Doc. No.

: 26071-203-CM00C-319-00003

Job No. : 26071 Rev.001

CATHODIC PROTECTION DESIGN FOR STEEL

PIPE PILE AT RFCC NEW FLARE AREA

PROJECT : Engineering, Procurement and Construction (EPC) Inside

Battery Limits (ISBL) and Outside Battery Limits (OSBL) for
the Refinery Development Master Plan (RDMP) Project
RU V Balikpapan
LOCATION : Refinery Unit V Balikpapan, East Kalimantan,Indonesia
OWNER : PT PERTAMINA (Persero)

ISEP.T.F/
001 18 MAR 23 ISSUED FOR APPROVAL SAID.N J.H.KIM
IWAN.P
ISEP.T.F/
000 05 JUL 22 ISSUED FOR APPROVAL SAID.N Y.D.KIM
IWAN.P
ISEP.T.F/
00A 27 APR 22 ISSUED FOR INFORMATION SAID.N Y.D.KIM
IWAN.P
REV. DATE DESCRIPTION PREPARED CHECKED APPROVED
 Doc. No.: 26071-203-CM00C-319-00003

Job No. : 26071 Rev.001

REVISION LOG

REV. DATE PAGE DESCRIPTION

00A 27 APR 22 - ISSUED FOR INFORMATION
000 05 JUL 22 - ISSUED FOR APPROVAL
001 18 MAR 23 - ISSUED FOR APPROVAL

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TABLE OF CONTENTS

1. INTRODUCTION .............................................................................................................. 4
1.1 BACKGROUND ............................................................................................................ 4
1.2 PURPOSE .................................................................................................................... 4
2. CODE AND REFERENCE DOCUMENT .......................................................................... 5
3. DESIGN PARAMETER .................................................................................................... 6
3.1 TIDAL AND WAVE CONDITION ................................................................................... 7
3.2 CURRENT DENSITY .................................................................................................... 8
3.3 COATING BREAKDOWN FACTOR.............................................................................. 8
3.4 SUMMARY ................................................................................................................... 9
4. ANALYSIS ..................................................................................................................... 10
4.1 ANALYSIS FOR PILE WHICH ITS 3LPE COATING EMBEDDED INTO SEABED ..... 10
4.2 ANALYSIS FOR PILE WHICH ITS 3LPE COATING NOT EMBEDDED INTO SEABED12
5. CONCLUSION ............................................................................................................... 14

ATTACHMENT 1 CALCULATION OF ANODE REQUIREMENT BASED ON ACTUAL DATA

FOR TRESTLE AREA
ATTACHMENT 2 CALCULATION OF ANODE REQUIREMENT BASED ON ACTUAL DATA
FOR PLATFORM AREA
ATTACHMENT 3 SUMMARY OF DESIGN CATHODIC PROTECTION FOR TRESTLE AREA
ATTACHMENT 4 SUMMARY OF DESIGN CATHODIC PROTECTION FOR PLATFORM AREA
ATTACHMENT 5 SUMMARY OF DESIGN CATHODIC PROTECTION REQUIREMENT

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1. INTRODUCTION

1.1 BACKGROUND
Trestle & Platform structure of RFCC New Flare will be supported by 193 pcs of Steel Pipe
Pile (SPP) foundation. Referring to Design Criteria of Marine Work Doc 26071-100-3DR-000-
00007, this type of foundation shall be protected by 3LPE coating together with cathodic
protection to provide corrosion protection of the piles during its service.

Figure 1.1. Plan of RFCC New Flare

Trestle Area
Platform Area

1.2 PURPOSE
The purpose of this document is to analyse sacrificial anode mass required to maintain
Cathodic Protection (CP) Steel Pipe Pile founadtion for 41 points at Trestle and 152 points at
Platform RFCC New Flare in accordance to actual 3LPE coating embedment length.

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2. CODE AND REFERENCE DOCUMENT

DOCUMENT NUMBER DOCUMENT TITLE

26071-100-3DR-000-00007 Design Criteria for Marine Work

26071-203-CM00C-319-00001 Calculation Sheet for Platform Structure Flare Area

26071-203-CP-319-0002_002 Piling Layout for Platform New Flare

26071-JO-KPB-TQ-00500 Metocean Reference for Marine Work

Replacement of Cathodic Protection Anode Material

26071-JO-KPB-TQ-00500 on Jetty – 6A from Zinc to be Aluminum and
Designing Cathodic Protection on Jetty 6A

Design of Offshore Steel Structures, General –

DNVGL-OS-C101 LRFD Method

Petroleum, petrochemical and natural gas industries

ISO 15589-2 – Cathodic protection of pipeline transportations
systems Part 2 : Offshore pipelines

Standard Practice Corrosion Control of Submerged

NACE SP0176-2007 Areas of Permanently Installed Steel Offshore
Structures Associated with Petroleum Production.

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3. DESIGN PARAMETER

Cathodic protection application considers two types of pile surface area (3LPE Coated &
Uncoated Steel Surface) exposed by both seawater and mud. As per actual pile driving record,
several piles of platform area not satisfied minimum required 2 meter 3LPE Coating embedment
as per 26071-100-3DR-000-0007_Design Criteria for Marine Work due to variation of pile length
and pile embedment length.

In order to provide mitigation for the piles of platform with unsatisfied conditions, the mass of
anode required will be analysed to provide proper anode mass to maintain cathodic protection
based on the actual condition. There are two analyses to be conducted which is defined as
follows:
1. Analysis 1 is for piles which their 3LPE Coating embedded into seabed, and
2. Analysis 2 is for piles which their 3LPE Coating are not embedded into seabed.

The coating embedment condition of the pile will determine the coating breakdown factor which
is different for each analysis. These coating embedment condition to be analysed are illustrated
in Figure 3.1.

Figure 3.1 Coating embedment condition.

The anode proposed for cathodic protection of 1500 mm diameter of 41 points SPP Trestle &
152 points SPP Platform New Flare is Galvalum III with 2445 Ah/Kg Design Protective
Electrochemical Capacity (ε) which its chemical compositions are tabulated in Table 3.1.

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Table 3.1 Chemical Composition of Galvalum III

Element Composition (%)
Zinc (Zn) 2.0 – 6.0
Indium (Im) 0.01 – 0.02
Silicon (Si) 0.08 – 0.2
Copper (Cu) 0.006 (Max)
Iron (Fe) 0.13 (Max)
Others 0.02 (Max)
Aluminium (Al) Remainder

The anode type which will be used is assumed to be the slender type, which in ISO 15589-2
Section 8.4, the anode utilisation factor 𝑢 recommended for this type is 0.90

3.1 TIDAL AND WAVE CONDITION

Tidal condition used for this calculation is referring to document no. 26071-JO-PMC-TQ-01671
Metocean Reference for Marine Work which is summarized in Error! Reference source not
found.. The elavation mentioned in the table is referred to BM1.

Table 3.2 Tidal Water Level

Tidal Description Elevation (m)
Highest Astronomical Tide (HAT) 3.010
Mean High Water Spring (MHWS) 2.550
Mean High Water Neap (MHWN) 1.660
Mean Sea Level (MSL) 1.430
Mean Low Water Neap (MLWN) 1.205
Mean Low Water Spring (MLWS) 0.310
Lowest Astronomical Tide (LAT) -0.153

Beside tidal condition, from the metocean study, it can be obtained the wave characteristic of
the location as in Table 3.3. Contractor to design anode according to the requirement to
protect steel pipe pile from Top of Pile (T.O.P) to pile tip buried in seabed.

Table 3.3 Wave Characteristic

Return Period Hs (m) Tz (s)
2 0.13 1.96
5 0.34 3.18
10 0.48 3.78
25 0.66 4.42
50 0.79 4.84
100 0.93 5.22

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3.2 CURRENT DENSITY

The initial mean and final current density value in this calculation is obtained from the
recommendation by NACE SP0176-2007. Design initial, mean, and final current densities for
Indonesia seawater to be used are 110 mA/m², 54 mA/m², 75mA/m2 respectively.

Table 3.4 Recommended Initial, Mean & Final Design Current Densities (A/m²) for Indonesia Seawater

Meanwhile, the current density for seabed is obtained from Section 5.6.2.2 which mention that
the recommended initial, mean, and final current densities are 11 to 33 mA/m². For this
calculation, the design initial, mean, and final current densities for seabed to be used is 20
mA/m².

3.3 COATING BREAKDOWN FACTOR

The steel pipe pile is also protected by 3LPE which consists of three layers and has 2.5 mm
thickness. The effect of the coating on current demand shall be taken into account by
application of coating breakdown factor. This coating will deteriorate through time so increase
factor in coating deterioration shall be applied. Referring to ISO 15589-2 initial coating
breakdown factor for 3LPE & average yearly increase in coating breakdown factor are 0.007 &
0.0005 respectively.

The mean, and final coating breakdown factor are determined by Eq. (1) to (2) according to
ISO 15589-2. Moreover, t is the design life which is 30 years.
𝑓 = 𝑓 + (0.5 ∆𝑓 𝑥 𝑡 ) (1)

𝑓 = 𝑓 + (∆𝑓 𝑥 𝑡 ) (2)

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3.4 SUMMARY
The following table summarized the determined design parameters to be used in this
calculation and its references.

Table 3.5 Design Parameter

No Parameter Value Unit Remarks
26071-JO-PMC-TQ-
1. Elevation High Water Spring, H.W.S +2,550
01671
2
2. Initial current density in seawater, Ci1 0,110 A/m
2 NACE SP0176-2007
3. Mean current density in seawater, Cm1 0,054 A/m
Table A-1
4. Final current density in seawater, Cf1 0,075 A/m2
2
5. Initial current density buried in seabed, Ci2 0,020 A/m
2 NACE SP0176-2007
6. Mean current density buried in seabed, Cm2 0,020 A/m
2 Sec. 5.6.2.2
7. Final current density buried in seabed, Cf2 0,020 A/m
8. Initial coating breakdown factor, fi 0,700 %
ISO 15589-2
9. Average yearly increase coating breakdown factor, ∆f 0,050 %
10. Design Life, tdl 30 years Project Specification
11. Safety Factor, SF 30 % -
12. Utilization Factor, μ 0,9 ISO 15589-2

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4. ANALYSIS

4.1 ANALYSIS FOR PILE WHICH ITS 3LPE COATING EMBEDDED INTO SEABED
The length of pile to be used in calculation is the actual length of the pile installed. The pile is coated
16 meter length from the top of the pile and due to the seabed condition, the pile penetration will
vary and the excessive pile length above the pile-cut-off elevation shall be cut off. This condition will
influence the final coating length of the pile. The actual pile length and coating length will be used in
this calculation. Calculation is done based on Analysis 1 as per Chapter 3.

Figure 4.1. Parameter for Analysis 1

Pile Diameter D = 1.5 m

Pile Length L = 40.87 m
Pile Coated Length Lc = 14.87 m
Pile Uncoated Length Lu = 26 m
Elevation Design Pile Cut Off P.C.O = +5.450
Elevation Seabed SB = -7.700

Pile Length Parameter

Pile Length above sea water surface (Coated) L1 P.C.O - H.W.S = 2.9 m
Pile Length below sea water surface (Coated) L2 H.W.S - SB = 10.25 m
Pile Length below seabed Led L - (P.C.O - SB) = 27.72 m
Pile Length below seabed (Coated) L3 Led - Lu = 1.72 m

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Pile Length below seabed (Uncoated) L4 Led - L3 = 26 m

(i) Pile Surface Area Parameter

Pile surface area above sea water surface
2
1 (Coated) A1 π.D.L1 = 13.67 m
Pile surface area below sea water surface
2 (Coated) A2 π.D.L2 = 48.30 m2
2
3 Pile surface area below seabed (Coated) A3 π.D.L3 = 8.11 m
2
4 Pile surface area below seabed (Uncoated) A4 π.D.L4 = 122.52 m

Coating Breakdown Factor

Initial fi = 0.007

Mean = 0.015
Final = 0.022

Current Demand
Initial current demand, Ici
= [(A1+A2)(fi)(Ci1)+ (A3)(fi)(Ci2)+ (A4)(Ci2)]×[1+SF]
= [(13.67+48.30)(0.007)(0.110) + (10.46)(0.007)(0.020) +
(120.17)(0.020)]×[1+30%]
= 3.188 A

Mean current demand, Icm = [(A1+A2)(fc)(Cm1)+ (A3)(fc)(Cm2)+ (A4)(Cm2)]×[1+SF]

= [(13.67+48.30)(0.015)(0.054) + (10.46)(0.007)(0.020) +
(120.17).(0.020)]×[1+30%]
= 3.191 A

Final current demand, Icf = [(A1+A2)(ff)(Cf1)+ (A3)(ff)(Cf2)+ (A4)(Cf2)]×[1+SF]

= [(13.67+48.30)(0.022)(0.075) + (10.46)(0.022)(0.020) +
(120.17)(0.002)]×[1+30%]
= 3.263 A

Anode mass required, Ma = (Icm × tf × 8760) / (μ × ɛ)

= (3.191 × 30 × 8760) / (0.9 × 2445)
= 381.13 kg

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4.2 ANALYSIS FOR PILE WHICH ITS 3LPE COATING NOT EMBEDDED INTO SEABED

The condition of the pile and its coating is the same as pile used for the calculation in Analysis 1.
The actual pile length and coating length will be used in this calculation considering the pile cutting
work done to the mentioned pile. Calculation is done based on Analysis 2 as per Chapter 3.

Figure 4.2. Parameter for Analysis 2

Pile Diameter D = 1.5 m

Pile Length L = 34.48 m
Pile Coated Length Lc = 8.78 m
Pile Uncoated Length Lu = 25.7 m
Elevation Design Pile Cut Off P.C.O = +5.450
Elevation Seabed SB = -5.200

Pile Length Parameter

Pile Length above sea water surface (Coated) L1 P.C.O - H.W.S = 2.9 m
Pile Length below sea water surface (Coated) L2 Lc - L1 = 5.88 m
Pile Length below seabed (Uncoated) L4 Lu = 25.70 m
Pile Length above seabed (Uncoated) L5 (P.C.O - SB ) - (L1 + L2) = 1.87 m

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(i) Pile Surface Area Parameter

Pile surface area above sea water surface
2
1 (Coated) A1 π.D.L1 = 13.67 m
Pile surface area below sea water surface
2 (Coated) A2 π.D.L2 = 27.72 m2
2
3 Pile surface area below seabed (Uncoated) A4 π.D.L3 = 121.11 m
2
4 Pile surface area above seabed (Uncoated) A5 π.D.L4 = 8.80 m

Coating Breakdown Factor

Initial fi = 0.007

Mean = 0.015
Final = 0.022

Current Demand
Initial current demand, Ici = [(A1+A2)(fi)(Ci1)+ (A4+A5)(Ci2)]×[1+SF]
= [(13.67+27.72)(0.007)(0.110) + (121.11+8.80)(0.020)]×[1+30%]
= 3.419 A

Mean current demand, Icm = [(A1+A2)(fc)(Cm1)+ (A4+A5)(Cm2)]×[1+SF]

= [(13.67+27.72)(0.015)(0.054) + (121.11+8.80)(0.020)]×[1+30%]
= 3.420 A

Final current demand, Icf = [(A1+A2)(ff)(Cf1)+ (A4+A5)(Cf2)]×[1+SF]

= [(13.67+27.72)(0.022)(0.075) + (121.11+8.80)(0.020)]×[1+30%]
= 3.466 A

Anode mass required, Ma = (Icm × tf × 8760) / (μ × ɛ)

= (3.420 × 30 × 8760) / (0.9 × 2445)
= 408.42 kg

Calculation for remaining piles for respective trestle and platform based on actual conditions will
be tabulated in ATTACHMENT 1 to ATTACHMENT 4.

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5. CONCLUSION

Based on calculation above, cathodic protection will be divided into 6 (six) type according the
requirement. The type proposed can be seen on the following table.

Table 5.1 Anode Type

Type Anode Net

No Area of Application
Proposed Mass (Kg)

1 Type-1 300,49 TRESTLE & PLATFORM

2 Type-2 316,79 PLATFORM

3 Type-3 377,76 PLATFORM

4 Type-4 390,16 PLATFORM

5 Type-5 419,39 PLATFORM

6 Type-6 483,89 PLATFORM

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ATTACHMENT 1
CALCULATION OF ANODE REQUIREMENT BASED ON ACTUAL DATA
FOR TRESTLE AREA

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ATTACHMENT 2
CALCULATION OF ANODE REQUIREMENT BASED ON ACTUAL DATA
FOR PLATFORM AREA

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ATTACHMENT 3
SUMMARY OF DESIGN CATHODIC PROTECTION
FOR TRESTLE AREA

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ATTACHMENT 4
SUMMARY OF DESIGN CATHODIC PROTECTION
FOR PLATFORM AREA

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ATTACHMENT 5
SUMMARY OF DESIGN CATHODIC PROTECTION
REQUIREMENT

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