Improvements in offshore cathodic protection retrofits

M. Edgar Lewis - Wasco Energy

Fully 35% of the world's offshore infrastructure has now been in service for 20 years
or more, which in many cases, exceeds the design lifetime of the original cathodic
protection (CP) systems installed on jackets and pipelines. This rapidly aging
infrastructure has necessitated CP technology innovations that reduce the cost of
installation without sacrificing performance or reliability

Abstract
On platforms, conventional CP retrofits methods, generally using clamp-on anodes,
are tedious, expensive and potentially dangerous for divers. First introduced in the
U.S, Gulf of Mexico, remote or semi-remote sacrificial anode arrays or buoyed
impressed current CP (JCCP) systems, set on bottom, are now widely accepted as
the most effective and economical means of retrofitting platform CP systems.

Offshore pipelines are at the highest risk of catastrophic external corrosion failure if
their CP systems are allowed to fall into disrepair. However, until the recent
introduction of DNV-RP-103, the offshore industry had not even addressed the issue
of CP retrofits on subsea pipelines. Such now provides for current attenuation
modeling, and the use of remote anode sleds for retrofits.

By way of selected case histories, this paper will highlight the design and installation
methodologies inherent in new generation CP retrofit practices; showing how
improved performance, reliability and cost savings can go hand in hand.
Introduction

The historical approach to CP retrofits has been to effectively replace anodes on a

one-for-one basis. That is, wherever an anode was installed during new
construction, so too will another anode or anodes be installed during a retrofit. This
approach is very costly and completely unnecessary. There is a tendency for the
industry to misinterpret the reasons why CP systems for new structures are
designed the way they are. They are invariably designed to satisfy installation
requirements, as opposed to CP considerations.
For example, a pipeline bracelet anode configuration is designed to facilitate pre-
installation of the cathodic protection system on the pipeline, as well as
accommodate pipe-laying operations. In truth, the bracelet anode is possibly the
worst anode shape and placement that an anode could have fro m a CP engineer's
standpoint. The resistance is high; the utilization factor is low; the manufacturing
cost is high; and the "throwing power" is poor.
Another example is the conventional platform anode. They are attached by welding
extremely stout pipe cores to the structure in order to withstand launch forces and
/or pile driving during installation. Again, the CP design is predicated on a less than
desirable installation method. Anode utilization is reduced; the standoff distance is

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not optimized; and additional anodes are required to offset these constraints. When
we are charged with designing a retrofit system, most of these installation
considerations disappear because the structure is already in place, so we should
not be constrained in any way by the original design methodology when designing
the retrofit.

CP retrofit strategies
When analyzing the cost of a retrofit project, the driver is always the same. Cost of
installation always drives the project budget. Therefore, the design should focus on
reduction of installation cost without sacrificing performance or reliability. Some of
the obvious ways in which this may be accomplished are:

Pipelines

 Minimize the number of locations on the pipeline that have to be visited

 Select areas where the dept h of cover is either minimal, or the pipeline is
exposed on the seabed
 Minimize bottom time requirements at each location.
 On deeper projects, use ROV's rather than saturation divers.
 Carefully evaluate and compare costs of 4-point moored systems vs.
dynamically positioned equipment.
 Evaluate Impressed Current, Sacrificial Anode and Hybrid solutions at design
phase.
 Have the flexibility to adjust the retrofit plan offshore based on survey results
obtained as the installation progresses.

Platforms

 Minimize the number of anode installations.

 Minimize the amount of marine growth removal.
 On deeper projects, use ROV's rather than saturation divers.
 Have the flexibility to adjust the retrofit plan offshore based on survey result s
obtained as the installation progresses.
 Carefully plan top side rigging and set equipment prior to mobilization of the
subsea installation spread.
 Evaluate Impressed Current. Sacrificial Anode and Hybrid solutions at design
phase.

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CP retrofit system selection
As with any CP system, three basic options are available: impressed current CP
(lCCP), sacrificial nodes, or hybrid systems, which employ an optimized combination
of ICCP and sacrificial anodes. Although sacrificial anodes are by far the most
common CP system used on offshore infrastructure, the suitability of ICCP merits
consideration, and will be determined largely based on the following broad criteria:

Pipelines
Isolation status of the pipeline - if the pipeline is electrically isolated at one or both
ends, the application of ICCP may be practical. Practicality of applying ICCP - there
are several sub-criteria that will determine the viability of using ICCP:

 Availability of suitable AC power supply

 Cost of access and maintenance
 Potential for stray current interference.
The length of the pipeline - ICCP can only be deployed at the ends of an offshore
pipeline if it starts or terminates at a platform or on dry land .The distance that can
be protected from an end current source will be limited by the linear resistance of
the pipeline and the current required to protect it (coating condition). Generally
speaking, ICCP offers no real advantage over sacrificial anodes when considering
attenuation. For short lines, gene rally less than 8 km in length that run between two
platforms, or otherwise provide access to a CP source at either end, the answer
may be simply to electrically connect (short) the pipeline to those CP sources at
either end (platforms). This is an ideal retrofit scenario when both platforms have
been retrofitted with adequate current to accommodate short lines connected
between them. Attenuation models, verified with a midpoint contact potential
measurement will usually be sufficient to provide adequate retrofit capacity; at a
very attractive price.

Platforms
As a rule of thumb, ICCP becomes the most cost effective CP retrofit option at water
depths greater than 60 msw. As with pipelines, the main sub-criteria in determining
the viability of ICCP is the availability of suitable AC power supply, the cost of
access and maintenance, and the potential for stray current interference .

CP retrofit systems
Dual Clamp-On Anode System
The dual clamp-on anode system is a tried and tested, albeit inefficient method of
deploying retrofitted sacrificial anodes to offshore plat forms. An optimized design,
whereby mutual interference between the anodes is minimized, can provide as
much 8.7 DC amperes of CP current for a cathode with a potential of (-) 0.800V vs.
Ag/AgCl (sw) in 22 ohm-cm sea water for a design life of 10 - 20 years.

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Anode Pod
The anode pod is a bottom set steel frame consisting of at least four 148 kg plat
form-type anodes; capable of delivering at least 18.75 DC amperes of CP current for
a cathode with a potential of (-) 0.800V vs. Ag /Cl (sw) in 22 ohm-cm seawater for a
design life of up to 20 years. Ballast is provided by an articulated concrete mattress,
mounted in the base frame.

Figure 1 Anode Pod on Bottom with Clamp Attached to Vertical Diagonal on Jacket
Pods are installed just inside or outside the base of the jacket. This semi-remote
location greatly improves current distribution, and the installation is accomplished
with divers or ROV, using an electromechanical clamping system.

Anode Sled
Anode sleds are designed for pipelines where anode burial below natural sea bed is
required or anticipated. A sled consists of four 129 kg platform-type anodes on a
steel structural frame, and is capable of delivering at least 4 DC amperes of CP
current for a cathode with a potential of (-) 0.800V vs. Ag /CP (sw) over the entirety
of the CP design life, which is typically 15 to 20 years.
Sleds are installed at least 5 meters from the pipeline, with two electro-mechanical
clamps for system redundancy.

Platforms
As a rule of thumb, ICCP becomes the most cost effective CP retrofit option at water
depths greater than 60 msw. As with pipelines, the main sub-criteria in determining
the viability of ICCP is the availability of suitable AC power supply, the cost of
access and maintenance, and the potential for stray current interference .

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CP retrofit systems
Dual Clamp-On Anode System
The dual clamp-on anode system is a tried and tested, albeit inefficient method of
deploying retrofitted sacrificial anodes to offshore plat forms. An optimized design,
whereby mutual interference between the anodes is minimized, can provide as
much 8.7 DC amperes of CP current for a cathode with a potential of (-) 0.800V vs.
Ag/AgCl (sw) in 22 ohm-cm sea water for a design life of 10 - 20 years.

Clamping System
The clamp and tie-back cables (2tie-back cables per clamp for system redundancy)
are designed to maintain both mechanical integrity and electrical continuity between
the galvanic anode array and the structure being protected for the life of the CP
system, while accommodating varying pipe or structural member diameters due to
thermal cycling and coating creep. The clamp is also designed with a calculated
failure mechanism to allow it to pull off the structure or pipeline with a force that will
not cause coating damage in the event of a snag or mechanical interference (e.g.,
trawling nets, anchors, etc.).

Figure 2 Anode Pods Protecting Subsea Production Equipment

Impressed Current Remote Sled

The ICCP sled is a modular, remote, bottom set system that can be customized to
provide current capacities from 250 - 500 amperes for a 15 - 25 year CP design life.
Anode elements are mixed metal oxide; buoyancy components are syntactic foam,
depth rated to 305 msw; main feed cables are 120 mm2 HMWPE insulated and
bedded, with a contra-helical double galvanized steel wire armor package; cable
connections are made inside an oil-filled, pressure compensated junction box, with
each anode element on a separate parallel circuit.

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Platforms
As a rule of thumb, ICCP becomes the most cost effective CP retrofit option at water
depths greater than 60 msw. As with pipelines, the main sub-criteria in determining
the viability of ICCP is the availability of suitable AC power supply, the cost of
access and maintenance, and the potential for stray current interference .

Figure 5 Clamping System on Pipeline with CP Monitoring Instruments Attached

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Anode Mat
The anode mat consists of an articulated grid of interconnected concrete blocks.
Depending on current required and design life; some to all of these blocks contain
embedded 8 kg cylindrical anodes (electrically continuous). Mats are capable of
delivering at least 4 DC amperes of CP current for a cathode with a potential of (-)
0.800V vs. Ag/ Cl (sw) over the entirety of the CP design life.

Link Anode System

The link anode system is comprised of a series of cylindrical anodes cast onto a
'wire rope core, and is designed for retrofitting minimal, shallow water structures and
caissons, or subsea pipelines. Strings are supplied in three standard lengths: 10m
(5 anodes), 20m (10 anodes), and 30m (15 anodes).

Figure 6 Anode Mat Installed on Pipeline using Clamping System

Links are deployed in three basic ways:

 Surface suspended with trailing mud anodes. Used for 3 - 5 year CP of

offshore structures in 30 msw or less. Used as riser or infield pipeline CP
system with an insulated hang-off option.
 Subsea suspended with trailing mud anodes.
 Mud deployed on ultra shallow structures (e.g., wind turbine caissons) or
subsea pipelines.

CP retrofit design
Just as new construction cathodic protection designs are made to facilitate
installation of the offshore platform or pipeline, the cathodic protection design criteria
are designed to polarize a structure from native state potential, provide adequate
redundancy in design to allow for some system damage during installation or for
unknown environmental affects. In new construction there is little incentive to "over-
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optimize" if it entails any added risk. When considering a retrofit, there are a number
of major differences that should be reflected in the design criteria selection:

 In most cases there will be some degree of polarization remaining, even if the
structure has fallen below "protective potential criteria". In many cases the
structure will still be adequately protected but will have heavily depleted
anodes.
 Design life requirement may be for only a few years, in which case it may not
be necessary to optimise protective potential levels.
 We have the benefit of being able to perform a survey to accurately define
the condition, and to measure the existing polarization characteristics (current
density vs. potential).
 We have the advantage of being able to monitor both anode and cathode
responses during the retrofit to verify design predictions.
So when designing a retrofit, it is rarely, if ever necessary, to provide the same
current density as one would for a new structure, and if existing maintenance
current densities can be demonstrated to be much lower than conventional wisdom
would dictate, significant savings can be realized [1].

Importance of survey
The value of a well-specified survey cannot be overestimated. This is true of both
platforms and pipelines, but particularly so with buried, or partially buried pipelines.
This is only true, however, of a high resolution type survey [2]. Remote or semi-
remote (trailing wire) type surveys provide little or no useful information.

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 Pipelines
The most important information obtained from a
detailed pipeline survey, in order of value, is: line
Location. Having an accurate position on the
pipeline is essential; particularly if the line is
buried. The hourly rate on the offshore
equipment necessary to effect a pipeline retro fit
is such that it is unacceptable to waste any time
trying to locate the pipeline.
Knowing where the pipeline is exposed or has
only minimal cover will save significant time and
money. If a retrofit site is inadvertently selected
where the pipe line is buried 2 meter s deep, it
could take divers many hours to excavate the
pipeline. They would then be forced to work in a
deep hole where visibility would be essentially
zero.
By measuring the field gradients as well as
potential, the resilience of the CP system can be
estimated, as well as any areas of significant
Figure 7 Link Anode on a
coating damage. In having an ROV fly the line
Single Well Caisson there is always the chance of obtaining a visual
inspection opportunity on one or more anodes.
Such can provide invaluable information to the
CP designer.
The survey will give a good indication of seabed conditions, current velocities, etc.,
as well as giving accurate seawater, and more importantly, mud resistivity
information.

Armed with this survey information, the designer can first select ideal sites for retrofit
anode locations based on the depth of cover survey. Knowing the current density
requirement and general coating condition facilitates accurate application of
attenuation models to optimize spacing between retrofit sites. Knowledge of the mud
resistivity allows accurate calculation of current outputs from various anode arrays.

Platforms
On platforms it is the same story; using an intelligent survey approach [3], [4]; will
yield valuable information on CP system performance. Again, structure potential
data alone does not tell the whole story. Estimation of anode depletion percentage
is another area where mistakes are often made. Thus it is important to take accurate
measurements on a few water blast-cleaned anodes to get a realistic status on
remaining anode material. The benefits of an intelligent platform inspection are, in
order of value:

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Knowing the existing maintenance current density on a structure gives the designer
a precise benchmark from which to work. This will always result in a lower (but still
safe) current density value being applied for the retrofit. This saves time and money
without adding risk.

Knowing the current output range of the existing anodes and their average degree
of consumption allows more precise prediction of remaining life. This could result in
deferring a retrofit for one or more seasons; again with no risk.

A typical survey will also include evaluation of the sea bed condition, silt and scour
and seabed debris. This is invaluable data if a sea bed pod or sled approach is
considered, or if access to mud line framing is required. Extent and thickness of
marine growth will affect structural attachments. Verification of the type and location
of original anodes may prove useful if original anodes are used to support retrofit
anodes. Condition of the structure regarding existing corrosion damage is also
important. A heavily corroded structure may not be a candidate for certain kinds of
retrofit.

Case histories
Cost and installation time assumptions are as follows:

Description Cost Per Day (US$)

Surface DSV (Diving <60m) 87,000
Saturation DSV (Diving >60m) 110,000
Topside Installation Crew (5 persons) 7,500

Description Unit Cost (US$) Installation Time (hours)

Dual Clamp-On (20 yr) 5,600 1.00

Anode Pod 14,700 0.75

Retro Buoy 145,000 12.00

Anode Sled 12,500 6.00

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Case history - ICCP (EI 296-B)
The EI 296-B complex is comprised of two structures with a connecting bridge. The
structure sits in 66meters of water in the U.S .Gulf of Mexico. Both are standard 8-
pile jackets; the drilling platform has 24 well conductors.
The cathodic protection systems on both jackets had depleted to the point where
the potential readings were below the minimum required levels. The potentials on
the structures ranged from (-) 0.680 to (-) 0.733 V vs. Ag / AgCl (sw) reference.
At these potentials the retrofit current was computed to be 1184Amperes. The
customer wanted an additional 20-year life extension on the CP systems.
Based on an economic analysis, it was decided to use an impressed current retrofit
solution as described below. There was also some concern about the additional
weight that a retrofitted sacrificial anode system would add to the structures
(approximately 176 MT) spread between 191 clamp-on anode arrays weighing
almost 1 MT each.
It was decided to deploy 3x400Ampere RetroBuoy sled systems to protect both
structures. Total installation time was extracted from the dive logs and is presented
below.

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Time Line from Dive Logs:
Sled 1

21Aug03 1005 Hrs Arrived EI-296

22Aug03 0536 Hrs rod. Platform Complete (1 Sled, Clamps & I-Tube)

Elapsed Time 20 Hrs 21 Min

Sled 2

0806 Moor to E1296-B. Drill. 2141 Hrs 1 Sled, Clamps & I-Tube
22Aug03
Hrs Installed

Elapsed Time 13 Hrs 35 Min

Sled 3

2210
22Aug03 Move to Second Sled Location
Hrs

0636 Sled Installation Complete. Dive Crew Moved to Inspection

23Aug03
Hrs Tasks

Elapsed Time 8 Hrs 26 Min

Total Subsea Installation Time = 42 Hrs 22 Min

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The selected ICCP solution was 32% of the cost of a conventional clamp-on anode
retrofit;
a savings of US$1.8 million.

Topsid
Subsea Total Total
# Material e
Install Install Project
System Type Req'd Cost Install
Time(hr Cost Cost
. (US$) Time
) (US$) (US$)
(hr)

1,069,60 1,604,40 2,674,00

Dual Clamp-on 191 191 N/A
0 0 0

RetroPod/Clam 1,735,87
65/46 955,500 95 N/A 780,375
p on 5

RetroBuoy
3 435,000 42 36 408,000 843,000
(ICCP)

Case history – Anode Pods (SS 216)

SS 216 is a 10-pile jacket in 34 meters of water in the U.S, Gulf of Mexico. The
platform has 21 conductors in 24 slots. The client wanted a 10-year life extension of
the CP system; the retrofit current was computed to be 305 amps.

The retrofit was originally planned for 2003, using standard anode pods, but was
delayed a year. During which time, the low potential had fallen an additional 50 mV
from (-) 0.730 V vs. Ag /Cl (sw) to a native state potential of (-) 0.680. This would
normally have required a "booster" pod design; however the in-built redundancy in
the system design assured full protection of the platform.

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Time Line from Dive Logs:

27Aug04 1 1900 Hrs Arrived SS 216

2103 Hrs First Pod Launched

28Aug04 0926 Hrs Last CP Check Made

1010 Hrs Depart SS 216

Total Time at Platform: 16 Hours 10 Minutes

Average Pod Installation Time: 54 Minutes

The selected anode pod solution was 70% of the costs of a conventional clamp-on
anode retrofit savings of US$179,000.

Total Total
Material Subsea Topside
# Install Project
System Type Cost Install Install
Req'd. Cost Cost
(US$) Time(hr) Time (hr)
(US$) (US$)

Dual Clamp-on 40 224,000 40 N/A 367,000 591,000

RetroPod/Clamp
18 265,000 16 N/A 147,000 412,000
on

RetroBuoy
1 145,000 12 12 118,000 263,000
(ICCP)

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Case history – pipelines
Unfortunately, pipeline CP retrofits have been fairly limited to d ate. When
undertaken, the methodologies deployed have been a re al mixed bag; some of
which have worked; some not. As there is no conventional, industry standard retrofit
methodology against which to compare our systems, such as clamp-on anodes for
jackets, the following is a costing based on using anode sleds and the clamping
system detailed in an earlier section. Such is based on an average spacing of
3,000m between sleds .The reader can compare these numbers against their own
experiences:

 60 m Water Depth - US$22,500 / km

 60 m Water Depth - US$18,300 / km

Summary and conclusions

Within the next ten years, almost two thirds of the existing global offshore facilities
will be 20 years and older. With rising oil prices driving deepwater developments,
the need to extend the service life of this aging infrastructure well beyond the
original CP design life may necessitate CP retrofits on a potentially grand scale.
Offshore CP designers cannot be constrained by the limits placed on us in new
construction designs. The operators will demand that we optimize to reduce costs,
yet will similarly insist that we not compromise performance and reliability. The
necessary technology exists today. It is proven.

References

 M.W. Mateer, NACE International CORROSION 91, Paper No. 233

 J. N. Britton, NACE International CORROSION 92, Paper No. 422
 J. N. Britton, NACE International CORROSION 98, Paper No. 729
 K. W. Kennelly, M.W. Mateer, NACE International CORROSION 93, Paper No. 526
Petromin thanks M. Edgar Lewis of Wasco Energy, Kuala Lumpur, Malaysia for this
paper, which was presented at the NACE East Asian & Pacific Regional Conference
& Exposition 2008, Kuala Lumpur, Malaysia 12 - 14 May 2008.
M. Edgar Lewis is the Business Development Director of Wasco Energy Ltd. He has
been involved in the offshore corrosion control industry for the past twenty-five years.
He is an active member of NACE, SSPC and the ACA, and is a NACE Certified
Coating Inspector. Mr. Lewis is a graduate of the University of Southern California.

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