105574 REP Z 0002 储罐规格

Turkish Petroleum Overseas Company (TPOC) 105574-REP-Z-0002 Rev 0
Mansuriya Gas Field (100 MMSCFD Modular Surface Facilities) Cathodic Protection Design Report - CPF
FEED and PMC services
HOLDS
Hold No. Section Description
Page 2 of 63
TABLE OF CONTENTS
HOLDS .....................................................................................................................................2
TABLE OF CONTENTS .............................................................................................................3
1 GENERAL ....................................................................................................................5
1.1 Introduction ..................................................................................................................5
1.2 Purpose & Scope .........................................................................................................6
1.3 Definitions ....................................................................................................................7
1.4 Abbreviations and Acronyms ........................................................................................7
1.5 Codes, Standards and Project Documents ...................................................................8
1.5.1 Industry and Other Standards .......................................................................................9
1.5.2 Project Documents........................................................................................................9
2 SCOPE OF WORK.......................................................................................................9
3 SUMMARY OF REQUIRED CP INSTALLATIONS ....................................................13
4 DESIGN CRITERIA AND DESIGN BASIS .................................................................17

4.1 Design Life .................................................................................................................17
4.2 CP Protection Potential Ranges .................................................................................17
4.3 Cathode Design Current Density ................................................................................18
4.4 Current Drain ..............................................................................................................19
4.5 Design Formulae ........................................................................................................19
4.6 Environmental Conditions ...........................................................................................19
4.7 Ambient Design Temperatures ...................................................................................20
4.8 Design Basis ..............................................................................................................20
4.8.1 External Protection of Buried Piping ............................................................................20
4.8.2 External Protection at Cased Road Crossings ............................................................22
4.8.3 External Protection of On-Grade Storage Tanks .........................................................22
4.8.4 External Protection of Buried Vessels .........................................................................24
4.8.5 External Protection of Buried Fire Hydrant Piping .......................................................25
4.8.6 Internal Protection of the Firewater Storage Tanks .....................................................26
APPENDIX 1: CP SAMPLE CALCULATIONS FOR BURIED PIPING (SHEETS 1-7)..............28
APPENDIX 2- CP SAMPLE CALCULATION FOR BURIED CASING (SHEETS 1-3) ..............36
APPENDIX 3 – CP SAMPLE CALCULATION FOR TANK BOTTOMS (SHEETS 1-5) ............40
APPENDIX 4 – CP SAMPLE CALCULATION FOR BURIED VESSELS (SHEETS 1-5) ..........46
Page 3 of 63
APPENDIX 5 – CP SAMPLE CALCULATION FOR HYDRANT PIPING (SHEETS 1-2) ..........52
APPENDIX 6 – CP SAMPLE CALCULATION FOR TANK INTERNALS (SHEETS 1-7) ..........55
APPENDIX 7 – SUMMARY OF CP SYSTEM FOR EXPORT PIPELINES ................................63
Page 4 of 63
1 GENERAL
1.1 Introduction
Turkish Petroleum Overseas Company (TPOC), Kuwait Energy Company (KEC) and
Korea Gas Corporation (KOGAS) have signed an initial agreement with the Iraqi Oil
Ministry for the Mansuriya Field Development Project. The development plan is to
achieve 100 MMSCFD of dry gas production no later than May 2018 in Phase 1 and
to increase the production capacity to 320 MMSCFD as a part of Phase 2. The
scope of this project is to develop the field for Phase 1 for the full design life of the
project with considerations for future expansion to Phase 2 capacity.
The Mansuriya gas field is located in Diyala governorate approximately 45 km north
of Ba’quba city in Iraq. This location is about 100 km north-east Baghdad and south-
west of Hamrin Lake. The location of the field is provided in Figure 1.1.
Figure 1.1 – Mansuriya Field Location
The wellstream production is sour (contains approximately 2.5 mol% H2S and 2.5
mol% CO2) and will require acid gas treatment. The gas will be treated and exported
via pipeline to the new build power station at Mansuriya.
Page 5 of 63
The FEED will consider the entire development including:

 Infield gathering system from four wellheads to CPF
 100 MMSCFD modular surface facilities for the gas plant to be provided by
process package suppliers in skids during EPC, consisting of
o Inlet separation facilities
o Gas processing – AGRU, Gas Dehydration, Hydrocarbon Dewpointing,
LPG Recovery, Condensate Stabilisation, Produced Water Treatment,
SRU
 Utilities
 Dry gas export to Mansuriya Power Station
 Condensate export to Naft Khana tie-in to an existing pipeline to Dura
Refinery
 Treated Water disposal to evaporation pond
 LPG and solid sulphur export via tankers
 Raw water intake facilities from the northern bank of Diyala River
 Provision of electric power and water to the police camp and temporary camp,
which will be utilised as operators camp for Phase 1.
 Roads & Infrastructure
1.2 Purpose & Scope
The purpose of this document is to describe the general strategy and specific
requirements for the detailed design of the cathodic protection systems for the CPF
facilities on the Mansuriya Full Field Development Project.
The scope of this document covers the facilities within the Gas Processing Plant,
comprising the following:
 External protection of buried In-Plant piping,
 External protection of isolated buried In-Plant piping casings,
 External and internal protection of on-grade storage tanks,
 External protection of vessels,
 External protection of buried fire hydrant/monitor riser pipes
The facilities that exist outside of the Gas Processing Plant are covered under
separate documents 105574-REP-Z-0003, but are summarised within appendix 7 of
this document. These include:
 Flowline from the 4 production wells to the CPF
 Export pipelines
This document was originally developed by KBR ZZ-CE-GEN-RPT-0010. The
documents have been reviewed and updated by Petrofac for correctness and
accuracy for the latest project information at the time of writing.
This document utilises SI and IUPAC nomenclature.
Page 6 of 63
1.3 Definitions
COMPANY Turkish Petroleum Overseas Company (TPOC)
CONTRACTOR EPC Contractor
SUBCONTRACTOR(S Means an organisation or organisations contracted by
and wholly responsible to CONTRACTOR for executing a
specific part of the WORK
VENDOR Means an organisation that has a contractual
arrangement with CONTRACTOR or a prospective
contractual arrangement with CONTRACTOR to supply
equipment, materials and/or services including
documentation
WORK Means all the work and services to be performed by
CONTRACTOR under a contractual arrangement with the
COMPANY
Must Defines a mandatory contractual or legal requirement or
action
Shall Defines a mandatory contractual requirement or action
Should Defines a desirable or recommended outcome or action
Will Defines an intended outcome or action
May Defines freedom of choice
1.4 Abbreviations and Acronyms
ACS Accidental contaminated surface run-off system

AGRU Acid Gas Recovery Unit
AJB Anode Junction Box
BS British Standard
CD Closed drain
CP Cathodic Protection
CPF Central Processing Facility
DC Direct Current
DIA. Diameter
DNV Det Norske Veritas
EN Euro Norm
EPC Engineering, Procurement and Construction
EXT External
FEED Front End Engineering and Design
HDPE High Density Polyethylene
ICCP Impressed current cathodic protection
Page 7 of 63
ID Identification
INT. Internal
IR Voltage Drop
ISO International Standards Organisation
IUPAC International Union of Pure and Applied Chemistry
KEC Kuwait Energy Company
KOGAS Korea Gas Corporation
LP Low Pressure
LPG Liquid petroleum gas
Min. Minimum
MMO Mixed Metal Oxide
MMSCFD Million standard cubic feet per day
N/A Not Applicable
NACE NACE International formerly National Association of
Corrosion Engineers
No. Number
OWS Oily water system
PDB Positive Distribution Box
QTY Quantity
SI International System of Units
SRU Sulphur Recovery Unit
TBC To Be Confirmed
TGTU Tail Gas Treatment Unit
TPOC Turkish Petroleum Overseas Company
TR Transformer rectifier
T-T Tan-to-tan length
1.5 Codes, Standards and Project Documents

The following comprise the documents and standards applicable to the design of the
cathodic protection systems:
Page 8 of 63
1.5.1 Industry and Other Standards

National Association of Corrosion Engineers (NACE)
NACE SP0169 Standard Practice – Control of External Corrosion on Underground
or Submerged Metallic Piping Systems
NACE RP0193 Standard Recommended Practice – External Cathodic Protection
of On-Grade Carbon Steel Storage Tank Bottoms
NACE SP0196 Standard Practice – Galvanic Anode Cathodic Protection of
Internal Submerged Surfaces of Steel Water Storage Tanks
NACE SP0285 Standard Practice – Corrosion Control of Underground Storage
Tank Systems by Cathodic Protection
NACE SP0388 Standard Practice – Impressed Current Cathodic Protection of
Internal Submerged Surfaces of Carbon Steel Water Storage
Tanks
NACE SP0575 Standard Practice – Internal Cathodic Protection Systems in Oil-
Treating Vessels
International Organization for Standardization (ISO)
ISO 15589-1 Petroleum and Natural Gas Industries – Cathodic Protection of
Pipeline Transportation Systems – Part 1: On-land Pipelines
Det Norske Veritas (DNV)
DNV-RP-B401 Cathodic Protection Design
British/European Standards (BS EN)
BS EN 12499 Internal Cathodic Protection of Metallic Structures
BS EN 12954 Cathodic Protection of Buried or Immersed Metallic Structures –
General Principles and Application for Pipelines
BS EN 13509 Cathodic Protection Measurement Techniques
BS EN 13636 Cathodic Protection of Buried Metallic Tanks and Related Piping
BS EN 14505 Cathodic Protection of Complex Structures
National Fire Protection Association (NFPA)
NFPA 70 National Electric Code (NEC)
1.5.2 Project Documents
105574-PHS-Z-0002 Cathodic Protection Design Philosophy
105574-REP Z-0003 Cathodic Protection Design Report – Pipelines
ZZ-CE-GEN-RPT-0010 Cathodic Protection Report (KBR)
2 SCOPE OF WORK
The following tables provide a summary of the facilities to which cathodic protection
has been designed for.
Page 9 of 63
Table 2.1 Buried Piping
PIPING DIA. (mm) (1) APPROXIMATE LENGTH (m) (2)
Oily Water System (OWS) Min. 100 ~ 10,000m
Accidental Contaminated Min. 200 ~ 5,000m

Surface Runoff System (ACS)
Closed drain lines (CD) Min. 100 ~ 5,000m
Vent pipes Min. 100 ~ 1m (100 No. of)

Notes:
(1) Diameters taken from doc 105574-PHS-C-0001, Design Philosophy for Underground Drainage.
(2) Approximate lengths given in table above are based on assumptions.
(3) For cathodic protection design purposes, pipeline operating temperatures are assumed not to
exceed max. soil temperature, 35°C (see sec. 4.7).
Table 2.2 Isolated Buried Piping Casings (1)
PIPING DIA. (mm) LENGTH No. OF EACH
Casings on OWS Min. 200 ~ 15 m ~ 20 No.
Casings on ACS Min. 400 ~ 15 m ~ 20 No.
Casings on CD Min. 200 ~ 15 m ~ 10 No.

Notes:
(1) Values given in table above are based on assumptions.
(2) For cathodic protection design purposes, casing operating temperatures are assumed not to
Page 10 of 63
Table 2.3 On-Grade Storage Tanks (1)
TANK ID DESCRIPTION DIA. HEIGHT (mm) OPER. EXT/INT

(mm) TEMP. PROT.
(internal water (°C)
wetted height if
applicable)
0-T-52 02 Off-Spec 18500 12000 45 EXT (Yes)

Condensate
Storage Tank INT (N/A) (4)
0-T-52 10 Condensate 39000 12000 55 EXT (Yes)

Storage Tank
INT (N/A) (4)
0-T-15 01 Amine Surge 79400 5500 42 EXT (N/A) (2)

Tank
INT (N/A)
0-T-55 02 AGRU Amine 4000 6750 50 EXT (N/A) (2)

Storage Tank
INT (N/A)
0-V-64 01 Oil/Water 3000 3000 TBC (4) EXT (N/A)

Separator
INT (N/A) (4)
0-T-81 01 Diesel Oil 10000 9000 TBC () EXT (N/A))

Storage Tank
INT (N/A) (4)
0-T-72 01 Diesel Oil 3000 3000 AMB EXT (N/A)

(4)
Storage Tank
INT (N/A) (4)
0-T-72 03 Service Water 32000 12000 TBC (4) EXT (Yes)

Storage Tank
INT (N/A) (4)
0-T-73 01 Potable Water 6600 9000 20 EXT (Yes)

Storage Tank
INT (N/A) (4)
0-T-74 01 Demineralised 8000 8000 25 EXT (Yes)

Water Storage
Tank INT (N/A) (4)
Page 11 of 63
TANK ID DESCRIPTION DIA. HEIGHT (mm) OPER. EXT/INT

(mm) TEMP. PROT.
(internal water (°C)
wetted height if
applicable)
0-T-76 01 LP Condensate 9500 10000 55 EXT (Yes)

Storage Tank
INT (N/A) (4)
0-T-79 01 – Firewater 28000 12000 50 EXT (Yes)

A/B Storage Tanks
INT (Yes)
Notes:
(1) Values given in table are derived from doc. 105574-EQL-P-0001, Equipment List.
(2) External CP not required as tanks are less than 6m in diameter and therefore constructed on
concrete slabs and not concrete ring beams.
(3) No values given in doc. 105574-EQL-P-0001, Equipment List.
(4) Internal CP not proposed, internal corrosion protection provided by a phenolic epoxy lining.
Page 12 of 63
Table 2.4 Vessels (1) (2)
VESSEL ID DESCRIPTION DIA. (mm) LENGTH OPER EXT

T-T TEMP PROT.
(internal (mm) (°C) ONLY
water wetted
height if
applicable)
0-V-22 01 A – F LPG Storage 3750 27420 60 EXT

(6 no.) Bullets (mounded
bullet)
0-V-22 02 Off-Spec LPG 3750 27420 53 EXT

Vessel (mounded
bullet)
Notes:
(1) Values given in table are derived from doc. 105574-EQL-P-0001, Equipment List.
(2) Vessels detailed in table are considered to be the only ones buried in sand. All other horizontal
vessels in on site are assumed to be either located above ground or in concrete pits but exposed
to air, i.e. not filled with sand.
Table 2.5 Fire Hydrant Riser Pipes (1)
PIPING DIA. (mm) LENGTH No. OF EACH
Fire hydrant riser Min. 200 ~ 2m ~ 100No.

Notes:
(1) Values given in table above are based on assumptions.
(2) For cathodic protection design purposes, riser pipe operating temperatures are assumed not to
3 SUMMARY OF REQUIRED CP INSTALLATIONS

The following tables provide a summary of the CP installations required for each of
the facilities defined within section 2.
Page 13 of 63
Table 3.1 Buried Piping – Temporary CP Summary
PIPING TOTAL CURRENT PRE-PACKAGED

DEMAND (Amps) ANODES (No. OFF)(1)
Oily Water System (OWS) 1.4 100
Accidental Contaminated 1.4 50

Surface Runoff System (ACS)
Closed drain lines (CD) 0.7 50

Note:
(1) Pre-packaged anodes based on Zinc alloy anodes.
Table 3.2 Buried Piping - ICCP Summary
DESCR. TOTAL MMO SELECTED SELECTED POSITIVE

CURRENT ANOD RECTIFIER RECTIFIER DISTRIBUTION
DEMAND E QTY DC QTY BOX (PDB)
(Amps) RATING
OWS / 1000 2000 50 A / 50V 100 200 (10 way)

ACS &
CD
Table 3.3 Casing Pipe – ICCP or Pre-Packaged Anodes
ROAD CROSSINGS(1) ICCP / PRE-PACKAGED ANODES (No OFF)(2)
~ 40 ICCP (3)
~ 10 Pre-Packaged Anodes(4) (20 No.)

Notes:
(1) Number of road crossings in plant are based on assumptions made for as CPF layout is not
available at time of writing.
(2) Number of road crossings protected by ICCP and that by Pre-packaged anodes are based on
assumptions on expected size.
(3) Protection to casing pipe taken from bleeding CP current of existing ICCP system protecting
normally buried piping.
Page 14 of 63
Table 3.4 Carrier Pipe in Cased Crossings – Zinc Ribbon Anodes
ROAD CROSSINGS(1) ZINC RIBBON ANODES (m)
~ 50 ~ 750
Notes:
(1) Number of road crossings in plant are assumed.
(2) Quantity of zinc ribbon anode per road crossing based on an assumed casing length of 15 metres.
Table 3.5 On-Grade Storage Tanks (External CP) - ICCP Summary
TANK Tag DESCR. TOTAL MMO Ti SELECTED POSITIVE

No. CURRENT RIBBON COND. RECTIFIER DISTRIB.
DEMAND ANODE BAR DC BOX
(Amps) QTY QTY RATING (PDB)
0-T-52 02 Off-Spec 40 1136 320 1 off 50 A / 1 Off 5

Condensate 50 V way
Storage
0-T-52 10 Condensate 47 1312 430 1 off 60 A / 1 Off 5

Storage 50 V way
0-T-72 03 Service Water 10.4 309 93 1 off 15 A / 1 Off 3

Storage 50 V way
0-T-73 01 Potable Water 3.7 110 28 1 off 5 A / 1 Off 3

Storage 50 V way
0-T-74 01 Demineralised 7.6 227 65 1 off 10 A / 1 Off 3

Water 50 V way
Storage
0-T-76 01 LP 7.3 217 55 1 off 10 A / 1 Off 3

Condensate 50 V way
Storage
0-T-79 01 – Firewater 11.7 343 109 1 off 15 A / 1 Off 5

A/B Storage (1) 50 V way
Note:
(1) Values given are based on the requirements for a single tank, for multiple tanks the values are to
be increased accordingly e.g. Firewater Storage Tanks, 2 No. in total.
Page 15 of 63
Table 3.6 On-Grade Storage Tanks (Internal CP) - ICCP Summary
TANK Tag No. DESCR. TOTAL MMO SELECTED POSITIVE

CURRENT ANODE RECTIFIER DISTRIBUTION
DEMAND QUANTITY DC RATING BOX (PDB)
(Amps)
0-T-79 01 – A/B Firewater 11.8 8 1 off 20 A / 1 Off 4 way

Storage(1) 50 V
Note:
(1) Values given are based on the requirements for a single tank, for multiple tanks the values are to
be increased accordingly e.g. Firewater Storage Tanks, 2 No. in total.
Table 3.7 Buried Vessels (External CP) - ICCP Summary
VESSEL Tag DESCR. TOTAL MMO SELECTED POSITIVE

No. CURRENT ANODE RECTIFIER DISTRIBUTION
DEMAND QUANTITY DC RATING BOX (PDB)
(Amps)
0-V-22 01 – A/D LPG 8.53 34 1 off 20A / 1 Off 4 way

Storage 50 V
0-V-22 02 Off- 8.53 34 1 off 20A / 1 Off 4 way

Spec 50 V
LPG
Note:
(1) Values given are based on the requirements for a single vessel, for multiple vessels the values are
to be increased accordingly e.g. LPG Storage 6 No. in total.
Page 16 of 63
Table 3.8 Fire Hydrant/Monitor Risers Pipes – Pre-Packaged Anodes
FIRE HYDRANT / MONITORS, No. PRE-PACKAGED ANODES, No OFF(2)

OFF(1)
~ 100 ~ 100
Notes:
(1) Number of fire hydrant / monitors in plant are based on assumptions.
4 DESIGN CRITERIA AND DESIGN BASIS

The CP design criteria are based on Document 105574-PHS-Z-0003.
4.1 Design Life
The design life for the temporary galvanic ‘sacrificial’ anode cathodic protection for
the in-plant buried piping is 2 years.
The design life for the impressed current cathodic protection systems for the buried
piping, on-grade storage tanks and vessels is 30 years.
The design life for permanent galvanic ‘sacrificial’ anode cathodic protection systems
for short piping section, casings at road crossings and the riser pipes on fire hydrants
is 30 years.
4.2 CP Protection Potential Ranges
The effectiveness of the CP system is determined by the potential shift. The instant-
off potentials applied in the design are given in table 4.1.
Table 4.1 CP Instant-OFF Potentials
ELECTROLYTE PROTECTION POTENTIAL
Steel in soil (aerobic -0.850 to -1.200 Volts versus copper/copper sulphate

conditions) reference electrode
Steel in soil/water -0.800 to -1.150 Volts versus silver/silver chloride reference

(aerobic conditions) electrode, OR
+0.25 to -0.10 Volts versus zinc reference electrode
Steel in soil/water Minimum -0.950 Volts versus copper/copper sulphate OR

(anaerobic -0.900 Volts versus silver/silver chloride OR +0.15 Volts
conditions) versus zinc reference electrode
Page 17 of 63
CP Instant-OFF ‘IR free’ potentials are normally measured after disconnecting all
bonds and sacrificial anodes and instantaneously following switching OFF of all
transformer rectifiers. However, given the number of rectifiers and sacrificial anodes
to be installed on the buried piping, this is considered to be impractical. Therefore,
‘IR free’ potentials are to be recorded on the buried piping via CP polarisation
coupons installed at all test stations except those at rectifier drain points. Each
coupon is to be fitted with a ‘Reed’ switch which will allow instantaneous
disconnection of the coupon from the CP circuit, thus allowing an ‘Instant-Off’
potential to be measured.
Excess overprotection, that is values more negative than -1.20 Volts versus
copper/copper sulphate reference electrode, should generally not occur.
For in-plant areas, the complicated nature which often exists in conjunction with the
combination of materials used in some locations, can influence the potential levels. It
may therefore be necessary to allow some flexibility in the protection potential criteria
required. For example the 100 mV polarisation decay test method (ref.
NACE SP0169) may be used in congested areas or areas subject to cathodic
shielding to determine that adequate protection has been achieved, although it would
first have to be demonstrated that polarization decay measured after switching off a
particular rectifier was not influenced by other adjacent rectifiers which were still
energised.
Alternatively, the methods of verification cathodic protection criteria, as detailed in BS
EN 14505, may be selected.
4.3 Cathode Design Current Density
The cathode current densities used in the design are given in table 4.2.
Table 4.2 Design Current Density Values
STRUCTURE APPLIED CURRENT APPLIED CURRENT

DENSITY UNCOATED DENSITY COATED STEEL
STEEL (mA/m2) (mA/m2) (1)
Buried piping 20 0.4 (Initial 0-10 yrs)(2)
0.9 (final 30 yrs) (3)
Buried casings at road 20 3

crossings
Carrier pipes inside 20 3

cased road crossings
On-grade tank (bottom) / 20 6

buried vessels
Water tank internal 27 5.4

(fresh water)
Page 18 of 63
STRUCTURE APPLIED CURRENT APPLIED CURRENT

DENSITY UNCOATED DENSITY COATED STEEL
STEEL (mA/m2) (mA/m2) (1)
Electrical earthing 20 N/A

(galvanised steel,
stainless steel ground
rods)
Electrical earthing 50 N/A

(copper ground rods)
Reinforcing steel within 2 N/A

concrete
Notes:
(1) Applied current density for coated steel based on end of design life values, unless otherwise
stated.
(2) Applied coated current density value to be applied to temporary CP for buried piping.
(3) Coated current density value based on buried piping coated with a fusion bonded epoxy system.
4.4 Current Drain

Cathodic protection of steel reinforcement within concrete is not considered herein as
concrete quality and below grade coating should negate its requirement. However,
the effect of current drain to steel reinforcement on the CP system will be considered
along with the effect of stray current corrosion on the steel reinforcement and other
structures, in particular in areas where concrete pile foundations are to be used.
Current drainage to buried electrical earthing is also addressed in the design.
4.5 Design Formulae
The formulae used in the CP design calculations are given on the calculation sheets
in Appendices 1 to 5.
4.6 Environmental Conditions
Pending release of the Geotechnical site survey report, the following assumptions
have been made with regards the resistivity values to be used during the design of
the cathodic protection systems:
Page 19 of 63
Table 4.3 Design Resistivity Values
LOCATION / ENVIRONMENT RESISTIVITY (ohm.metres)
Soil (for buried piping) 1.319(1)
On-grade tank (infill below tank bottom) 150 - 500
Buried vessels (infill around vessel) 150 - 500
Water storage tanks (fresh water) 20

Notes:
(1) Soil resistivity values for soil based on a survey undertaken along the Naftkhaneh to Baghdad gas
pipeline project.
4.7 Ambient Design Temperatures

The ambient design temperatures for CP equipment are 13.4°C to 25.4°C.
Average relative humidity range are 5% to 100%.
Soil temperature range is 10°C to 35°C.
Average annual rainfall is 254mm, with a design max. rainfall in one day of 100mm.
4.8 Design Basis
4.8.1 External Protection of Buried Piping
Buried piping will be protected against corrosion by the application of a coating
system in accordance with Project specification and a cathodic protection system.
A temporary cathodic protection system will be applied during the construction phase,
comprising use of galvanic ‘sacrificial’ anodes (pre-packaged zinc alloy type) installed
alongside the buried piping.
The galvanic anodes will be installed at piping invert depth, with maximum 2 metre
spacing from the piping and will be bonded to the piping via above ground test
facilities. In the absence of such facilities, to ensure they are not damaged during the
construction phase, a temporary connection between the anodes and the potential
monitoring cables installed for the test facilities will be made.
Details of the quantities of pre-packaged zinc anodes required will be detailed within
the design calculations as presented in Appendix 1.
Note:
Although it is assumed that buried in-plant piping will be electrically continuous with
above ground piping and station earthing and that this will have a drain on the CP
current. It is considered that during the construction no electrically continuity will be
in place and therefore temporary CP will have a beneficial effect on the protection of
the buried piping.
Page 20 of 63
Permanent cathodic protection of buried metallic piping will be by a distributed

impressed current cathodic protection system. This type of system will ensure that
protective current can be applied in congested piping areas and where piping may be
shielded due to the proximity of structures such as buildings with steel reinforced
concrete pilings or concrete support foundations.
The system will use tubular mixed metal oxide (MMO)/titanium anodes with a
petroleum coke backfill within a steel canister. The titanium substrate shall be coated
with a MMO layer of sufficient thickness to achieve the design life at the maximum
design current output. The diameter of the tubular anode shall be 25mm. The
anodes will be connected to a 10mm2 conductor cable.
The anode-to-pipe spacing and anode-to-anode spacing depend primarily upon the
pipe diameter, pipe coating and soil resistivity. For the In-Plant buried piping, an
inter-anode spacing has been chosen to achieve the optimum potential shift of the
buried piping. Sample potential shift calculations are given in Appendix 1 and a
summary is given in Table 4.4.
There will be 100 transformer rectifiers dedicated to the buried piping, each will feed
2No. PDB’s (in total 2 x 100) and a total of 2000 No. MMO anodes.
Provision will be made to control individual anode circuit currents via resistors
installed within the PDB, which will be fed from the transformer rectifier. PDB’s shall
be sited in non-hazardous areas alongside anode runs so as to evenly balance
anode cable tail lengths wherever possible.
Table 4.4 Summary of CP calculations for buried piping
TR PDB ANODE ANODE ANODE POTENTIAL POTENTIAL

TO PIPE TO OPPOSITE BETWEEN
QTY QTY QTY SPACING ANODE ANODES (V) ANODES (V)
(m) SPACING
(m)
100 200 2000 1.5 10 -1.114 -1.066
Where possible all CP cables from the anodes to the PDBs and from the PDBs to the
transformer rectifiers shall be run underground along the ‘anode’ trench. Cables will
be buried to a depth of at least 1m and shall have electrical warning tape laid above
them. Positive and negative cables from the transformer rectifier shall be armoured.
Above-ground concrete cable markers will be installed every 30m and at each
change of direction.
A total of 200 No. test facilities will be installed at selected locations along the buried
piping within the plant, to allow routine testing of the performance of the installed
system. Permanent reference electrodes and CP polarisation coupons will be
installed at all test facilities.
The steel reinforcement within the concrete is not included in the CP system;
however it is assumed that the buried piping will not be electrically isolated from
above ground piping and ultimately station earthing.
Therefore, current drain to concrete reinforcement and current drain to the plant
electrical earthing (assumed to be galvanised steel) is included in the CP system for
buried piping. The current demand by the concrete reinforcing steel and the earthing
electrodes is outlined in the design calculations as presented in Appendix 1.
Page 21 of 63
4.8.2 External Protection at Cased Road Crossings

Cathodic protection of the buried metallic piping casings shall be either by:
 the existing impressed current system protecting the normally buried metal
piping, supplemented to cover the casing, or
 galvanic anodes for casings of normally above grade piping.
Where protection of the pipe casings is provided by the existing impressed current
system, bonding facilities will be installed at either end of the casing to allow a
resistive connection to the impressed current system via the normally buried metal
piping. This will also provide facilities for monitoring the level of cathodic protection
applied to the casing, using permanent reference electrodes.
Cathodic protection systems for the piping casings by galvanic anodes will have test
facilities at either end of the casing to allow connection of the galvanic anodes and
monitoring of the CP system, using permanent reference electrodes.
Cathodic protection of the carrier pipe within casings at road crossings will be by zinc
ribbon anode, installed at the 6 o’clock position along the length of the carrier pipe.
The zinc anodes will be tied back to a test post installed at either end of the casing.
Permanent reference electrodes will be installed within the casing and tied back to
the test facilities to enable monitoring of the CP system in the event of its activation
due to water ingress into the casing.
Details of the quantities of pre-packaged zinc anodes and the length of zinc ribbon
required will be detailed within the design calculations as presented in Appendix 2.
4.8.3 External Protection of On-Grade Storage Tanks
Corrosion protection of the external bottoms of on-grade storage tanks, supported on
concrete ring beams with a sand infill, will consist of a coating system in accordance
with Project specification and a cathodic protection system.
The cathodic protection system will comprise an impressed current grid anode
installed directly below the tank bottom in the sand infill.
The system will use ribbon MMO/titanium anodes laid in parallel lines with titanium
conductor bars laid perpendicular to the anode and spot welded to each other at
each crossing point.
The anode titanium substrate shall be coated with a MMO layer of sufficient thickness
to achieve the design life at the maximum design current output. The ribbon anodes
will be nominally 6.35mm wide by 0.6mm thick. The titanium conductor bar will be
nominally 12.7 mm wide by 0.9 mm thick and will be connected to a 10 mm2
conductor cable.
The anode-to-tank bottom spacing and anode-to-anode spacing has been calculated
to achieve the optimum potential shift on the tank bottom. Sample potential shift
calculations are given in Appendix 3 and a summary is given in Table 4.5.
There will be 1No. transformer rectifier dedicated to each tank external CP system,
which will feed 1No. AJB into which a minimum of 3 No. power cables to the titanium
conductor bars will be terminated. Number of power cables required will be sufficient
to cope with the maximum current output from the TR.
Page 22 of 63
Table 4.5 Summary of CP calculations for tank bottoms
TANK ID ANODE Ti ANODE ANODE TO POTENTIAL POTENTIAL

QTY (m) BAR TO TANK ANODE RANGE RANGE
QTY SPACING SPACING OPPOS BETWEEN
(m) (m) (m) ANODES ANODES
(V) (V)
0-T-52 02 1136 320 1.00 1.00 -1.083 -1.051
0-T-52 10 1312 430 1.00 1.50 -1.089 to -1.022 to

-1.093 -1.026
0-T-72 03 309 93 1.00 0.50 -1.054 to -1.046 to

-1.058 -1.050
0-T-73 01 110 28 1.00 0.40 -1.054 to -1.048 to

-1.059 -1.053
0-T-74 01 227 65 1.00 0.50 -1.059 to -1.051 to

-1.055 -1.046
0-T-76 01 217 55 1.00 0.40 -1.060 to -1.055 to

-1.058 -1.052
0-T-79 01 – 343 109 1.00 1.00 -1.064 to -1.032 to

A/B -1.065 -1.034
Note:
(1) The quantities of anode and Ti conductor bar are based on the requirements for a single tank, for
multiple tanks the values are to be increased accordingly e.g. 0-T-79 01, 2 No. in total.
Where possible all CP cables from the titanium conductor bars to the AJB (once clear
of the tank bottom) and from the AJB to the transformer rectifier shall be run
underground. Cables will be buried to a depth of at least 1m and shall have electrical
warning tape laid above them. Positive and negative cables from the transformer
rectifier shall be armoured. Above ground concrete cable markers will be installed
every 30m and at each change of direction.
Monitoring of the cathodic protection system shall be through access tubes through
tank ring walls (to monitor tank periphery potentials), and a slotted monitoring tube
laid under the full diameter of the tank (to monitor tank bottom potentials).
Permanent reference electrodes shall also be installed within the sand in-fill beneath
the tank bottom, to provide additional cathodic protection monitoring facilities.
A single test facility will be installed opposite to where the cable tails for the
permanent reference electrodes exit from underneath the tank, to allow termination of
the cable tails. This test facility will also allow termination of a cathode sensing cable,
from the tank, to enable monitoring of the CP system.
Electrical isolation of the tank from piping off the tank will not be applied, however
due to the design of the CP system there will be no need to account for drain on the
CP system from concrete reinforcing or station earthing system.
Page 23 of 63
A HDPE liner shall be installed within the concrete ringbeam, between the concrete
and the sand infill. This will provided a secondary containment barrier as well as
protecting the ring beam steel reinforcing from interference effects from the under
tank CP system.
Where possible, all test facilities, junction boxes and transformer rectifiers will be
installed in non-hazardous areas.
4.8.4 External Protection of Buried Vessels
Corrosion protection of the external surfaces of buried vessels, including those
supported on mounds then covered over and those installed in concrete chambers
then filled with sand, will consist of a coating system in accordance with Project
specification and a cathodic protection system.
Cathodic protection of buried vessels will be by MMO coated titanium anodes,
installed around the periphery of the buried vessel in anode strings/loops, a minimum
number of 2 anode loops per buried vessel to be installed. For vessels installed in
concrete chambers backfilled with sand, the CP anodes shall be installed within the
concrete chamber.
The system will use tubular MMO/titanium anodes with a petroleum coke backfill
within a steel canister. The titanium substrate shall be coated with a MMO layer of
sufficient thickness to achieve the design life at the maximum design current output.
The diameter of the tubular anode shall be 25 mm. The anodes will be connected to
a 10 mm2 conductor cable which will in turn be connected to a main 35 mm2 anode
loop feeder cable.
The anode-to-anode spacing per loop and anode loop-to-anode loop spacing being
dependent upon the vessel diameter and the soil resistivity. For the buried vessels,
an inter-anode spacing has been chosen to achieve the optimum potential shift on
the buried vessel. Sample potential shift calculations are given in Appendix 4 and a
There will be 1 No. transformer rectifier dedicated to each buried vessel external CP
system, which will feed 1 No. PDB into which the anode loop feeder cables shall be
terminated.
Page 24 of 63
Table 4.6 Summary of CP calculations for buried vessels (external)
VESSEL ANODE ANODE LOOP TO POTENTIAL POTENTIAL

ID TO LOOP RANGE RANGE
QTY ANODE SPACING OPPOS BETWEEN
SPACING (m) ANODES (V) ANODES (V)
(m)
0-V-22 34 2.00 4.75 -1.067 to -1.053 to

01 – A/F -1.068 -1.065
0-V-22 34 2.00 4.75 -1.067 to -1.053 to

02 -1.068 -1.065
Note:
(1) The quantities of anode are based on the requirements for a single vessel, for multiple vessels the
values are to be increased accordingly e.g. 0-V-22 01 A/F 6No. in total.
Where possible all CP cables from the anode loop feeder cables to the PDB and from
the PDB to the transformer rectifier shall be run underground. Cables will be buried
to a depth of at least 1 m and shall have electrical warning tape laid above them.
Positive and negative cables from the transformer rectifier shall be armoured. Above
ground concrete cable markers will be installed every 30 m and at each change of
direction.
Monitoring of the cathodic protection system shall be through use of above ground
test facilities located at one end of the buried vessel. Permanent reference
electrodes and CP polarisation coupons shall be employed at each test facility to aid
potential monitoring; in addition a 3 inch dia. plastic pipe shall be installed directly
above the buried vessel, to enable a portable reference electrode to make direct
contact with the soil.
Electrical isolation of the buried vessel from piping off the structure will not be
applied. However, a fully bonded buried vessel will result in current drain from the
cathodic protection system to earthing, rebar, foundations etc., which will be
accounted for in the detailed design. Where direct connection between the buried
vessel and an earthing system is proposed then dc decouplers, such as polarisation
cell replacement units, will be installed in series between the buried vessel and the
earthing system.
4.8.5 External Protection of Buried Fire Hydrant Piping
Buried fire hydrant piping will be protected against corrosion by the application of a
coating system in accordance with Project specification and a cathodic protection
system.
Cathodic protection of the Fire Hydrant buried piping will be by pre-packaged
galvanic ‘sacrificial’ anode. The galvanic anode will be installed horizontally, at piping
invert depth, with a maximum 2 m spacing from the piping. The galvanic anode will
be bonded to the piping via an above ground test facility.
Page 25 of 63
The type of galvanic anode and the number and size will be based on meeting the
potential criteria as specified in section 4.2 and the current density requirements as
per section 4.3. Sample design calculations as presented in Appendix 5.
Monitoring of the cathodic protection system shall be through use of above ground
test facilities located adjacent to, but not in a position that interferes with the
operation of the hydrant system. Permanent reference electrodes shall be employed
at each test facility to aid potential monitoring; in addition a 3 inch dia. plastic pipe
shall be installed directly above the buried piping, to enable a portable reference
electrode to make direct contact with the soil.
Where possible, all test facilities will be installed in non-hazardous areas.
4.8.6 Internal Protection of the Firewater Storage Tanks
The internal wetted surfaces of firewater storage tanks will be protected against
corrosion by the application of a coating system in accordance with Project
specification and a cathodic protection system.
The cathodic protection system will be based on a suspended impressed current
anode system.
Note:
Other than firewater storage tanks, there is no further requirement to provide CP to tanks with a possible
water layer, corrosion protection will be provided solely by use of an internal lining, see Table 2.3 for
further details.
Firewater storage tanks will be protected internally using an impressed current CP

system based on suspended MMO coated titanium anodes arranged in a circular
pattern with one at the centre.
The system will use tubular MMO/titanium anodes. The titanium substrate shall be
coated with a MMO layer of sufficient thickness to achieve the design life at the
maximum design current output. The diameter of the tubular anode shall be 25mm.
The anodes will be connected to a 10 mm2 conductor cable which will be terminated
in cable splice box located on the roof of the tank directly above the suspended
anode. A 35 mm2 anode power feed cable will be connected to the anode cable tail
within each of the cable splice boxes and brought across the roof to a common point
then down the side of the tank, to be terminated inside a PDB at ground level.
The arrangement of the suspended anode strings has been chosen to achieve the
potential criteria as specified in section 4.2 and the current density requirements as
per section 4.3. Sample design calculations as presented in Appendix 6 and a
There will be 1 No. transformer rectifier dedicated to each tank internal CP system,
which will feed 1 No. PDB into which the suspended anode power feeder cables shall
be terminated.
Page 26 of 63
Table 4.7 Summary of CP calculations for water tanks (internal)
TANK ID ANODE ANODE AT DIAMETER POTENTIAL

QTY TANK CENTRE OF ANODE RANGE (V)
(Y/N) ARRAY (m)
0-T-79 01 – A/B 8 N 12.3 -0.917 to -

1.130
(2 anodes per 4
suspended anode
strings)
Note:
(1) The quantities of anode are based on the requirements for a single tank, for multiple tanks the
values are to be increased accordingly e.g. 0-T-79 01 A/B 2No. in total.
Where possible all CP cables from the PDB to the transformer rectifier shall be run
underground. Cables will be buried to a depth of at least 1m and shall have electrical
warning tape laid above them. Positive and negative cables from the transformer
rectifier shall be armoured. Above ground concrete cable markers will be installed
every 30 m and at each change of direction.
Monitoring of the cathodic protection systems (ICCP) for the water storage tanks
shall be undertaken by use of ‘through wall’ mounted permanent reference electrodes
(installed through the tank side wall). Cable tails from each permanent reference
electrode shall be brought down the side of the tank to terminate inside a test box
located at ground level. Permanent reference electrodes shall be approved to
withstand the environment they shall be used in. As an alternative and to cover for
possible failure of the permanent reference electrodes, use of roof-top access holes
to allow insertion of a portable reference electrode shall be employed. It should be
noted that accessing the roof top is considered an increased safety hazard and so
should only be used in the event of failure of the permanent reference electrodes.
Electrical isolation of the tank from piping off the tank will not be applied.
Page 27 of 63
APPENDIX 1: CP CALCULATIONS FOR BURIED PIPING (SHEETS 1-7)

The following calculations were developed by KBR, Report ZZ-CE-GEN-RPT-0010. The
calculations have been reviewed by Petrofac for correctness and accuracy. Note that
the sizes have changed but the change has not affected the calculated anode
requirement. This information is attached for reference and the EPC Contractor shall
revisit the analysis to confirm the suitability.
Page 28 of 63
TEMPORARY CATHODIC PROTECTION DESIGN USING ZINC ALLOY ANODES - IN-PLANT BURIED PIPING
Design Criteria Calculations Eqn 1 A s    d  L piping

Design Life (tf) 2 yrs Coated surface area (As) (Eqn 1) 31.416 m2
Anode efficiency (ε) 738 Ahr/kg Current Required (Icp) Initial 0.0141 Amps Eqn 2 I cp  icp ,coated  As
Anode potential 1.1 V wrt Cu/CuSO4 ref cell (Eqn 2) Average 0.0141 Amps
Utilisation factor (u) 0.9 Final 0.0141 Amps Eqn 3 I cm  t  8760
W ( kg ) 
f
Current density initial 4.00E-04 A/m2 Anode efficiency 738 Ahr/kg
u 
(coated) average 4.00E-04 A/m2 Total weight required (W) (Eqn 3) 0.37 kg
final 4.00E-04 A/m2 Delta V (Eqn 4) 0.25 Eqn 4 V  Eco  Eao
Alloy density (ρ d) 7.1 g/cm3 Length of anode-final (Lf) (Eqn 5) 104.01 cm
Protected potential 0.85 V wrt Cu/CuSO4 ref cell Mass of anode-final (m f) (Eqn 6) 2040 g Eqn 5 L f  Li  0.10  u  Li
Surface Area to apply initial 100% Vol of anode-final (Vf) (Eqn 7) 287.32 cm3
coated current density average 100% Dia of anode-final (df) (Eqn 8) 1.88 cm Eqn 6 m f  mi  1  u 
value final 100%
Anode depth below surface (t) 120 cm Eqn 7 mf
Vf 
Resistance of anode (initial) 3.888 ohms
d
Anode Dimensions Environment Details Resistance of anode (final) 7.816 ohms
Length (bare) 114.3 cm (Eqn 9)
Length (pack.) 129.5 cm Soil Resistivity (ρr) 1319 ohm.cm Eqn 8 Vf
Width (bare) 5.1 cm Temperature (t') 35 C0
Anode current output Initial 0.064 Amps d f  2
Height (bare) 5.1 cm (Eqn 10) Final 0.032 Amps
Lf 
Eq. Dia (bare) 6.49 cm
Dia (pack) 12.7 cm No of for mass 0.018 = 1 No. Eqn 9
r  L2 
Net weight 20.4 kg anodes for current 0.442 = 1 No. Ra  ln  
Notes 2   L  td 
1) Current density values based on that proposed in Table 7.2 = 0.4mA/m 2, and includes for coating breakdown factor
envisaged over the design life e.g. 10 years where anode is placed horizontally at shallow
2) Table below details list of buried CS casings at road crossing within the Mansuriya Gas Plant. depths below grade
3) Item No. 1 surface area used as example for calculation above.
Eqn 10 V
I A 
Ra
Page 29 of 63
Temperature Corrected Current Density Requirements Current Density Correction For Elevated Temperature Service
i' = io + io 0.25 t' - to

10
Base Surface Area (r2) = 31.416 m²
Temperature Corrected : Where : i' = Protective current density at operating temperature (mA/m 2)
Coated Current Density (initial) = 0.450 mA/m² io = Protective current density at 30 oC (mA/m2)
Coated Current Density (average) = 0.450 mA/m² t' = Operating Temperature (oC)
Coated Current Density (final) = 0.450 mA/m²
to = 30 oC
Initial Coating Breakdown = 100% (initial) (average) (final)
Initial Current Requirement = 14.14 mA If : io = 0.400 0.400 0.400 mA/m²
35 o
t' = C
Mean Coating Breakdown = 100% o 30 o
t = C
Mean Current Requirement = 14.14 mA
i' = 0.450 0.450 0.450 mA/m²
Final Coating Breakdown = 100% (initial) (average) (final)
End of Life Current Requirement = 14.14 mA
Final 'temp
correctd'
Item No. Fire Hydrant Riser Riser pipe Surface Current Current Anode Calc No. of
Dia Dia Len. Area Density Required I Output Weight Anodes
in m m (m2) (mA/m2) (mA) (mA) (kg) Required
1 OWS - 0.10 100 31.416 0.450 14.1 32.0 0.37 1

2 ACS - 0.20 100 62.832 0.450 28.3 32.0 0.75 1
3 CD - 0.10 100 31.416 0.450 14.1 32.0 0.37 1
Page 30 of 63
CATHODIC PROTECTION DESIGN Sheet: Cathodic Protection Current Requirement Calculation By: PAN 22/02/13
PERMANENT ICCP Facility: 100mm dia. Buried Piping Checked By:
Plant: Mansuriya Refinery Rev: 0
Drawing
1) Current Demand Calculation
Facility: Buried CS Piping

0.90 = Base Current Density at 30 o C (mA/m2 ) ** ** From Table 7.2 - current density criteria for FBE coated piping at end of 30yr life
35 = Operating Temperature (o C)
1.01 = Protective Current Density (as base current density) (mA/m2 )
Line Description Line Ø (m) Length (m) S.A. (m²) Current (A)
Oily Water System (OWS) or Closed Drain (CD) lines 0.1 200 63 0.06
0 0 0.00
0 0 0.00
0 0 0.00
Totals = 200 63 0.06
Facility: Concrete Reinforcing Steel
2.00 Current Density For Coated Steel at End of Life (mA/m2 ) **
Qty Length (m) Width (m) Depth (m) S.A. (m²) Current (A)
10 15.0 0.3 0.3 182 0.36
0.0 0.0 0.0 0 0.00
Totals = 182 0.36
Facility: Electrical Earthing
50 Current Density (mA/m2 ) **
S.A. (m²) Current (A) Current Demand Summary

100 5.00 Buried CS Piping 0.06
0.00 Concrete Reinforcing Steel 0.36
0.00 Electrical Earthing 5.00
Totals = 5.00 Total Current Demand : 5.43A
2) Choose Anode Type, Size, Weight & Arrangement
Anode Material Mixed Metal Oxide (MMO)

Anode Length 1.5 m Based on Vendor data
Anode Diameter 0.025 m Based on Vendor data
Anode Weight 2.5 kg Based on Vendor data
Anode Consumption Rate 1.00E-06 kg/amp-y Based on Vendor data

Maximum Current Density 66.7 A/m2 Based on Vendor data
Anode Current Capacity 7.86 Amps/anode Based on Vendor data
a) CP Arrangement
TR
PDB PDB
No. of individually cable tailed anodes evenly spaced No. of individually cable tailed anodes evenly spaced
Number of Anodes in each Groundbed 10 No.

Anode to Anode Spacing 10 m
Anode to Pipeline Horizontal Spacing 1 m Page 31 of 63
3) Anode Resistance
a) Vertical Anode Resistance to Earth, Single Anode (Dwight's modified equation)
Ra,v = Single Vertical Anode Resistance to Remote Earth (W)

  8L 
Ra ,V   ln  1
Where; 2   L  d 
r = Soil Resistivity, (Wcm)
L = Backfill Column Length, (cm)
d = Backfill Column Diameter, (cm)
b) Resistance to Earth, Multiple Anodes (Baeckmann, Schwenk, Prinz; Cathodic Corrosion Protection, 1997, p544, section 24.2)
Interference Factor (F ) : 
Where; F  1 ln 0.66n
r = Soil Resistivity, (Wcm)   s  Ra,V
R = Single Anode Resistance, (W)
s = Anode Spacing, (cm)
n = No. of Anodes in Groundbed, (n)
R
Total resistance of n anodes (R n ) : Rn  Fn
n
c) Calculations
PDB 1 PDB 2
Where; Soil Resistivity, r (Wcm) = 1319 1319

Anode Canister Length, L (cm) = 200 200
Anode Canister Ø, d (cm) = 16 16
Single Anode Resistance, R t (Ω) = 3.78 3.78
No. of Anodes in Groundbed (n) = 10 10

Anode Spacing (S) Within Groundbed (m) = 10.0 10.0
Interference Factor (F ) : 1.2094 1.2094

Total resistance of n anodes, R n , (Ω): 0.4576 0.4576
4) Resistance of Anode & Header Cables

Outside Ambient Temperature = 25 DegC From Section 7.7 - Ambient Design Temperatures
Resistance
Resistance (Ω/m) @ DC Current
Conductor Size (Awg or mm ) 2
(Ω/m) @ 25
20 deg.C Rating (A)
deg.C
AWG10 0.00335 0.00350 30 Relation between cable resistance and temperature (US
Dept of Commerce, Nation'l Bureau of Standards
AWG8 0.00210 0.00220 45
Handbook 100, pg 14, Table 3)
AWG6 0.00132 0.00138 65
Rt  Rti  1   ti  t  t i 
Cable Resistance Figures From NACE
AWG4 0.00083 0.00087 85
Corrosion Eng's Ref Book, 2nd Ed'n.;
AWG3 0.00066 0.00069 100
p 109.
AWG2 0.00052 0.00055 115
AWG1 0.00041 0.00043 130 Where:
10 0.00183 0.00191 45 Rt = Resistance at temperature, t (Ω/m)
16 0.00115 0.00120 65 Rti = Resistance at 20degC temperature (Ω/m)
25 0.000727 0.000760 85 αti = Temp.coefficient @ 20degC = 0.00383
35 0.000524 0.000548 115 Cable Resistance Figures From t = Temperature (degC)
50 0.000387 0.000405 150 Vendor data. ti = Initial temperature (20degC)
70 0.000268 0.000280 185
95 0.000193 0.000202 230
Page 32 of 63
TR Locations per Drawings, Cable Length Take Offs as Follows; Entries from input sheet
PDB 1 Anode No.: 1 2 3 4 5 6 7 8 9 10

Cable Length (m) Lc 55 45 35 25 15 15 25 35 45 55
2
Anode Cable Gauge (mm ) 10 0.00191 0.00191 0.00191 0.00191 0.00191 0.00191 0.00191 0.00191 0.00191 0.00191
Cable Resistance (W) Rc 0.1053 0.0861 0.0670 0.0479 0.0287 0.0287 0.0479 0.0670 0.0861 0.1053
Anode Cabling Resistance For Anodes In Parallel Calculated Using Following Expression; 1/Rc = 1/R1 + 1/R2 + 1/R3 + . . . 1/Rn
Resistance of Anode Cables, Rc = 0.00544888 W
2
Main Positive Header Cable Gauge (mm ) = 35
Main Positive Header Cable Length (m) = 100
Resistance (Ω/m) @ 25 deg. C= 0.000548
Main Positive Header Cable Resistance, Rp = 0.05481 W
Cable Resistance RwT1 PDB 1 = Rc + Rp 0.0603 W
Resistance For PDB 1 (anode + cabling) = Rn + Rw = 0.51789 W
PDB 2 Anode No.: 1 2 3 4 5 6 7 8 9 10

Cable Length (m) Lc 55 45 35 25 15 15 25 35 45 55
Anode Cable Gauge (mm2 ) 10 0.00191 0.00191 0.00191 0.00191 0.00191 0.00191 0.00191 0.00191 0.00191 0.00191
Anode Cabling Resistance For Anodes In Parallel Calculated Using Following Expression; 1/Rc = 1/R1 + 1/R2 + 1/R3 + . . . 1/Rn
Resistance of Anode Cables, Rc = 0.00544888 W
Main Positive Header Cable Gauge (mm2 ) = 35

Cable Resistance RwT1 PDB2 = Rc + Rp 0.0603 W
Resistance For PDB 2 (anode + cabling) = Rn + Rw = 0.51789 W
Main Negative Header Cable

Main Negative Header Cable Gauge (mm2 ) = 35
Main Negative Header Cable Length (m) = 20
Main Negative Header Cable Resistance, Rn = 0.01096 W
Total Resistance For , Rtotal, (ohms) = 0.2699 W R_total={1/(1/R_PDB1 +1/R_PDB2)}+R_NEG
Page 33 of 63
5) Transformer Rectifier Output

V= 50 V
I= 50 A
Allowance For Back EMF = 2 V
R Allowable (V=IR) = 0.960 W

R Actual = 0.270 W (Therefore Rectifier Sizing OK )
6) Cable Volt Drop

Volt Drop Across Cables = Vd = I max . Rw = % Voltage Drop 3.013 V Based On Longest Pos Run
Calculated % Voltage Drop = 6.03% Maximum Permissable Voltage Drop to be 10% of Applied Voltage
Maximum Allowable % Voltage Drop = 10.00% (Therefore Volt Drop is OK)
7) Anode Current Density
A Total of 20 Anodes Are Required For Design Purposes. Anodes Will Be Designed To Operate at Maximum (including contingency) 120% Output
Anode Maximum Operating Output = 3.00 Amps

Anode Surface Area = 0.12 m2
Maximum Allowable Anode Current Density = 67 A/m2 Based on max. cd for 20yr life (100A/m2) in pet coke backfill and extroplated for project design life (30yrs)
Actual Anode Operating Current Density = 25.46 A/m2 (Therefore Anode Operating Current Density is OK)
Coke Canister Surface Area = 1.0 m2
Actual Coke Operating Current Density = 2.98 A/m2
Maximum Allowable Coke Backfill Current Density = 10 A/m2 (Therefore Coke Operating Current Density is OK)
(Current Density Held at 10A/m2 in Order to Prevent Degradation of Backfill)
8) Potential Shift At Maximum Current Output

I  t  L  r 2  t  L 2 
The Potential Shift For a Single Vertical Anode (Vx) Is Given By; Ur  ln   Based on formula given in sec 7.2.1 of Design Philosophy (ZZ-CE-GEN-PHL-0006)
2  L  t  r2  t2 
 
Where,
L = Anode length, (cm) = 200
r = Anode to Pipe Separation, (cm) = 150
t = Anode depth below surface, (cm) = 300 Total Current Output of TR
I = Current flow from the anode, (Amp) = 0.5A Manual Entry 10.00A
 = Soil Resistivity, (W.cm) = 1319
Case 1 - 10m Single Sided Spacing. Protection to Midpoint Between Two Adjacent Anodes (seven anode contribution considered)
G E 1000cm C A B D F
W
Horizontal distance from anode to a given point on the structure (cm), =
Anode Distance (cm) to W Shift
Anode A 522.0 0.160V Contibutions >50mV
Anode B 522.0 0.160V Contibutions <50mV
Anode C 1,507.5 0.067V
Anode D 1,507.5 0.067V
Anode E 2,504.5 0.041V
Anode F 2,504.5 0.041V
Anode G 3,503.2 0.030V
Total shift (-V) = 0.566V wrt Cu/CuSO4 ref electrode
Page 34 of 63
Natural potential (-V) = 0.500V wrt Cu/CuSO4 ref electrode
Applied potential (V) = -1.066V wrt Cu/CuSO4 ref electrode
Case 2 - Single Sided Spacing. Protection to Directly Opposite an Anode (seven anode contribution considered)
F D 1000cm B A C E G
X
Anode Distance (cm) to X Shift
Anode A 150.0 0.249V
Anode B 1,011 0.096V
Anode C 1,011 0.096V
Anode D 2,005.6 0.051V CP POTENTIAL RANGES (steel in soil) **
Anode E 2,005.6 0.051V The target IR free potential value for protection shall be:-0.85 to -1.2 Volts versus Cu/CuSO4 half-cell
Anode F 3,003.7 0.035V
Anode G 3,003.7 0.035V
Total shift (-V) = 0.614V wrt Cu/CuSO4 ref electrode
Natural potential (-V) = 0.500V wrt Cu/CuSO4 ref electrode
9) Calculated System Life
Design life for an impressed current distributed anode system is given by:
 AnodeMaxCurrentDensi ty 
AnodeLife     DesignLife
 AnodeOperatingCurrentDensity 
Where:
Maximum Allowable Anode Current Density = 67 A/m2
Actual Anode Operating Current Density = 25.46 A/m2
Project Design Life = 30 Years
DL = Design Life, (years) 79 OK Meets project Design Life requirements (30 years)
Page 35 of 63
APPENDIX 2- CP CALCULATIONS FOR BURIED CASING (SHEETS 1-3)

The following calculations were developed by KBR, Report ZZ-CE-GEN-RPT-0010.
The calculations have been reviewed by Petrofac for correctness and accuracy. Note
that the sizes have changed but the change has not affected the calculated anode
Page 36 of 63
PERMANENT CATHODIC PROTECTION DESIGN USING ZINC ALLOY ANODES - CASING PROTECTION AT RDX

W ( kg ) 
f
u 
value final 100%
Vf 
d
Width (bare) 5.1 cm Temperature (t') 35 C0
Anode current output Initial 0.064 Amps d f  2
Lf 
r  L2 
Notes 2   L  td 
1) Current density values based on that proposed in Table 7.2 = 0.003A/m 2, and includes for coating breakdown factor
2) Table below details list of buried CS casings at road crossing within the Mansuriya Gas Plant. depths below grade
Eqn 10 V
I A 
Ra
Page 37 of 63
i' = io + io 0.25 t' - to

10
to = 30 oC
35 o
t' = C
t = C
i' = 3.375 3.375 3.375 mA/m²
Final
'temp
correctd' No. of Total No. of
Item No. RDX No. Carrier Pipe Casing Pipe Surface Current Current Anode Calc No. of anodes anodes
Dia Dia Len. Area Density Required I Output Weight Anodes per test based on
in m m (m2) (mA/m2) (mA) (mA) (kg) Required post 2 No. TP's
1 - 100mm OWS - 0.20 15 9.425 3.375 31.8 32.0 12.59 1 1 2

2 - 200mm ACS - 0.40 15 18.850 3.375 63.6 32.0 25.17 2 1 2
3 - 100mm CD - 0.20 15 9.425 3.375 31.8 32.0 12.59 1 1 2
Page 38 of 63
CATHODIC PROTECTION DESIGN - IN PLANT ROAD CROSSINGS, CARRIER PIPES INSIDE CASINGS
Calculation of anode requirements for protection of carrier piping inside cased road crossings utilising zinc ribbon anodes.
Actual
Carrier Carrier Length of
Pipe Pipe Calculated Ribbon to
/Casing Surface Current Current Anode Current Current Length of be
Carrier Locn Ø Length Area Density Required Output Supplied Calc. Weight Ribbon Casing Length Installed
2
Pipe (in) (m) (m) (m²) (mA/m ) (mA) (mA/lin.m) (mA) (kg) Required (m) (m) (m)
100mm OW - 0.10 15.00 4.71 3 14 18 74 6 4.0 15.0 15.0

200mm ACS - 0.20 15.00 9.42 3 28 18 129 12 7.0 15.0 15.0
100mm CD - 0.10 15.00 4.71 3 14 18 74 6 4.0 15.0 15.0
Total = 15
Zn anode alloy weight 1.8 kg/m Anode Output 1.1 Vcse Anode Width 1.6 cm
Design life 30 Years Resistivity 1319 W.cm Anode Width 2.2 cm
Anode capacity 738 Ah/kg Alloy Density 7,100 kg/m3 Anode Insert Ø 0.32 cm
Anode utilisation 0.85 Anode Length 1 m
Anode life can be calculated from the formula L = (Anode Weight X Capacity X Utilisation) / (8,766 X Current Demand)
Mean anode alloy weight required = (L X 8,766 X Current Demand) / (Capacity X Utilisation)
Alloy weight required (kg) = See Calc. Weight Column in Spreadsheet
Start of Life;
Resistance of 1m of Zinc Ribbon where: Ra = Anode Resistance (W) r= 1.210 cm
Ra = (/(2L))x(ln(4L/r)-1)  = Soil Resistivity (W.cm) Ra = 10.08 W
(modified Dwight) L = Length of Anode (cm)
r = Effective Anode Radius (cm) = (Anode Circumference / 2pi)
The potential has been taken as -850 mV vs. a Cu/CuSO4 half cell for design purposes, if the natural potential of the line is more negative there will be corresponding reduction in current demand from the anode.
Current output of Zn ribbon anode in site conditions can therefore be calculated from V over the anode resistance to earth
Anode open circuit potential - pipe design protective potential / Anode resistance to electrolyte
Anode current = 0.025 Amps per linear metre
Alloy length required at start of life = (Start of Life Current Demand) / (Start of Life Anode Current Output)
Length of Zn Ribbon Required = See Length of Ribbon Reqd - Initial in Spreadsheet
End of Life;
At the end of life, it is assumed that 85% of the anode weight has been consumed;Weight of Zn Alloy remaining at end of life = (1-U) x1.8 kg = 0.27 kg Effective Anode Ø at End of Life = 0.73 cm
Length of Zn ribbon at end of life = Linitial - (0.1*U*Linitial) = 0.915 m
Resistance of 1m of Zn Ribbon where: Ra = Anode Resistance (W)
Ra = (/(2L))x(ln(4L/r)-1)  = Soil Resistivity (W.cm) r= 0.364 cm
L = End of Life Length of Anode (cm) Ra = 13.57 W
r = Effective Anode Radius (cm)
The potential has been taken as -850 mV vs. a Cu/CuSO4 half cell for design purposes, if the natural potential of the line is more negative there will be corresponding reduction in current demand from the anode.
Current output of Zn ribbon anode in site conditions can therefore be calculated from V over the anode resistance to earth
Anode open circuit potential - pipe design protective potential / Anode resistance to electrolyte
Anode current = 0.018 Amps per linear metre
Alloy length required at end of life = (End of Life Current Demand / End of Life Anode Current Output) OR (Calc Weight Reqd / anode unit weight) - whichever is the greater
Length of Zn Ribbon Required = See Length of Ribbon Reqd - Final in Spreadsheet Calculation By: PAN 25/02/13
Checked By:
Rev: 1
Page 39 of 63
APPENDIX 3 – CP CALCULATIONS FOR TANK BOTTOMS (SHEETS 1-5)

Page 40 of 63
CATHODIC PROTECTION DESIGN Sheet: Cathodic Protection Current Requirement Calc. By: PAN 25/02/13
Facility: Aboveground Storage Tank External Checked By:
(Permanent CP System)
Rev: 0
Plant:
1) Tank Tag 0-T-52 02 REFERENCE SOURCES EQUATIONS / FORMULAE

Off-Spec Condensate
Storage Tank
Tank IDØ (Dia tank) m 39.00 Equipment List : ZZ-PR-DAS-LST-0050
Diameter of Exposed tank Bottom (Dia tankbottom) m 38.00 Assumed, based on tank rim supported on half thickness of concrete ringbeam
Ring Beam thickness (Thkringbeam) m 1.00 Assumed
〖〗_ = ×( 〗_
Exposed Tank Bottom Surface (SAtank) m2 1,134.11
2
/2)^2
Base Current Density, (i°) mA/m 20.00 Doc: ZZ-CE-GEN-PHL-0006
Operating Temperature (t') °C 55.00 Equipment List : ZZ-PR-DAS-LST-0050
 i  0.25  t 't  
Temperature Correction Factor Cuts in @ Temperature of (t°) °C 30
Temperature Corrected Current Density (i') mA/m2 32.50 i '  i   
 10 
Coating Breakdown Factor (cbf) Initial % 10.00 Base current density incl. coating breakdown
Coating Breakdown Factor (cbf) Mean % 20.00 Base current density incl. coating breakdown
Coating Breakdown Factor (cbf) Final % 30.00 Base current density incl. coating breakdown
Initial Current Requirement mA 3,686
Mean Current Requirement mA 7,372 I req  SAtan k  i 'cbf
Final Current Requirement mA 11,058
Project Design Life yrs 30.00 Doc: ZZ-PE-GEN-G20-0001
Max soil resistivity (anode resistance check) ohm.m 500.00 Doc: ZZ-CE-GEN-PHL-0006
Min soil resistivity (voltage gradient check) ohm.m 150.00 Doc: ZZ-CE-GEN-PHL-0006
Anode buried depth m 1.00 Assumed
MMO current capacity (soil/no coke) - Manufacturers data for 50
mA/lin.m 42.0 Based on Anode Manufacturers data for : 50 year design life
year design life
MMO max current capacity (soil /no coke) - corrected for project
mA/lin.m 70
design life
MMO ribbon width (W ribbonanode) mm 6.35 Based on Anode Manufacturers data
MMO ribbon thickness (Thribbonanode) mm 0.60 Based on Anode Manufacturers data
MMO ribbon equivalent dia. (Dia ribbonanode) mm 4.425 = (anode cross section perimeter) / π
MMO ribbon internal resistance for 1m length (Rintribbon ) ohms 0.14000 Based on Anode Manufacturers data
Ti conductor bar width (W conductor ) mm 12.70 Based on Anode Manufacturers data
Ti conductor bar thickness (Thconductor ) mm 0.90 Based on Anode Manufacturers data
Ti conductor bar internal resistance for 1m length (Rintconductor ) ohms 0.04199 Based on Anode Manufacturers data
Current output based on calc length & Final Current Requirement mA/lin.m 10 = (final current reqd) / (calc total length of anode reqd)
OK CHECKSUM to ensure calc final anode current output is LESS THAN anode max current output
Page 41 of 63
Page 42 of 63
b) Cable Resistances
Outside Ambient Temperature = 25 DegC
2 Resistance (Ω/m) @ 25 DC Current
Conductor Size (Awg or mm ) Resistance (Ω/m) @ 20 deg.C
deg.C Rating (A)
AWG10 0.00335 0.00341 30 Relation between cable resistance and temperature (US Dept
of Commerce, Nation'l Bureau of Standards Handbook 100, pg
AWG8 0.00210 0.00214 45
14, Table 3)
AWG6 0.00132 0.00135 65 Cable Resistance Figures
AWG4 0.00083 0.00085 85 From NACE Corrosion
Rt  Rti  1   ti  t  t i 
AWG3 0.00066 0.00067 100 Eng's Ref Book, 2nd Ed'n.; p
AWG2 0.00052 0.00053 115 109.
AWG1 0.00041 0.00042 130 Where:
25 0.000727 0.000741 85 αti = Temp. coefficient @ 20degC = 0.00383
35 0.000524 0.000534 115 Cable Resistance Figures t= Temperature (degC)
50 0.000387 0.000394 150 From Vendor data. ti = Initial temperature (20degC)
70 0.000268 0.000273 185
95 0.000193 0.000197 230
Anode Power Feed Cables

Cable Size 10
Cable Resistance Rating (ohm/m length) @ 25 degC 0.00187
No. of Power Feed Cables 5
Average Length of Each Power Feed Cable (m) 50
Resistance of 1No. Power Feed Cable (ohms) 0.09325 W = (cable resistance) x (cable length)
Resistance of 5No. Power Feed Cables in Parallel (ohms) 0.01865 W = (cable resistance) x (cable length) / (No. of cables in parallel)
Main Positive Cable

Cable Size 35
Length of Main Positive Cable (m) 50
Resistance of Main Positive Cable (ohms) 0.02670 W = (cable resistance) x (cable length)
Main Negative Cable

Cable Size 35
No. of Main Negative Cables 1
Average Length of Each Main Negative Cable (m) 50
Resistance of 1No. Main Negative Cable(s in Parallel) (ohms) 0.02670 W = (cable resistance) x (cable length) / (No. of cables in parallel)
Total Resistance of All Cables (ohms) 0.072 W = sum of cable resistances (power feed + positive + negative)
Page 43 of 63
c) Total Circuit Resistance

Max. Soil Resistivity Min. Soil Resistivity
Total Circuit Resistance (ohms) W 1.437 0.482 = sum of anode groundbed + cable resistances
4) Min. Output Ratings for Transformer Rectifier

(min. requirement to meet design final current, see sec 1, and potential shift requirements, see sec 6) Percentage of TR voltage capacity at which max predicted current demand met : 100.0%
Max. Soil Resistivity Min. Soil Resistivity Min. TR current rating safety factor over CP current requirement : 10.0%
Min. Current Requirement Calc. for End of Design Life (sec 1) A 11.058 11.058
Min. Current Required to Meet Potential Shift Requirements (sec 6) A 12 40 Adjust current value to obtain min. potential shifts as detailed in Sec 6.
Min. TR Voltage Rating (incl Back EMF) V 17.2 19.3 = (total circuit resistance) x (largest current requirement)
Proposed TR Voltage Rating V 50 50

(Transformer Rectifier Voltage Rating OK ) (Transformer Rectifier Voltage Rating OK )
Proposed TR Current Rating A 50 50

(Transformer Rectifier Current Rating OK ) (Transformer Rectifier Current Rating OK )
Circuit Resistance Allowable (R=V/I) W 4.0 1.2 = (Proposed TR Voltage Rating - Back EMF) / (Min. Current Reqd)
Calc. Total Circuit Resistance W 1.437 0.482
(Transformer Rectifier Sizing OK ) (Transformer Rectifier Sizing OK )

Percentage of TR current capability, that anode groundbed will be able to dissipate: 120%
A Total of 1136 metres of MMO Ribbon Anode Are Required For Design Purposes. Anode Capacity Will Include a Safety Factor of : 0%
Max. Allowable Anode Current Output mA/lin.m 70.0 70 Taken from Vendor data of 42mA/lin.m for 50yrs for MMO in sand backfill and extrapolated for Project
Min. Anode Current Output to Dissipate 120% of TR Current mA/lin.m 52.8 52.8 design life of 30yrs
Capability (Anode Current Output OK) (Anode Current Output OK)
Max. Operating Anode Current Output mA/lin.m 44 44

(Anode Operating Current Output OK ) (Anode Operating Current Output OK )
6) Potential Shift With Respect to Remote Earth
I  t r 0.5L 0.5L
Ur = Potential shift from a single horizontal anode (V) 2 2 2 The Potential Shift For a Single HorizontalAnode (Ur) As Given By Baeckmann/Schwenk ;
Where;
Ur   ln (based on the formula by Baeckmann/Schwenk in Handbook of Cathodic Corrosion Protection, eqn 9 page 539)
I = Anode current output (Amps) 2L  t 2 r2 0.5L2 0.5L where d, anode dia, L, anode length and
ρ = Soil Resistivity, (W.m)   t, anode depth below surface
L = Anode Length, (m)
t = Burial depth of anode, (m)
r = Distance from anode to tank surface, (m)
Page 44 of 63
Potential Shift Caused by a 1m Length of Anode

Assumed Anode Length (L) m 1.00 1.00
Anode Burial Depth (t) m 1.00 1.00
Min Anode to Tank Distance (Directly Over Anode), (r) m 1.00 1.00
Max Anode to Tank Distance (Midpoint Between Anodes), (r) m 1.118 1.118 = sqrt (anode burial depth^2 + half spacing between anode loops^2)
Minimum Soil Resistivity (ρ) Wm 500 150 Ur formula breakdown
Anode Current (Full Rated Output) A/lin.m 0.011 0.035 Ip/πL Ip/πL ln top line bottom line
Gradient Opposite Anode @ Anode Rated Output Vcse 0.58 0.58 0.840895052 0.840895052 0.693147181 2 1
Gradient Mid-Point Between Anodes @ Anode Rated Output Vcse 0.55 0.55 0.840895052 0.840895052 0.6549003 2.08113883 1.08113883
Max. SRes Min. SRes
Natural Potential (Vcse): -0.5 -0.5
Potential at Min Anode to Tank Distance, V x cse V -1.083 -1.083 = (natural potential + voltage gradient oppos. anode)
Potential at Max Anode to Tank Distance, V x cse V -1.051 -1.051 = (natural potential + voltage gradient between anodes)
7) Voltage Attenuation Along The Anode Ribbon

(confirms length of anode ribbon, equal to the conductor bar spacing, does not exceed 10% potential attenuation at mid-point of MMO ribbon)
Input Data Max. Soil Resistivity Min. Soil Resistivity

MMO ribbon equivalent dia. (Dia ribbonanode) m 0.004 0.004
Soil resistivity ohm.m 500.00 150.00
MMO ribbon anode length (2Lconnec) m 4.00 4.00
Linear Resistance of MMO Ribbon Anode (rlinear ) Ohm/m 0.140 0.140
Calculation
Anode resistance to earth for Lconnec wire (Ra-Lconnec) Ohms 270.84 81.25 Using same formula as detailed in Sec 3) CP System Circuit Resistance
Anode conductance to earth for Lconnec wire (Ga-Lconnec) Siemens 0.0037 0.0123 = 1 / (Ra-Lconnec)
Linear Conductance of MMO Wire Anode (glinear ) S/m 0.0018 0.0062 = 2 x (Ga-Lconnec) / (2Lconnec)
Attenuation constant (α) 0.0161 0.0294 = sqrt ( rlinear x glinear )
Potential attenuation on MMO ribbon at mid-point between
% 0.05% 0.17%
conductor bar connections
= 1 - ( 1 / (cosh(α x (2Lconnec / 2) ) ) ) - expressed as a percentage
Proposed conductor bar Proposed conductor bar
spacing of 4m is OK spacing of 4m is OK
8) Summary of CP System Requirements
Selected TR Voltage Rating : V 50 Anode Power Feed Cables 10mm2

Selected TR Current Rating : A 50 - No. no. 5
- Length each m 50
No. of MMO Ribbon Anodes Ea 38 - Total length m 250
Total MMO Ribbon Anode Length m 1136 Main Positive Cable 35mm2
Spacing between Each Ribbon Anode m 1.00 - Total length m 50
No. of Ti Conductor Bars Ea 10 Main Negative Cable 35mm2
Total Ti Conductor Bar Length m 320 - No. no. 1
Spacing between Each Conductor Bar m 4 - Length each m 50
No. Power Feed Connectors m 5 - Total length m 50
Page 45 of 63
APPENDIX 4 – CP CALCULATIONS FOR BURIED VESSELS (SHEETS 1-5)

.
Page 46 of 63
CATHODIC PROTECTION DESIGN Sheet: Cathodic Protection Current Requirement Calculation By: PAN 22/02/13
Facility: Mounded Bullets - LPG Storage Bullet Checked By: 0 00/01/00
Plant: Mansuriya Refinery Rev: 0
Drawing
1) Current Demand Calculation
Facility: Buried CS Piping

6.00 = Base Current Density at 30 o C (mA/m2 ) ** ** From Table 7.2 - current density criteria for FBE coated piping at end of 30yr life
53 = Operating Temperature (o C)
9.45 = Protective Current Density (as base current density) (mA/m2 )
Vessel Description Vessel Ø (m) Length (m) S.A. (m²) Current (A)
LPG Storage Bullets (0-V-22 01 A/D) 3.75 26.25 373.71 3.53
0 0 0.00
0 0 0.00
0 0 0.00
Totals = 26 374 3.53
Facility: Concrete Reinforcing Steel
2.00 Current Density For Coated Steel at End of Life (mA/m2 ) **
Qty Length (m) Width (m) Depth (m) S.A. (m²) Current (A)
0 15.0 0.3 0.3 0 0.00
0.0 0.0 0.0 0 0.00
Totals = 0 0.00
Facility: Electrical Earthing
50 Current Density (mA/m2 ) **
S.A. (m²) Current (A) Current Demand Summary

100 5.00 Buried CS Piping 3.53
0.00 Concrete Reinforcing Steel 0.00
0.00 Electrical Earthing 5.00
Totals = 5.00 Total Current Demand : 8.53A
2) Choose Anode Type, Size, Weight & Arrangement
Anode Material Mixed Metal Oxide (MMO)

Anode Length / Canister Length 1.5 2 m Based on Vendor data
Anode Diameter / Canister Diameter 0.025 0.16 m Based on Vendor data
Anode Weight / Canister Weight 2.5 5 kg Based on Vendor data
Anode Consumption Rate 1.00E-06 kg/amp-y Based on Vendor data

Maximum Current Density 66.7 A/m2 Based on Vendor data
Anode Current Capacity 7.86 Amps/anode Based on Vendor data
PDB TR
a) CP Arrangement
Number of Anode Loops 2 No.

Number of Anodes in each Loop 17 No.
Anode to Anode Spacing 2 m
Anode to Vessel Horizontal Spacing 1 m Page 47 of 63
3) Anode Resistance
a) Horizontal Anode Resistance to Earth, Single Anode (Baeckmann, Schwenk, Prinz; Cathodic Corrosion Protection, 1997, p544, section 24.2)
Ra,h = Single Horizontal Anode Resistance to Remote Earth (Ω)

  L2 
Ra ,h  ln  
Where; 2    L  td 
ρ = Soil Resistivity, (Ω.cm)
L = Backfill Column Length, (cm)
t = Depth below surface of anode (cm)
d = Backfill Column Diameter, (cm)
b) Resistance to Earth, Multiple Anodes (Baeckmann, Schwenk, Prinz; Cathodic Corrosion Protection, 1997, p544, section 24.2)

ln 0 . 656 n 
Interference Factor (F ) :
Where; F  1
ρ = Soil Resistivity, (Ω.cm)
  s  R a ,h
Ra,h = Single Anode Resistance, (Ω)
s = Anode Spacing, (cm)
n = No. of Anodes in Groundbed, (n)
R
Total resistance of n anodes (R n ) : Rn  Fn
n
c) Calculations
Anode Loop 1 Anode Loop 2
Where; Soil Resistivity, ρ (Ω.cm) = 1319 1319

Anode Canister Length, L (cm) = 200 200
Depth below surface of anode, t (cm) = 50 525
Anode Canister Ø, d (cm) = 16 16
Single Anode Resistance, R t (Ω) = 4.11 1.64
No. of Anodes in Groundbed (n) = 17 17

Anode Spacing (S) Within Groundbed (m) = 2.0 2.0
Interference Factor (F ) : 2.2360 4.0983

Total resistance of n anodes, R n , (Ω): 0.5401 0.3949
4) Resistance of Anode & Header Cables

Outside Ambient Temperature = 25 DegC From Section 7.7 - Ambient Design Temperatures
Resistance
2 Resistance (Ω/m) @ DC Current
Conductor Size (Awg or mm ) (Ω/m) @ 25
20 deg.C Rating (A)
deg.C
AWG10 0.00335 0.00350 30 Relation between cable resistance and temperature (US
Dept of Commerce, Nation'l Bureau of Standards
AWG8 0.00210 0.00220 45
Handbook 100, pg 14, Table 3)
AWG6 0.00132 0.00138 65
Rt  Rti  1   ti  t  t i 
Cable Resistance Figures From NACE
AWG4 0.00083 0.00087 85
Corrosion Eng's Ref Book, 2nd Ed'n.;
AWG3 0.00066 0.00069 100
p 109.
AWG2 0.00052 0.00055 115
AWG1 0.00041 0.00043 130 Where:
25 0.000727 0.000760 85 αti = Temp.coefficient @ 20degC = 0.00383
35 0.000524 0.000548 115 Cable Resistance Figures From t = Temperature (degC)
50 0.000387 0.000405 150 Vendor data. ti = Initial temperature (20degC)
70 0.000268 0.000280 185
95 0.000193 0.000202 230
Page 48 of 63
Anode Loop 1 Anode No.: 1 2 3 4 5 6 7 8 9 10

Cable Length (m) Lc 2 2 2 2 2 2 2 2 2 2
Anode Cabling Resistance For Anodes In Parallel Calculated Using Following Expression; 11 12 13 14 15 16 17 18 19 20
1/R c = 1/R1 + 1/R2 + 1/R3 + . . . 1/R n 2 2 2 2 2 2 2 0 0 0
0.00191 0.00191 0.00191 0.00191 0.00191 0.00191 0.00191 0.00191 0.00191 0.00191
Resistance of Anode Cables, Rc = 0.00022519 W 0.0038 0.0038 0.0038 0.0038 0.0038 0.0038 0.0038 0.0000 0.0000 0.0000
Positive Anode Feeder Loop Cable Gauge (mm2 ) = 35
Positive Anode Feeder Loop Cable Length (m) = 110
Positive Anode Feeder Loop Cable Resistance, Raf = 0.06029 W
Cable Resistance Rw Anode Loop 1 = Rc + Raf 0.0605 W
Resistance For Anode Loop 1 (anode + cabling) = Rn + Rw = 0.60060 W
Anode Loop 2 Anode No.: 1 2 3 4 5 6 7 8 9 10

Cable Length (m) Lc 2 2 2 2 2 2 2 2 2 2
Anode Cabling Resistance For Anodes In Parallel Calculated Using Following Expression; 11 12 13 14 15 16 17 18 19 20
1/R c = 1/R1 + 1/R2 + 1/R3 + . . . 1/R n 2 2 2 2 2 2 2 0 0 0
0.00191 0.00191 0.00191 0.00191 0.00191 0.00191 0.00191 0.00191 0.00191 0.00191
Resistance of Anode Cables, Rc = 0.00022519 W 0.0038 0.0038 0.0038 0.0038 0.0038 0.0038 0.0038 0.0000 0.0000 0.0000
2
Positive Anode Feeder Loop Cable Gauge (mm ) = 35
Positive Anode Feeder Loop Cable Length (m) = 110
Positive Anode Feeder Loop Cable Resistance, Raf = 0.06029 W
Cable Resistance Rw Anode Loop 2 = Rc + Raf 0.0605 W
Resistance For Anode Loop 2 (anode + cabling) = Rn + Rw = 0.45542 W
Main Positive Header Cable

Main Positive Header Cable Gauge (mm2 ) = 35
Resistance (Ω/m) @ deg. C= 0.000548
Main Negative Header Cable

Main Negative Header Cable Gauge (mm2 ) = 35
Main Negative Header Cable Length (m) = 25
Main Negative Header Cable Resistance, Rn = 0.01370 W
Total Resistance For , Rtotal, (ohms) = 0.2782 W R_total={1/(1/R_PDB1 +1/R_PDB2)}+R_POS+R_NEG
Page 49 of 63

V= 50 V
I= 20 A
Allowance For Back EMF = 2 V
R Allowable (V=IR) = 2.400 W

R Actual = 0.278 W (Therefore Rectifier Sizing OK )
6) Cable Volt Drop

Volt Drop Across Cables = Vd = I max . Rw = % Voltage Drop 1.210 V Based On Longest Pos Run
Calculated % Voltage Drop = 2.42% Maximum Permissable Voltage Drop to be 10% of Applied Voltage
Maximum Allowable % Voltage Drop = 10.00% (Therefore Volt Drop is OK)
A Total of 34 Anodes Are Required For Design Purposes. Anodes Will Be Designed To Operate at Maximum (including contingency) 120% Output
Anode Maximum Operating Output = 0.71 Amps

Anode Surface Area = 0.12 m2
Maximum Allowable Anode Current Density = 67 A/m2 Based on max. cd for 20yr life (100A/m2) in pet coke backfill and extroplated for project design life (30yrs)
2
Actual Anode Operating Current Density = 5.99 A/m (Therefore Anode Operating Current Density is OK)
Coke Canister Surface Area = 1.0 m2
Actual Coke Operating Current Density = 0.70 A/m2
2
Maximum Allowable Coke Backfill Current Density = 10 A/m (Therefore Coke Operating Current Density is OK)
2
(Current Density Held at 10A/m in Order to Prevent Degradation of Backfill)
8) Potential Shift At Maximum Current Output

 2 
 t 2  r 2   L   L 
The Potential Shift For a Single Vertical Anode (Vx) Is Given By; I  2 2 Based on formula given in sec 7.2.1 of Design Philosophy (ZZ-CE-GEN-PHL-0006)
Ur  ln  
2  L  L
2
L
 t r    
2 2
 2 2
Where, Anode Loop 1 Anode Loop 2

L = Anode length, (cm) = 200 200
r = Anode to Vessel Separation, (cm) = 100 100
t = Anode depth below surface, (cm) = 50 525 Total Current Output of TR
I = Current flow from the anode, (Amp) = 0.11A 0.25A Manual Entry 6.12A
 = Soil Resistivity, (W.cm) = 1319 1319
Case 1 - 2m Single Sided Spacing. Protection to Midpoint Between Two Adjacent Anodes (seven anode contribution considered - from one side of mounded bullet)
G E 200cm C A B D F
Horizontal distance from anode to a given point on the structure (cm), = Loop 1 Loop 2 W
Anode Distance (cm) to W Shift Shift

Anode A 141.4 0.144V 0.096V
Anode B 141.4 0.144V 0.096V
Anode C 316.2 0.071V 0.085V
Anode D 316.2 0.071V 0.085V
Anode E 509.9 0.045V 0.071V
Anode F 509.9 0.045V 0.071V
Anode G 707.1 0.032V 0.059V
Page 50 of 63
Anode G 707.1 0.032V 0.059V

Total shift (-V) = 0.553V 0.565V wrt Cu/CuSO4 ref electrode
Natural potential (-V) = 0.500V 0.500V wrt Cu/CuSO4 ref electrode
Applied potential (V) = -1.053V -1.065V wrt Cu/CuSO4 ref electrode
Case 2 - Single Sided Spacing. Protection to Directly Opposite an Anode (seven anode contribution considered - from one side of mounded bullet)
F D 200cm B A C E G
X
Loop 1 Loop 2
Anode Distance (cm) to X Shift Shift
Anode A 100.0 0.186V 0.098V
Anode B 224 0.098V 0.092V
Anode C 224 0.098V 0.092V
Anode D 412.3 0.055V 0.078V CP POTENTIAL RANGES (steel in soil) **
Anode E 412.3 0.055V 0.078V The target IR free potential value for protection shall be:-0.85 to -1.2 Volts versus Cu/CuSO4 half-cell
Anode F 608.3 0.038V 0.065V
Anode G 608.3 0.038V 0.065V
Total shift (-V) = 0.567V 0.568V wrt Cu/CuSO4 ref electrode
Natural potential (-V) = 0.500V 0.500V wrt Cu/CuSO4 ref electrode
Applied potential (V) = -1.067V -1.068V wrt Cu/CuSO4 ref electrode
9) Calculated System Life
Design life for an impressed current distributed anode system is given by:
 AnodeMaxCurrentDensi ty 
AnodeLife     DesignLife
 AnodeOperatingCurrentDensity 
Where:
Maximum Allowable Anode Current Density = 67 A/m2
Actual Anode Operating Current Density = 5.99 A/m2
Project Design Life = 30 Years
DL = Design Life, (years) 334 OK Meets project Design Life requirements (30 years)
Page 51 of 63
APPENDIX 5 – CP CALCULATIONS FOR HYDRANT PIPING (SHEETS 1-2)

Page 52 of 63
Mansuriya Gas Field (100 MMSCFD Modular Surface Facilities) Cathodic Protection Design Report- CPF
PERMANENT CATHODIC PROTECTION DESIGN USING ZINC ALLOY ANODES - FIRE HYDRANT RISER PIPIES

W ( kg ) 
f
u 
value final 100%
Vf 
d
Width (bare) 5.1 cm Temperature (t') 35 0C Anode current output Initial 0.064 Amps d f  2
Lf 
r  L2 
Notes 2   L  td 
1) Current density values based on that proposed in Table 7.2 = 0.9mA/m 2, and includes for coating breakdown factor
2) Table below details list of buried risers for Fire Hydrants within the Mansuriya Gas Plant. depths below grade
Eqn 10 V
I A 
Ra
Page 53 of 63
i' = io + io 0.25 t' - to

10
to = 30 oC
35 o
t' = C
t = C
i' = 1.013 1.013 1.013 mA/m²
Final 'temp
correctd'
Item No. Fire Hydrant Riser Riser pipe Surface Current Current Anode Calc No. of
Dia Dia Len. Area Density Required I Output Weight Anodes
in m m (m2) (mA/m2) (mA) (mA) (kg) Required
1 200mm - 0.20 2 1.257 1.013 1.3 32.0 0.50 1

2
3
Page 54 of 63
APPENDIX 6 – CP CALCULATIONS FOR TANK INTERNALS (SHEETS 1-7)

Page 55 of 63
CATHODIC PROTECTION DESIGN Sheet: Cathodic Protection Current Requirement Calc. By: PAN 26/02/13
Facility: Aboveground Storage Tank Internal Checked By:
(Permanent CP System)
Rev: 0
Plant:
REFERENCE EQUATIONS / FORMULA

1) Data SOURCES
Tank Tag 0-T-79 01 A/B
FireWtr
Tank
Tank Net Capacity cu.m 5797 Equipment List : ZZ-PR-DAS-LST-0050
Tank Diameter (Dia tank) m 22 Equipment List : ZZ-PR-DAS-LST-0050
Water Level in tank (Hwater ) m 13.73 Assumed
Tank Height (Htank) m 15.25 Equipment List : ZZ-PR-DAS-LST-0050
Base Current Density, (i°) mA/m2 27 Doc: ZZ-CE-GEN-PHL-0006
Operating Temperature (t') °C 50.00 Equipment List : ZZ-PR-DAS-LST-0050
Temperature Correction Factor Cuts in @ Temperature of (t°) °C 30  i  0.25  t 't  
i '  i   
Temperature Corrected Current Density (i') mA/m2 40.50  10 
Coating Breakdown Factor (cbf) Initial % 5.00 Doc: ZZ-CE-GEN-PHL-0006
Coating Breakdown Factor (cbf) Mean % 10.00 Doc: ZZ-CE-GEN-PHL-0006
Coating Breakdown Factor (cbf) Final % 20.00 Doc: ZZ-CE-GEN-PHL-0006
Design life yrs 30.00 Doc: ZZ-CE-GEN-G20-0001
Average Water Resisitivity (ρ) ohm-cm 2000 Doc: ZZ-CE-GEN-PHL-0006
2) Calculate Wetted Surface Area

Wetted Surface Area of Tank internal m2 1329.08
 2

SA    rtan k    Dia tan k  H water 
Plus 10% contingency factor m2 1461.99 Assumed - to cover possible extra fittings inside tank
3) Calculate Current Requirements

Initial Current Requirement mA 2,961
Mean Current Requirement mA 5,921 I req  SAtan k  i 'cbf
Final Current Requirement mA 11,842
Page 56 of 63
4) Calculate Minimum Anode Requirements

MMO current density (water) - Manufacturers data for Based on Anode Manufacturers
A/m2 150.00 20 year design life
20 year design life data for :
MMO max current density (water) - corrected for A/m2 100.00

project design life
MMO tubular anode dia (Dia tubanode) cm 2.54
MMO tubular anode length (Ltubanode) cm 100.00
MMO tubular surface area (SAtubanode) m2 0.07980
MMO max current output at max applied CD Amps 7.980
Anodes Will Be Designed To Operate at Maximum
% 0% Assumed
Output (including contingency) of
No. of MMO tubular anodes reqd to meet final current
Ea 2
req.+ contingency
MMO anode current output (per unit) at final current requirement Amps 5.921
5) Calculate Anode Arrangement and Numbers
Main Anode Array - Outer Ring

Anodes generally arranged in circular arrays to provide uniform current distribution. E.R. Shepard and Henry J.
Shepard and Graeser design parameters indicated: Graeser, Jr., CORROSION Vol.
1. Spacing between bottom of an anode (or string of anodes) to tank bottom/side wall 6, Nov 1950, pp 360-375
should be equal.
2. Distance between tank wall and anode is one-half of the anode to anode spacing on the
same anode array.
Assumed no. of anode strings in main anode array (N) Ea 4
= (Diatank x no. of anode units) / 2x(pi +
Radius of main anode array m 6.16
no. of anode units)
Circumferential spacing between anodes (Sa) m 9.68 = (2 x pi x radius of anode array) / no. of anode units
Anode distance to tank wall (Ss ) m 4.84 = (one half of anode circumferential spacing)
No. of Anodes per Anode String

Spacing of the anodes on an anode string shall be based on the following assumptions:
1. Length of influence of an anode = anode length + 2 x anode to tank spacing (to cover
the top and bottom of anode)
2. Anode at top of string shall be located from the HLL (high level water line) the same
spacing as the anode to tank spacing.
Calc. No. of Anodes per Anode String Ea 2

Proposed No. of Anodes per Anode String Ea 2
Spacing between each anode m 2.05
Anode distance to HL water line and tank bottom (S s ) m 4.84
Anode Array - Inner Ring
No anode string at tank
Central anode array shall comprise
centre
Page 57 of 63
Page 58 of 63
V(r → ∞ ) = Potential rise above an arbitrary remote earth in the electrolyte at a point r (metres) away from the anode.
Electrolyte resistivity (ρ) = ohm-m 20 Steel Natural Potential -Vcse 0.500

Anode current (I) based of final Amps 1.480
current requirement=
Proposed Anode current (I) = Amps 0.800 Min. Tank to Electrolyte Pot -Vcse 1.200
Anode length (L) = m 1 Max. Tank to Electrolyte Pot -Vcse 0.850
POTENTIAL RISE DESIGN CALCULATION RESULTS

Separation, m Potential rise (QV)
Anode
A B C D E A B C D E
1 4.8 9.3 4.8 8.0 7.8 0.250 0.133 0.250 0.154 0.158
2 12.6 16.7 10.0 8.0 7.8 0.099 0.075 0.125 0.154 0.158  L 
 r  
 I
3 17.2 16.7 13.2 16.0 7.8 0.073 0.075 0.094 0.078 0.158 V r     ln  2 
4 12.6 9.3 10.0 16.0 7.8 0.099 0.133 0.125 0.078 0.158 2   L  r 
 
5 0.0 0.0 0.0 0.0 0.0 N/A N/A N/A N/A N/A  
Cumulative potential rise (V) 0.522 0.417 0.594 0.465 0.630
A B C D E
Cum. potential rise is greatest at point : E

Cumulative potential rise is least at point : B
Relative potential rise between point : E and point B is :
0.630 V - 0.417 V = 0.213 V
This is less than the max. value of 0.3V and is ACCEPTABLE
Tank to Electrolyte Potential wrt CSE -1.130 Vcse -0.917 Vcse
7) Anode to Remote Earth Resistance
Ra = Anode Resistance to Remote Earth (Ω)

  8L  Dwight's modified equation
Where; Ra   ln  1
ρ = Electrolyte Resistivity, (Ω.m) 2   L  d 
L = Anode Length, (m)
d = Anode Diameter, (m)
Page 59 of 63
Resistance of Anode & Header Cables Outside Ambient Temperature = 25 DegC

Relation between cable resistance and
DC
Conductor Size Resistance (Ω/m) @ Resistance (Ω/m) @ temperature (US Dept of Commerce,
Current
(Awg or mm 2) 20 deg. C 25 deg. C Nation'l Bureau of Standards Handbook
Rating (A)
100, pg 14, Table 3)
AWG10 0.00335 0.00341 30
AWG8 0.00210 0.00214 45
AWG6 0.00132 0.00135 65 Cable Resistance Figures From
AWG4 0.00083 0.00085 85 NACE Corrosion Eng's Ref
Book, 2nd Ed'n.; p 109.
Rt  Rti  1   ti  t  t i 
AWG3 0.00066 0.00067 100
AWG2 0.00052 0.00053 115
AWG1 0.00041 0.00042 130 Where:
25 0.00073 0.00074 85 αti = Temp. coefficient @ 20degC = 0.00383
Cable Resistance Figures From
35 0.00052 0.00053 115 t= Temperature (degC)
Vendor data.
50 0.00039 0.00039 150 ti = Initial temperature (20degC)
70 0.00027 0.00027 185
95 0.00019 0.00020 230
a) Anode String Suspended Cable Tail

No. of Anode Strings 4 1 2 3 4 5 6 7 8 9 10
Cable Length per string (m) Lc 20 20 20 20
Cable Resistance Rating (ohm/m length) 10 0.00187 0.00187 0.00187 0.00187 0.00187 0.00187 0.00187 0.00187 0.00187 0.00187
Cable Resistance (Ω) Rc 0.0373 0.0373 0.0373 0.0373 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
= (cable length) x (cable resistance)
a) Anode Power Feed Cable
No. of Power Feed Cables 4 1 2 3 4 5 6 7 8 9 10
Cable Length per string (m) Lc 50 50 50 50
Cable Resistance Rating (ohm/m length) 35 0.00053 0.00053 0.00053 0.00053 0.00053 0.00053 0.00053 0.00053 0.00053 0.00053
Cable Resistance (Ω) Rc 0.0267 0.0267 0.0267 0.0267 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
= (cable length) x (cable resistance)
c) Anode Resistance
No. of Anode Strings 4 1 2 3 4 5 6 7 8 9 10
Anode Length (cm) L 200 200 200 200
Anode diameter (cm) d 2.54 2.54 2.54 2.54 2.54 2.54 2.54 2.54 2.54 2.54
Electrolyte Resistivity (ohm-cm) ρ 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000
Anode Resistance (ohms) Ra 8.67 8.67 8.67 8.67 #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!
Page 60 of 63
Anode Resistance (ohms) Ra 8.67 8.67 8.67 8.67 #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!
d) Anode String
Cable Resistance per anode string (ohms) 0.0373 0.0373 0.0373 0.0373 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
Cable Resistance per anode power feed (ohms) 0.0267 0.0267 0.0267 0.0267 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
Anode resistance per string (ohms) 8.6669 8.6669 8.6669 8.6669 #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!
Total Resistance per String (ohms) 8.7309 8.7309 8.7309 8.7309 #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!
= (cable res. per string) + (anode res. per string)
Overall Anode String Resistance For Anodes In Parallel Calculated Using Following Expression; 1/RL,all = 1/R1 + 1/R2 + 1/R3 + . . . 1/Rn Resistance of All Anode
Resistance of All Anode Loops in One PDB, RL, all = ohms 2.18 Loops
1 8.730936
d) Main Positive Cable 2 4.365468
Main Positive Header Cable Gauge mm2 35 3 2.910312
Main Positive Header Cable Length m 50 4 2.182734
Conductor Resistance Ω /m 0.00053 5 #DIV/0!
Main Positive Header Cable Resistance (Rp ) Ohms 0.02670 = (cable length) x (cable resistance) 6 #DIV/0!
7 #DIV/0!
e) Main Negative Cable 8 #DIV/0!
Main Negative Header Cable Gauge mm2 35 9 #DIV/0!
Main Negative Header Cable Length m 50 10 #DIV/0!
Conductor Resistance Ω /m 0.00053
Main Negative Header Cable Resistance (Rn ) Ohms 0.02670 = (cable length) x (cable resistance)
Total Resistance For Tank 0-T-79 01 Ohms 2.2361

A/B, = RL, all + Rp + Rn =
Contingency (safety) factor on TR output rating 0%
Proposed TR Voltage Rating V 50

Calc TR Current Rating based on max. anode current reqs A 11.84
(TR Current Rating EXCEEDS final design current
Proposed TR Current Rating A 20.00
requirements, GOOD)
Allowance For Back EMF 2V
Circuit Resistance Allowable (V=IR) Ohms 2.400 = (TR Voltage Rating - Back EMF) / (TR Current Rating)
Actual Circuit Resistance Ohms 2.236 (Therefore Rectifier Sizing OK )
Page 61 of 63
A Total of 8 No. MMO Tubular Anodes Are Required For Design Purposes. Anodes Will Be Designed To Operate at Maximum Output (including contingency) of : 20%
Taken from Vendor data of 150A/m2 for 40yrs for MMO in water and
Maximum Allowable Anode Current Density A/m2 100.000
extrapolated for Project design life of 30yrs
Maximum Allowable Anode Current Output = Amps 7.980
Max. Operating Anode Current Output = Amps 3.00 (Therefore Anode Operating Current Output is OK)
10) Summary of CP System Requirement
Selected TR Voltage Rating Volts 50

Selected TR Current Rating Amps 20.00
Main Anode Array - Outer Ring

Diameter of Anode Array m 12.32
No. of Anode Strings Ea 4
No. of Anodes per String Ea 2
Spacing between Anodes on String m 2.05
Anode to Tank Spacing m 4.84
Anode Array - Inner Ring

No anode string at
No. of Anode Strings Ea
tank centre
No. of Anodes per String Ea 0
Spacing between Anodes on String m 0.00
Anode to Tank Spacing m 0.00
Page 62 of 63
APPENDIX 7 – SUMMARY OF CP SYSTEM FOR EXPORT PIPELINES AND PRODUCTION

FLOWLINES
Export pipelines to be provided with cathodic protection shall be as follows:

 16” Gas Export to tie-in to Al- Mansuriya Pipeline
 12” Condensate Export tie-in to Naft Khana Pipeline
 In-Field Production 8” Flowlines
Cathodic protection for the above shall be as per the details provided in the following
Project documents:
 105574-REP-Z-0003 – Cathodic Protection Design Report Pipeline
Page 63 of 63

105574 REP Z 0002 储罐规格

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

105574 REP Z 0002 储罐规格

Uploaded by

Copyright:

Available Formats

Turkish Petroleum Overseas Company (TPOC) 105574-REP-Z-0002 Rev 0

Hold No. Section Description

TABLE OF CONTENTS .............................................................................................................3

3 SUMMARY OF REQUIRED CP INSTALLATIONS ....................................................13

4 DESIGN CRITERIA AND DESIGN BASIS .................................................................17

APPENDIX 1: CP SAMPLE CALCULATIONS FOR BURIED PIPING (SHEETS 1-7)..............28

APPENDIX 2- CP SAMPLE CALCULATION FOR BURIED CASING (SHEETS 1-3) ..............36

APPENDIX 3 – CP SAMPLE CALCULATION FOR TANK BOTTOMS (SHEETS 1-5) ............40

APPENDIX 4 – CP SAMPLE CALCULATION FOR BURIED VESSELS (SHEETS 1-5) ..........46

APPENDIX 5 – CP SAMPLE CALCULATION FOR HYDRANT PIPING (SHEETS 1-2) ..........52

APPENDIX 6 – CP SAMPLE CALCULATION FOR TANK INTERNALS (SHEETS 1-7) ..........55

APPENDIX 7 – SUMMARY OF CP SYSTEM FOR EXPORT PIPELINES ................................63

Figure 1.1 – Mansuriya Field Location

The FEED will consider the entire development including:

1.4 Abbreviations and Acronyms

ACS Accidental contaminated surface run-off system

1.5 Codes, Standards and Project Documents

1.5.1 Industry and Other Standards

Table 2.1 Buried Piping

PIPING DIA. (mm) (1) APPROXIMATE LENGTH (m) (2)

Oily Water System (OWS) Min. 100 ~ 10,000m

Accidental Contaminated Min. 200 ~ 5,000m

Closed drain lines (CD) Min. 100 ~ 5,000m

Vent pipes Min. 100 ~ 1m (100 No. of)

(2) Approximate lengths given in table above are based on assumptions.

Table 2.2 Isolated Buried Piping Casings (1)

PIPING DIA. (mm) LENGTH No. OF EACH

Casings on OWS Min. 200 ~ 15 m ~ 20 No.

Casings on ACS Min. 400 ~ 15 m ~ 20 No.

Casings on CD Min. 200 ~ 15 m ~ 10 No.

(1) Values given in table above are based on assumptions.

Table 2.3 On-Grade Storage Tanks (1)

TANK ID DESCRIPTION DIA. HEIGHT (mm) OPER. EXT/INT

0-T-52 02 Off-Spec 18500 12000 45 EXT (Yes)

0-T-52 10 Condensate 39000 12000 55 EXT (Yes)

0-T-15 01 Amine Surge 79400 5500 42 EXT (N/A) (2)

0-T-55 02 AGRU Amine 4000 6750 50 EXT (N/A) (2)

0-V-64 01 Oil/Water 3000 3000 TBC (4) EXT (N/A)

0-T-81 01 Diesel Oil 10000 9000 TBC () EXT (N/A))

0-T-72 01 Diesel Oil 3000 3000 AMB EXT (N/A)

0-T-72 03 Service Water 32000 12000 TBC (4) EXT (Yes)

0-T-73 01 Potable Water 6600 9000 20 EXT (Yes)

0-T-74 01 Demineralised 8000 8000 25 EXT (Yes)

TANK ID DESCRIPTION DIA. HEIGHT (mm) OPER. EXT/INT

0-T-76 01 LP Condensate 9500 10000 55 EXT (Yes)

0-T-79 01 – Firewater 28000 12000 50 EXT (Yes)

(3) No values given in doc. 105574-EQL-P-0001, Equipment List.

Table 2.4 Vessels (1) (2)

VESSEL ID DESCRIPTION DIA. (mm) LENGTH OPER EXT

0-V-22 01 A – F LPG Storage 3750 27420 60 EXT

0-V-22 02 Off-Spec LPG 3750 27420 53 EXT

Table 2.5 Fire Hydrant Riser Pipes (1)

PIPING DIA. (mm) LENGTH No. OF EACH

Fire hydrant riser Min. 200 ~ 2m ~ 100No.

(1) Values given in table above are based on assumptions.

3 SUMMARY OF REQUIRED CP INSTALLATIONS

Table 3.1 Buried Piping – Temporary CP Summary

PIPING TOTAL CURRENT PRE-PACKAGED

Oily Water System (OWS) 1.4 100

Accidental Contaminated 1.4 50

Closed drain lines (CD) 0.7 50

(1) Pre-packaged anodes based on Zinc alloy anodes.