosen starting from the worst case (Sabka soil, rich in chlorides)
estimated to be 20 mA/m 2. Considering this value, the current densities for bare
steel buried in ZOF soil have been chosen as follows:
Because the maximum operating temperature is 77°C, the current density values
“shall be increased by 25% for each 10°C rise in operation temperature above
30°C, so the “temperature” factor is:
𝑇−30 77−30
( )
Ft = 1.25( 10
)
= 1.25 10 = 2.85
Length
ND Pipeline name / Tot. length including 5% Surface
[inch] well [m] contingency [m²]
[m]
12 HIPF-L1 10141.13 10648.18 10833.03
Length
ND Pipeline name / Tot. length including 5% Surface
[inch] well [m] contingency [m²]
[m]
8 River Water PPG 2976.42 3125.241 2149.1
The current demand shall be calculated for each pipeline by using the following
formula (for multiple pipelines in the same trench i.e. pipe-ways the current
demand shall be assessed as the sum of individual pipelines current demands):
Ir = 20.73 A corresponds to total current demand for all pipelines for 30 years
protection
The existing CP system that geometrically and technically could include the new
pipelines would be CPS12&15, composed by n.2 CPS placed respectively at
Hammar DGS and Zubair Mishrift New Trap area.
Total current deliverable by CPS12&15 is 50 A, but the calculated spare is 5% =
2.5 A.
The spare so calculated is not sufficient to protect the new RGPs, so a solution
composed by a new CPS has been chosen.
New Transformer rectifier CP-PPG has been installed for this purpose to protect
raw gas pipelines & River/Reject Water.
Selected total
Surface to Current Current
current Current spare
CPS protect density required
output [%]
[m²] [mA/m²] [A]
[A]
CP-PPG 36369 0.570 20.73 25 120.6
External
Wall Total Length current Required Commissioning
Existing Pipeline ND OD diameter Surface Complection
Typology From To thickness Length including 5% density current and construction
T/R No name / w ell [inch] [MM] of [m²] Date
[mm] [M] contingency [mA/m2] [A] status
pipeline
8" River ZM
ZM existing Commissioning
T/R CPS PPG Existing DGS to FL-water New ZM trap area 8" 219 0.219 12.7 2976 3124.8 2149.89 0.57 1.225437 24/12/2019
DGS completed.
new trap area.
8" Reject ZM
ZM existing Commissioning
T/R CPS PPG Existing DGS to FL-water New ZM trap area 8" 219 0.219 12.7 2987.4 3136.791 2158.14 0.57 1.23014 24/12/2019
DGS completed.
new trap area.
8" River ZM
New Trap DGS New ZM Commissioning
T/R CPS PPG FL-water New PPG trap area 8" 219 0.219 12.7 1400 1470 1011.37 0.57 0.576483 24/12/2019
to new trap trap area completed.
area.
8" Reject ZM
New Trap DGS New ZM Commissioning
T/R CPS PPG FL-water New PPG trap area 8" 219 0.219 12.7 1422 1493.1 1027.27 0.57 0.585542 24/12/2019
to PPG new trap area completed.
trap area.
8" Condensate
New ZM Pre-
T/R CPS PPG PPG Trap to ZM FL-water New PPG trap area 8" 219 0.219 12.7 2490 2614.5 1798.8 0.57 1.025315
trap area Commissioned
Existing DGS .
T/R unit shall According to Doc (00250600BERB47300) and will have the following
characteristics:
Maximum voltage output: 50 V
Maximum current output: 25 A.
Anodes shall According to Doc (00250600BERB47300) and will have the following
characteristics:
Material: Ti/MMO
Shape: Tubular
Diameter: 25 mm
Length: 1,000 mm
Weight (single anode) 0.25 kg
Maximum operative current density in backfill: 100 A/m2.
Figure 1
Table 1 here below lists the characteristic of pipelines subdivided per section.
Table 1
Approx. Section
Pipeline Wall
section length +
Section Pipelines in section ND thickness
length contingency
[inch] [mm]
[m] (5%) [m]
H-IPF L1 12 10,31
A-B 9086 9540
H-IPF L2 12 10,31
H-IPF L1 12 10,31
H-IPF L2 12 10,31
B-C RG ZM EXT TO PPG 12 10,31 657 690
RIVER WATER 8 12.7
REJECT WATER 8 12.7
CONDENSATE ZM EXT
F 8 12.7 2489 2613.45
TO PPG
H-IPF L1 12 10,31
G H-IPF L2 12 10,31 95 100
ZB-383 8 12.7
where:
Ap = the cross-sectional area of the pipe wall (m 2)
Rlp = Single element (pipeline) longitudinal resistance (/km)
Rtp = Single element leakage resistance (km)
s = Element wall thickness (m)
Dp = Element external diameter
0 = Steel resistivity = 0.18 x 10-6 ·m
Ri = Insulation resistance (Ω∙m 2, function of coating, soil resistivity, etc:
see ISO 15589-1 (2015), Appendix E).
Each pipe-way sections (e.g. pipelines section laid in the same corridor) equivalent
characteristic parameters will be further calculated as follows:
1
𝑅𝑙 =
1
∑
𝑅𝑙𝑝
1
𝑅𝑡 =
1
∑
𝑅𝑡𝑝
where:
Rl = Pipe-way section equivalent longitudinal resistance (/km)
Rt = Pipe-way section equivalent leakage resistance (·km).
𝑅𝑙
𝛼=√
𝑅𝑡
𝑅𝑘 = √𝑅𝑙 ⋅ 𝑅𝑡
where:
α = Attenuation constant (km -1)
Rk = Pipe-way characteristic resistance ().
The potential increment and current necessary to protect the pipeline are defined
by the following formulas:
where:
Ex1 = Change in potential at drainage point “x1” (V);
Ex2 = Change in potential at point “x2” (V);
Ix1 = Current at drainage point “x1” (A);
Ix2 = Current at point “x2” (A).
SECTION A-B:
Approx. Section
Pipeline Wall
Pipelines in section length +
Section ND thickness
section length contingency
[inch] [mm]
[m] (5%) [m]
RGP1 12 10.31
A-B 9086 9540
RGP2 12 10.31
5000
Leakage Resistance Rtp = = 4.914 Ω/km.
𝜋∙0.324∙1000
0.009 1
𝛼=√ = 0.060
2.457 km
ΔV at point B (close):
𝐸𝑥1 = 0.350 ∙ 𝑐𝑜𝑠ℎ[0.060 ∙ (9.540 − 0)] + 0.148 ∙ 0 ∙ 𝑠𝑖𝑛ℎ[0.060 ∙ (9.540 − 0)] = 0.409 V
0.350∙𝑠𝑖𝑛ℎ[0.060∙(9.540−0)]
𝐼𝑋1 = 0 ∙ 𝑐𝑜𝑠ℎ[0.060 ∙ (9.540 − 0)] + = 1.434 A.
0,148
SECTION E-D:
Approx.
Pipeline Wall Section length
Pipelines in section
Section ND thickness + contingency
section length
[inch] [mm] (5%) [m]
[m]
RG ZM New to
12 10.31
ZM EXT
E-D 8 12.7 1014 1064.7
River Water
8 12.7
Reject Water
5000
Leakage Resistance Rtp = = 4,914 Ω/km.
𝜋∙0.324∙1000
Point D (x1): 0 km
0.018 1
𝛼=√ = 0.060
4.914 km
ΔV at point D (close):
𝐸𝑥1 = 0.350 ∙ 𝑐𝑜𝑠ℎ[0.060 ∙ (1.064 − 0)] + 0,295 ∙ 0 ∙ 𝑠𝑖𝑛ℎ[0.060 ∙ (1.0647 − 0)] = 0,351 V
0.351∙𝑠𝑖𝑛ℎ[0.060∙(1.0647−0)]
𝐼𝑋1 = 0 ∙ 𝑐𝑜𝑠ℎ[0.060 ∙ (1.0647 − 0)] + = 0,077 A.
0,295
SECTION D-B:
Approx.
Pipeline Wall Section length
Pipelines in section
Section ND thickness + contingency
section length
[inch] [mm] (5%) [m]
[m]
RG ZMEXT TO
12 10.31
PPG
D-B 8 12.7 2185 2300
REJECT WATER
8 12.7
RIVER WATER
5000
Leakage Resistance Rtp = = 4,914 Ω/km.
𝜋∙0.324∙1000
Point B (x1): 0 km
0.018 1
𝛼=√ = 0.060
4.914 km
ΔV at point B (close):
𝐸𝑥1 = 0.351 ∙ 𝑐𝑜𝑠ℎ[0.060 ∙ (2.3 − 0)] + 0,295 ∙ 0 ∙ 𝑠𝑖𝑛ℎ[0.060 ∙ (2.3 − 0)] = 0,354 V
0.354∙𝑠𝑖𝑛ℎ[0.060∙(2.3−0)]
𝐼𝑋1 = 0 ∙ 𝑐𝑜𝑠ℎ[0.060 ∙ (2.3 − 0)] + = 0,166 A.
0,295
SECTION E-D:
ΔV at point D (close):
𝐸𝑥1 = 0.406 ∙ 𝑐𝑜𝑠ℎ[0.060 ∙ (1.0647 − 0)] + 0,295 ∙ 0 ∙ 𝑠𝑖𝑛ℎ[0.060 ∙ (1.064.7 − 0)] = 0,406 V
0.406∙𝑠𝑖𝑛ℎ[0.060∙(1.647−0)]
𝐼𝑋1 = 0 ∙ 𝑐𝑜𝑠ℎ[0.060 ∙ (1.0647 − 0)] + = 0,0247A.
0,295
SECTION D-B:
Equivale
nt
Equivalent Section
Longitud
Leakage α Rk length +
Section Pipelines in section inal
Resistance (1/km) (Ω) contingency
Resistan
(Ω/km) (5%) [m]
ce
(Ω km)
RG ZMEXT TO PPG
D-B REJECT WATER 4.914 0.018 0.060 0,295 2300
RIVER WATER
ΔV at point B (close):
𝐸𝑥1 = 0.407 ∙ 𝑐𝑜𝑠ℎ[0.060 ∙ (2.3 − 0)] + 0,295 ∙ 0 ∙ 𝑠𝑖𝑛ℎ[0.060 ∙ (2.3 − 0)] = 0,4077 V
0.407∙𝑠𝑖𝑛ℎ[0.060∙(2.3−0)]
𝐼𝑋1 = 0 ∙ 𝑐𝑜𝑠ℎ[0.060 ∙ (2.3 − 0)] + = 0,19 A.
0,295
SECTION B-C:
Approx.
Pipeline Wall Section length
Pipelines in section
Section ND thickness + contingency
section length
[inch] [mm] (5%) [m]
[m]
H-IPF L1
12 10,31
H-IPF L2
12 10,31
RG ZM EXT TO
B-C 12 10,31 657 690
PPG
8 12.7
RIVER WATER
8 12.7
REJECT WATER
5000
Leakage Resistance Rtp = = 4.914 Ω/km.
𝜋∙0.324∙1000
Point C (x1): 0 km
0.006 1
𝛼=√ = 0.060
1,638 km
ΔV at point C (close):
𝐸𝑥1 = 0.409 ∙ 𝑐𝑜𝑠ℎ[0.060 ∙ (0.69 − 0)] + 0.098 ∙ 0 ∙ 𝑠𝑖𝑛ℎ[0.060 ∙ (0.69 − 0)] = 0.410
0.409∙𝑠𝑖𝑛ℎ[0.060∙(0.69 −0)]
𝐼𝑋1 = 0 ∙ 𝑐𝑜𝑠ℎ[0.060 ∙ (0.69 − 0)] + = 2.096 A.
0.09
SECTION F:
Equivalent
Equivalent Section
Longitudin α
Leakage Rk length +
Section Pipelines in section al (1/k
Resistance (Ω) contingency
Resistance m)
(Ω/km) (5%) [m]
(Ω km)
F 8’’ CONDENSATE 4.914 0.018 0.060 0,295 2613.45
ΔV at point B (close):
𝐸𝑥1 = 0.407 ∙ 𝑐𝑜𝑠ℎ[0.060 ∙ (2.613 − 0)] + 0,295 ∙ 0 ∙ 𝑠𝑖𝑛ℎ[0.060 ∙ (2.613 − 0)] = 0,411 V
0.407∙𝑠𝑖𝑛ℎ[0.060∙(2.613−0)]
𝐼𝑋1 = 0 ∙ 𝑐𝑜𝑠ℎ[0.060 ∙ (2.613 − 0)] + = 0,217 A
0,295
SECTION G:
1 1
Equivalent Leakage Resistance 𝑅𝑡 = 1 = 1 = 4.914 Ω/km
∑
𝑅𝑡𝑝 4,914
1 1
Equivalent Longitudinal Resistance 𝑅𝑙 = 1 = 1 = 0.018 Ω km
∑
𝑅𝑙𝑝 0.018
0.018 1
𝛼=√ = 0.060
4.914 km
ΔV at point C (close):
𝐸𝑥1 = 0.409 ∙ 𝑐𝑜𝑠ℎ[0.060 ∙ (0.1 − 0)] + 0.098 ∙ 0 ∙ 𝑠𝑖𝑛ℎ[0.060 ∙ (0.1 − 0)] = 0.4
0.40∙𝑠𝑖𝑛ℎ[0.060∙(0.1 −0)]
𝐼𝑋1 = 0 ∙ 𝑐𝑜𝑠ℎ[0.060 ∙ (0.1 − 0)] + = 0.09 A.
0.295
Calculation demonstrates that current requirement for potential shift will be 2.096
A, which is less than the calculated value for current density requirement; as
consequence, current requirements are verified.
The new groundbeds will be sized for the maximum current output of the T/R unit.
The groundbed configuration will be verified according to groundbed and total
circuit resistance requirements.
Since each T/R has the same characteristics, new groundbeds will be identical to
the existing ones, with the exception of concrete ring depth, which will change for
each CPS location, according to first groundwater level.
Anode quantity
𝐼𝑜𝑢𝑡 𝐼𝑜𝑢𝑡
𝑁𝑎 = =
𝐼𝑎 𝑆𝑎 ⋅ 𝑖𝑎
25
𝑁𝑎 = = 3.18 → 4
1 ⋅ 0.025 ⋅ 𝜋 ⋅ 100
The design life of CP systems for processing facilities, including off-plot pipelines,
shall be 30 years, since each CPS start-up.
The expected life of Ti/MMO anodes is verified to be greater than the design life.
Vout − ϕ 50 − 2
R max = = = 1.92 Ω
Iout 25
Considering Nos. 4 Ti/MMO anodes, 2.5 m spaced, deep well groundbed active
length is (using Equation 25 reported in Doc. n. 00250600DESG4182S):
𝐿 = {(𝑁𝑎 ⋅ 𝐿𝑎 ) + [(𝑁𝑎 − 1) ⋅ 𝐿𝑠 ]}
where:
𝐿 = {(4 ⋅ 1) + [(4 − 1) ⋅ 2.5]} = 11.5 m + 1 m (0.5 at the top+0.5 at the bottom) = 1 2.5 m
Groundbed resistance calculation will take into account a soil resistivity values at
groundbeds installation area (PPG) of 75 m:
𝜌 8⋅𝐿
𝑅𝑎 = ⋅ [𝑙𝑛 ( ) − 1]
2⋅𝜋⋅𝐿 𝐷
where:
75 8⋅12.5
𝑅𝑎 = ⋅ [𝑙𝑛 ( ) − 1]= 4.7
2⋅𝜋⋅12.5 0.270
Because Ra > Rmax, this groundbed resistance value is not acceptable and
calculation shall be repeated until Ra results less than Rmax.
75 8⋅54.5
𝑅𝑎 = ⋅ [𝑙𝑛 ( ) − 1]= 1.4
2⋅𝜋⋅54.5 0.270
it will be obtained:
Log 30 ≤ 3.477 – Log (79.6) 1.47 < 1.57
The expected life of Ti/MMO anodes is verified to be greater than the design life.
The total DC circuit resistance Rtot [], including pipeline resistance vs. earth and
connecting cables resistance, is calculated as follows:
1.4
𝑅𝑡𝑜𝑡 = =1.66
0.85
Since 𝑅𝑡𝑜𝑡 ≤ 𝑅𝑚𝑎𝑥 => 1.66 < 1.92, groundbed is correctly sized.
3.5 Summary
The CPS shall be constituted by:
Concrete
Total Active Inactive Backfill Backfill
Diameter ring Anodes
CPS depth depth depth overburden volume
[m] depth number
[m] [m] [m] [m] [m3]
[m]
PPG 0.27 96 54.5 41.5 5.45 HOLD 16 3.34
4 Annex A
Calculation of characteristic resistance and attenuation constant &
pipelines potential shift
Section A-B
Pipe wall Insulation Leakage Longtidunal
External Dia
Pipeline External Dia (m) Thickness resistance resistance resistance
(inch)
(mm) (Ώ*m2) (Ώ/Km) (Ώ*Km)
H-IPF L1 12 0.324 10.31 5,000,000 4.914 0.018
H-IPF L2 12 0.324 10.31 5,000,000 4.914 0.018
Equivalent
Equivalent Leakage Longtidunal Partial
From Km To Km α(1/Km) Rk(Ώ)
resistance (Ώ/Km) resistance Length(m)
(Ώ*Km)
2.457 0.009 0 9.54 9540 0.06 0.148
OFF Potential at Point Current at OFF Potential at Current at
A ( CUSO4) point A (A) Point B ( CUSO4) point B (A)
Section D-B
Pipe wall Insulation Leakage Longtidunal
External Dia
Pipeline External Dia (m) Thickness resistance resistance resistance
(inch)
(mm) (Ώ*m2) (Ώ/Km) (Ώ*Km)
RG ZM EXT TO PPG 12 0.324 10.31 5,000,000 4.914 0.018
River Water 8 0.219 12.7 5,000,000 4.914 0.018
Reject water 8 0.219 12.7 5,000,000 4.914 0.018
Equivalent
Equivalent Leakage Longtidunal Partial
From Km To Km α(1/Km) Rk(Ώ)
resistance (Ώ/Km) resistance Length(m)
(Ώ*Km)
4.914 0.018 0 2.3 2300 0.06 0.295
OFF Potential at Point Current at OFF Potential at Current at
A ( CUSO4) point A (A) Point B ( CUSO4) point B (A)