the conductors are electrically shorted to

Cathodic Protection the surface casing. Under this condition,

CP will prevent corrosion only on the
external surface of the conductor (the
outermost casing in the string and the

of Well Casings in
liner) to a depth that is largely restricted
by the attenuation of protective current.
The annulus between the conductor and
surface casing relies on cement for corro-
sion protection. Figure 1 shows a typical

Abu Dhabi
well casing configuration.
CP is only a part of the owner’s corro-
sion prevention and rehabilitation pro-
gram. Other important aspects of that
program include high-quality cementing
DAVID H. KROON AND GERALD D. WILLIAMS, Corrpro Companies, Inc. in the annulus between concentric cas-
ALI N. MOOSAVI, Abu Dhabi Co. for Onshore Operations ings, continuation of the surface casing
inspection and repair program, and pre-
vention of surface water leaks that increase
An oil company based in U.A.E. needed to upgrade the corrosiveness of the environment near
its external corrosion protection systems on more the top of the well.
than 1,300 well casings. In 2001, Front-End Engineering
Design (FEED) work for cathodic protection (CP) was Cathodic Protection
completed, which covered the operational wells in five CP is an important part of the well
casing corrosion protection program. To
production fields. The FEED scope included a literature advance the program, in 2001 the owner
search, field studies, CP current attenuation modeling, retained a corrosion consultant (Corrpro
evaluation of flowline considerations, life-cycle cost Companies, Inc. [Medina, Ohio]) under
analyses of alternative designs and materials, basic the contract “Front-End Engineering
design, and cost estimates. Final design work began in Design (FEED) for Cathodic Protection
2002 and construction started in 2003. This article of Well Casings.” The scope of the work
included:
describes the results of the study, the design, and initial • Technical Evaluation and Report
phases of construction. • Site Survey and Report
• Economic Evaluation and Report
• Conceptual Design Report

T
he Abu Dhabi Co. for On-
shore Operations (ADCO)
(Abu Dhabi, U.A.E.) oper-
ates ~$5 billion of down-
hole assets with a desired
operating life of 100 years.
Very high rates of well cas-
ing corrosion threaten the life of these
assets. Problems related to casing corro-
sion were first detected in 1983 during
the workover of an oil well. It was found
that the completion string was corroded
throughout the area of the pay zone.
Cathodic protection (CP) is the only
means for mitigating external corrosion
on the existing well casings in situ. Electri-
cal continuity data suggest that 81% of
18 MATERIALS PERFORMANCE August 2004
• Basic Engineering Design and Docu-
mentation
• Engineer, Procure, and Construct
(EPC) Contract Tender Preparation
• Presentations to the owner.
The economic evaluation was per-
formed to evaluate CP alternatives from
both a techno-economic and sensitivity
perspective. This analysis was supported
by cost estimates for initial capital expen-
diture, operating expenditures, and main-
tenance costs. Specific items addressed
were:
• Utilization of existing surface CP
equipment
• Best use of existing power sources
• Feasibility of integrating the flow-

AUG 2004 MP pp 1-57.indd 18 7/13/04 11:34:12 AM

 FIGURE 1

lines into the CP system scheme for

the well casings
• Cost differences between permanent
alternating current (AC) power and
solar power for impressed current CP
• Economic implications of a “blan-
ket” current requirement for all wells,
compared to estimating optimum cur-
rent for each well based upon type,
location, geological formations, depth,
E log I testing, and casing potential
logs.
Life-cycle cost analyses were performed
for various CP design alternatives with the
following results:
• Air-cooled transformer-rectifiers are
the most economical power source at
locations with existing AC power.
• Surface anode groundbeds are the Typical well casing configuration.
most economical and should be used
at all locations where soil conditions
(resistivity and stability) are suitable. FIGURE 2
• Mixed metal oxide (MMO) anodes
are the most economical.
• Closed-hole deep-anode groundbeds
are more economical than open-hole
deep-anode groundbeds because the
latter present a combination of higher
drilling costs and the need for special
casing.
• The installation of a new 33-kV AC
power supply for the sole purpose of
providing CP to the well casings is not
economically viable when compared
to solar power.
• Economic analysis indicates that all
available existing AC power sources
should be used in conjunction with
transformer-rectifier-powered CP
systems.
• Costs for installing and maintaining
electrical isolation between the well- E log I test data interpretation.
heads and flowlines are significantly
higher than providing partial CP to the
flowlines. In addition, an integrated
system has technical and economical well casings are electrically continuous vided with CP in an isolated condition.
benefits. with flowlines and station piping. One Under ideal conditions, it is desirable
approach for the corrosion prevention to electrically isolate the well casing from
Electrical Isolation program is to provide CP to the well cas- the flowline and provide a bond box
The well casings are connected to sur- ings, flowlines, and station piping as a across the isolator to control current flow
face-level flowlines that ultimately ter- fully integrated system. Another approach to both the flowline and well casing. This
minate at remote and central degassing is to electrically isolate the flowline at the approach provides the best control for
stations. As originally constructed, the wellhead so that the casing can be pro- distributing protective current between
August 2004 MATERIALS PERFORMANCE 19

AUG 2004 MP pp 1-57.indd 19 7/13/04 11:34:20 AM

 FIGURE 3
Downhole CD on 9-in. (23-cm) casing.
FIGURE 4
Deep-anode installation.
the well casing and the flowlines. At the
same time, it overcomes the interference
effects with the flowline and nearby well
casings when only isolated well casings are
protected. For the project in question, this
option was not economical because the
water-cut in production ranges from 10
to 20% and increases over time; the pro-
20 MATERIALS PERFORMANCE August 2004
AUG 2004 MP pp 1-57.indd 20
duced water exhibits very low resistivity
(5 to 10 Ω-cm).
Using flange isolation to isolate flow-
lines from the wellheads has proven inef-
fective on water supply, water injection,
and oil-producing wells in these fields.
Internally coated spool pieces also have
been used, but they were found to be in-
effective as a long-term solution. Over
time, the owner’s experience has been that
maintaining the integrity of electrical
isolation is an extensive maintenance
problem. The high cut of low-resistivity
water may make effective CP of well cas-
ings impossible to achieve. Internal cor-
rosion cells also would be introduced
because a potential difference would exist
across the isolation spools. The owner
therefore adopted a CP program that in-
tegrates systems for well casings, flowlines,
and station piping.
Well Casing Current
Requirements
The primary CP criterion chosen for
the well casings was applied protective
current. The decision was based on NACE
Standard RP0186,1 “Application of Ca-
thodic Protection for External Surfaces of
Steel Well Casings,” which states “The CP
current applied to well casings shall be
considered adequate when measurements
indicate that a net flow of current to the
casing has eliminated all anodic areas.”
The specific current criterion was devel-
oped with information obtained from:
• Casing potential profile logs
• E-log I test results
• Current density (CD) calculations
• Current attenuation modeling.
The authors selected a secondary CP
criterion for surface equipment, the top of
the well casing, and the flowline. The crite-
rion provided a 100-mV polarization shift
between native state to polarized potential
with respect to a copper/copper sulfate
(Cu/CuSO4) reference electrode placed at
least 5 m from the wellhead. The polarized
potential is to be recorded as an “instant-
off” potential measured immediately after
interruption of the CP current flow.
Thirty-seven E-log I tests (Figure 2)
were performed. The current require-
ments, as defined by the E-log testing,
ranged from a low of 12 A to a high of 18
A per well casing. The overall average
value of the current requirement for CP
of the well casings was 14.8 A.
Based on his previous experience in
North America, the consultant for the
project assumed that the nominal CD for
7/13/04 11:34:30 AM

CP of well casings is ~0.5 mA/ft2 (4.6 mA/
m2). This relatively low CD requirement
stems from the lack of oxygen at depth.
Because the subsurface geology and aquifer
waters in North America are relatively
less corrosive than those in Abu Dhabi, it
was estimated that the CD requirement for
CP would be from 0.5 and 1.0 mA/ft2
(4.6 to 9.3 mA/m2). The increase in current
demand would be needed to compensate
for the high-salinity waters.
CDs for protection were calculated
based upon results of the casing potential
profile logs for four wells. The results in-
dicated a range of CDs from 0.57 mA/ft2
(5.3 mA/m2) to 0.85 mA/ft2 (7.9 mA/m2),
with an average value of 0.76 mA/ft2 (7.1
mA/m2). They were within the antici-
pated range.
One of the controlling factors in well
casing CP is current attenuation, which
occurs downhole along the casing. Cur-
rent attenuation was therefore modeled
using standard attenuation formulas. To
perform the attenuation calculations, the
subsurface geology was researched. For
each formation, depths and total dissolved
solids were extracted from available lit-
erature.
The pore water resistivity declines with
increasing depth to 7,000 ft (2,134 m).
Dolomite exists below 7,000 ft, and it
causes a significant increase in soil resistiv-
ity. The calculations indicate that CDs
>0.77 mA/ft2 (7.2 mA/m2) will be achieved
on the 9 5/8-in. (24.4-cm) casing to a
depth of 7,000 ft with 15 A of CP current
(Figure 3).
Documentation showed that the best
tool for determining the well casing cur-
rent requirements for CP is the casing
potential profile log. The owner intends
to perform more logs, both before and
after CP application, to refine the current
criterion to be used for well casing CP. At
the present time, the owner follows a 15-
A current criterion. This value is sup-
ported by the average results of the logs
and E-log I tests performed to date. Fur-
thermore, it is consistent with CD and
current attenuation calculations.
Because the flowline will not be electri-
cally isolated from the well casing, the CP
AUG 2004 MP pp 1-57.indd 21
FIGURE 5
Surface-anode installation.
system at the wellhead needs to provide
sufficient current for protection of the
well casing. Moreover, it needs to supply
an incremental amount of current to pro-
tect the associated flowline. Recommend-
ed capacities were 20 A for single-well,
solar-powered systems and 25 A for sin-
gle-well, transformer-rectifier-powered
systems.
Another controlling factor for deep-
anode CP installations is that the current
output per deep anode should be limited
to 50 A. When operated at higher cur-
rents, deep-anode CP systems often expe-
rience shortened life from cable connec-
tion failures, gas blocking, or elevated
temperatures resulting from high current
flows. As a result, a maximum of two wells
can be protected with one deep-anode
installation—provided that the direct cur-
rent (DC) cable run for the power supply
to each well is ≤500 m (1,640 ft).
Anode Systems
The MMO-coated titanium tubular
with a center connection was shown to be
the most economical anode material for
the application in question. The MMO-
coated electrodes are used in both surface
and deep-anode configurations. The an-
odic reactions are anticipated to be both
oxygen evolution and chlorine evolution.
Hence it is important that the oxide coat-
ing be a combination of iridium and
tantalum oxides—and not the more com-
mon (and less expensive) ruthenium oxide
designed for use under chlorine evolution
conditions. The tubular shape is superior
to rods or mesh because a low-resistance,
well-sealed wedge connector can be
placed at the center of the anode for con-
necting the anode lead wires. The consul-
tant considered Halar† lead wire insula-
tion preferable to either high-molecular-
weight polyethylene or Kynar† because
one of the anticipated anodic reactions is
chlorine evolution. Lead wires from indi-
vidual anodes extended, without splices,
from the anode to a junction box for both
surface and deep-anode groundbeds.
Four anode configurations were se-
lected. Two are deep anodes for either a
one- or two-well cluster, and two are sur-
face anodes for either a one- or two-well
cluster. In the case of deep anodes, the
depth to the top of the active anode col-
umn will vary by field to account for
variations in subsurface geology and
depth to water. Surface anode configura-
tions are used only in stable soils with low
†
Trade names.
August 2004 MATERIALS PERFORMANCE 21
7/13/04 11:34:37 AM
 FIGURE 6

ft (150 to 200 m) from the wellhead, and

a minimum separation of 246 ft (75 m)
from all buried metallic structures. The
basis for surface anode design was a layer
of soil whose resistivity was ≤200 Ω-cm,
which restricted the use of surface
groundbeds to sabkha areas. Surface
groundbeds were always selected where
soils were stable and met the resistivity
criterion. During the final design process,
however, it was not possible to determine
the depth to groundwater at each site ac-
curately.
The EPC project commenced in
October 2002, with a 31-month con-
struction schedule. For deep-anode instal-
lations, either truck-mounted or track-
240-W (0- to 24-V) solar array. mounted drill rigs were used. The depth
to groundwater had been estimated using
the best available information, but it was
unknown on a site-specific basis. It was
resistivities, limiting their use to sabkhas capacity to protect the well casing and to therefore necessary to monitor the drill
(small areas of low resistivity and high provide current for partial protection of stem resistance to the well casing when
chloride content). the flowlines. The systems are as follows: drilling the borehole to detect the pres-
• System No. 1—Transformer-recti- ence of saline groundwater accurately.
Power Supplies fier rated for single-well protection This procedure has proven to be effec-
The consultant recommended two using either deep-anode or surface- tive.
types of power supplies: a transformer- anode configurations
Construction to date has been success-
rectifier and a solar unit using photo- • System No. 2—Transformer-recti-
ful. All systems have been constructed
voltaic cells. In general, it is beneficial to fier rated for a two-well cluster using
with a DC circuit resistance of less than
standardize on both types of power sup- either surface-anode or deep-anode
the target maximum 0.6 Ω. In all cases,
plies. Standard units provide economies configurations
the min. 15 A of current to the well casing
of scale when manufacturing the initial • System No. 3—Solar power system,
has been achieved. Figure 4 shows the
components, yielding lower initial costs. for single well protection, using either
installation of the anodes in a deep
Additionally, the number of spare parts deep-anode or surface-anode configu-
groundbed. Figure 5 depicts a surface
will be reduced and personnel training rations.
groundbed installation and Figure 6
will be simplified because there will be Note that DC runs between the pow-
shows the solar array.
similarities in equipment. er supply and the wellhead were limited
Air-cooled, transformer-rectifiers op- to 1,640 ft. Two wells can be clustered and
erating on 415-V, three-phase AC power protected by a single transformer-rectifier Health, Safety, and
were selected. During the economic provided that they do not exceed this Environmental Considerations
evaluation, the units were shown to have threshold. An evaluation of the most appropriate
a much lower life-cycle cost than oil-im- type of CP systems necessitated consid-
mersed or pulsed rectifiers. The design life Final Design and Construction eration of several factors such as avail-
of the transformer-rectifiers is 20 years. The owner awarded the consultant an ability, constructability, the local environ-
A standard 240-W (0- to 24-V) solar EPC contract to perform the final design, ment, reliability, and economics. The
power system with battery storage was material procurement, and construction assessment also considered factors relating
selected for single-well installations only phases of the project. As part of the con- to health, safety, and the environment.
where no AC power is available or where tract, site-specific field surveys were per- The power supply configurations de-
the distance to existing AC power exceeds formed and a final design prepared. Cri- tailed earlier in this article limit the instal-
1,640 ft. teria for optimizing CP groundbed lation of 415-V AC power cable to a
Three power supply configurations locations were defined as 180 degrees maximum distance of 1,640 ft—and only
were recommended. Each has sufficient +90 degrees from the flowline, 492 to 656 under stable soil conditions. The final
22 MATERIALS PERFORMANCE August 2004

AUG 2004 MP pp 1-57.indd 22 7/13/04 11:34:45 AM

 design does not require the installation of
33-kV overhead lines.
Air-cooled transformer-rectifiers were
included in the recommended configura-
tions not only to reduce cost, but also to
eliminate the need to dispose of oil as-
sociated with oil-cooled transformer-
rectifiers.
The installation of solar systems neces-
sitates the use of batteries, which have an
anticipated service life ranging from 5
to 10 years. The actual performance de-
pends on the battery itself and the
operating conditions. It will be necessary
to dispose of the batteries in accordance
with local regulations for hazardous waste
material.
Conclusions
The results of the design effort revealed
some important considerations for future
projects:
• E-log I and CD calculations can be
used to define a current range for CP.
• The most reliable current require-
ment data come from casing potential
logs.
• Better knowledge, documentation,
and data about the subsurface geology
in the first 10,000 ft (3,048 m) would
be of great assistance in more accu-
rately modeling downhole current at-
tenuation, CD, and polarization. It
would be helpful if soil resistivity logs
were run on a sample of wells through-
out each field, beginning at the surface
and extending through the production
zones.
• Although it is preferable to electri-
cally isolate flowlines from the well
casings, it is not always possible to do
so effectively and economically with
high water-cuts of low resistivity.
• Depth to groundwater should be
documented whenever possible, such
as when water wells are developed to
support drilling operations.
• Where depth to groundwater is un-
certain, taking drill stem resistance-to-
earth measurements is an excellent way
to obtain definitive electrode and ac-
tive column depths during deep-
anode installations.
AUG 2004 MP pp 1-57.indd 23
Reference
1. NACE Standard RP0186, “Application of Cathodic
Protection for External Surfaces of Steel Well Castings”
(Houston, TX: NACE, 2001).
This article is based on a paper presented at
the NACE Middle East Conference in Bahrain,
March 7 to 10, 2004.
DAVID H. KROON is Executive Vice President
and Chief Engineer of Corrpro Companies,
Inc., 7000B Hollister, Houston, TX 77040. He
has a B.S. in chemistry from Yale University
and is a registered professional engineer in
eight states. Kroon has more than 30 years of
experience in corrosion prevention including
materials performance, protective coatings,
pipeline integrity, CP, and AC/DC interference
mitigation. A 33-year member of NACE, he has
been actively engaged in solving corrosion
problems for oil and gas producers throughout
his career.
GERALD D. WILLIAMS is a Senior Project
Manager at Corrpro Companies, Inc., PO Box
4705, Abu Dhabi, U.A.E. He has been exten-
sively involved in the CP industry for more
than 27 years. A 27-year NACE member, he is
a NACE Corrosion Specialist and CP Special-
ist. He has spent the past 15 years working in
Asia, Australia, and the Middle East on various
CP projects. He is currently managing a major
project in Abu Dhabi involving CP for more
than 1,300 well casings.
ALI N. MOOSAVI is a Senior Corrosion Engi-
neer at ADCO, PO Box 270, Abu Dhabi, U.A.E.
He has 25 years of research and development
and corrosion consultancy experience, primar-
ily in the oil and gas sector—16 years in the
U.K. and 9 years in the U.A.E. He has a Ph.D.
in corrosion from UMIST, holds a Research
Fellowship at Aberdeen University, and is a
Visiting Professor at U.A.E. University. A NACE
member since 1981, he has authored more
than 20 publications.
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