PT.

AIR PRODUCTS INDONESIA

PT. GREGAH SUKSES MANDIRI ENGINEERING

SMIP OFFSITE PROJECT

CALCULATION FOR CATHODIC PROTECTION

DOC. NO.: AP-GSME-PL-CAL-004

A 05/06/2024 Issued for Review FD AR CHY

PREP’D CHK’D APP’D APP’D
REV DATE DESCRIPTION
PT. GSME PT. AP
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TABULATION OF REVISION SHEET

REVISION REMARKS SHEET REVISION REMARKS

SHEET
A B 0 1 2 A B 0 1 2
1 X
2 X
3 X
4 X
5 X
6 X
7 X
8 X
9 X
10 X
11 X
12 X

ATTACHMENT
1 X
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REVISION SHEET DESCRIPTION

NO PAGE SECTION DESCRIPTION OF CHANGE REV

1
2
3
4
5
6
7
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COMMENT RESPONSE SHEET

NO PAGE COMPANY'S COMMENTS CONTRACTOR'S COMMENTS REMARK

1
2
3
4
5
6
7
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TABLE OF CONTENT
TABLE OF CONTENT ........................................................................................................... 5
1. INTRODUCTION ............................................................................................................ 6
1.1. Purpose................................................................................................................... 6
1.2. Scope ...................................................................................................................... 6
2. Definitions ...................................................................................................................... 6
3. ABBREVIATION ............................................................................................................. 6
4. CODE AND STANDARDS.............................................................................................. 7
4.1. International Standards ........................................................................................... 7
4.2. International Standards ........................................................................................... 8
5. GENERAL REQUIREMENTS ......................................................................................... 8
5.1. Cathodic Protection Criteria..................................................................................... 8
5.2. Type of Cathodic Protection System ....................................................................... 8
5.3. Design Parameter ................................................................................................... 8
6. CALCULATION DESIGN ................................................................................................ 9
6.1. Area to be Protected (AP) ....................................................................................... 9
6.2. Current Density Used (CDU) ................................................................................... 9
6.3. Protection Current Required (IP) ........................................................................... 10
6.4. Weight of Anode Required (WT)............................................................................ 10
6.5. Quantity of Anode Required Based on Mass Method (NW) ................................... 10
6.6. Anode Groundbed Resistance for Horizontal Installation (RA) .............................. 11
6.7. Current Output Capacity of Anode (IA) .................................................................. 11
6.8. Quantity of Anode Required Based on Current Output Method (NI) ...................... 11
7. CALCULATION RESULT ............................................................................................. 12
7.1. Number of Anode .................................................................................................. 12
7.2. Number of Anode (Current Output Method) ........................................................... 12
7.3. Number of Test Point ............................................................................................ 12
8. CONCLUSION ............................................................................................................. 13
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1. INTRODUCTION
1.1. Purpose
The project is for the construction of an Underground Nitrogen & Hydrogen Pipeline by
PT. Air Products Indonesia. The total length/distance of pipeline is as per the Alignment
Sheet
Drawing. The method of installing the pipes will be open cut. The site address is PT Air
Products Indonesia Jl Kelapa Sawit 1 Kav A7 KEK Sei Mangkei, Kecamatan Bosar
Maligas, Kabupaten Simalungun, Sumatera Utara, 21183..

1.2. Scope
This document defines Calculation for Cathodic Protection for SMIP Offsite Project.

2. DEFINITIONS
COMPANY PT. Air Products, the owner of DED & Survey Gas
Pipeline in Manyar, Gresik SMIP Offsite SMR + 40
HPN – SOG Sei Mangkei – Piping Construction
Work

CONTRACTOR PT. Gregah Sukses Mandiri Engineering, The

main contractor of Engineering, Procurement &
Construction Piping Construction Work

VENDOR/MANUFACTURER The party which supply materials, equipment,

technical document/ drawing, and service to
perform the duties by the Contractor

THIRD PARTY INSPECTOR A third party inspector to be appointed by PT. Air

Products to inspect the works of Contractor

PROJECT DOCUMENTS All documents which are prepared, revised, and

issued for accelerating the project execution, such
as correspondence, drawings, specifications,
requisitions, purchase orders, vendor prints, etc.

3. ABBREVIATION
AC Alternating Current
ASTM American Society for Testing and Materials
CP Cathodic Protection
DC Direct Current
DNV Det Norske Veritas
EPC Engineering, Procurement, and Construction
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HSE Health, Safety, and Environment

ICCP Impressed Current Cathodic Protection
IEC International Electrotechnical Commission
ISO International Organization for Standardization
NACE National Association of Corrosion Engineer
PPE Personal Protective Equipment
SACP Sacrificial Anode Cathodic Protection

4. CODE AND STANDARDS

The requirements and recommendations of the latest revisions of the following listed
codes, and standards shall apply:

4.1. International Standards

The International Standards shall be used in this report of UPS and Battery Sizing but
not limited as follows:
NACE - National Association of Corrosion Engineers
SP0169 Control of External Corrosion on Underground or Submerged
Metallic Piping Systems

SP0177 Mitigation of Alternating Current Mitigation of Alternating

Current and Lightning Effects On Metallic Structures and
Corrosion Control System
SP0286 The Electrical Isolation of Cathodically Protected Pipelines
IEC - International Electrotechnical Commission
61643 Low Voltage Surge Protective Devices
60079 Electrical Apparatus for Explosive Gas Atmospheres
60529 Degrees of Protection Provide by Enclosures IP (Code)

DNV - Det Norske Veritas

RP B401 Cathodic Protection Design

ISO - International Organization for Standardization

15589-1-2003 Petroleum and natural gas industries - Cathodic
protection of pipeline transportation systems - Part 1: On-
land pipelines
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4.2. International Standards

In case of conflict between the technical requirements defined by Codes, Standards,
Specifications etc., the more stringent requirement shall govern.
All apparent conflicts shall be immediately reported to the COMPANY for resolution
before proceeding with design and construction.
The order of precedence shall be as follows:
• Indonesian Statutory Requirements / Other relevant National or International
Legislation in the absence of Indonesian Legislation
• Mandatory requirements of codes and standards
• Equipment Datasheets
• This Specification
• Referenced Project specifications
• Referenced Codes and Standards

5. GENERAL REQUIREMENTS
5.1. Cathodic Protection Criteria
Based on the applicable standard, a cathodic protection system is considered as working
effectively if the structure potential can be lowered equal or more negative than -850 mV
vs Cu/CuSO4 reference electrode. This figure is equivalent with -800 mV vs Ag/AgCl.

5.2. Type of Cathodic Protection System

Type of Cathodic Protection system to be used in this project shall be Sacrificial Anode
System.

5.3. Design Parameter

Design Life Time : 20 Years (1)
: High Potential Prepackaged Magnesium
Type of Anode
Anode
Weight of Anode : 32 lbs (14.5 kg nett)
Length of Anode : 0.850 m
Diameter of Anode : 0.180 m
Soil Resistivity for 0.8 up to 3.6 m depth : 568 Ohm.m (Pipeline) (2),
Operating Temperature : 79°F (26.1 °C)
Coating Breakdown Factor : 6.5% (4)
Contingency Factor : 1.15
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Current Density for Bare Pipe at 25 °C : 0.020 A/m2 (3)

: 8” Sch 40 (0.219 m),
6” Sch 40 (0.168 m),
Pipeline Diameter
4” Sch 40 (0.114 m),
3” Sch 40 (0.089 m),
Total Pipeline Length : 2000 m

Note:
(1) Design Life based on Client Specification.
(2) Estimated Value.
(3) Current Densities at Temperature Effect based on ISO 15589-1, Petroleum and natural
gas industries Cathodic Protection of pipeline transportation systems, Part 1: On- Land
pipelines, Table 2, Page 22.
(4) Breakdown Value As per standard ISO 15589-1:2003 Petroleum and Natural Gas
Industries – Cathodic Protection of Pipeline Transportation
Part-1, table 1, page 9

6. CALCULATION DESIGN
6.1. Area to be Protected (AP)
The surface area to be protected for 6” underground pipeline is calculated according to
the following formula:
AP =πxDxL (eq.1)
Where:
AP = Surface area to be protected (m²)
D = Pipeline Outside Diameter (m)
π = 3.14159
L = Pipeline Length (m)

6.2. Current Density Used (CDU)

Current density used is calculated as follow:
CDU = (CD + (T – 25) x I) x CBF (eq.2)
Where:
CDU = Current density used (A/m²)
CD = Cathode mean current density (A/m²)
T = Operating temperature (°C)
I = Current density increased at temperature > 25°C (0.001 A/m² per 1°C)
CBF = Coating breakdown factor (%)
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• For Pipeline used FBE Coating:

CBF = fi + (Δf x tdl)
CBF = 0.005 + (0.003 x 20)
CBF = 0.065

6.3. Protection Current Required (IP)

Protection Current required is calculated as follow:
IP = AP x CDU (eq.3)
Where:
IP = Protective Current required (A)
AP = Area to be Protected (m²)
CDU = Current Density Used (A/m²)

6.4. Weight of Anode Required (WT)

The weight of anode required is calculated as follow:

(eq.4)

Where:
W = Required anode net weight (kgs)
IP = Protective Current requirement (A)
Y = Design Lifetime (20 years)
8760 = Conversion factor from year to hour
U = Anode utilization factor (0.85)
C = Anode current capacity (1100 Ah/kg)

6.5. Quantity of Anode Required Based on Mass Method (NW)

The quantity of anode required based on mass method is calculated as follow:
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(eq.5)

Where:
Nw = Number of anode (ea)
W = Required anode net weight (kg)
Wa = Proposed Anode Weight (kg)

6.6. Anode Groundbed Resistance for Horizontal Installation (RA)

Anode Ground bed resistance for horizontal installation can be calculated by the
following formula:

(eq.6)

Where:
RA = Ground bed / anodes to soil resistance (ohm)
ρ = Soil resistivity (ohm.m)
La = Length of Anode (m)
Da = Diameter of Anode (m)

6.7. Current Output Capacity of Anode (IA)

The current output capacity of anode is calculated from driving voltage between anode
and protected pipe, and the anode ground bed resistance as follow:

(eq.7)

Where:
IA = Current output capacity of anode (Amp)
Ea = Steel pipe protective potential (-0.85V)
Es = Anode potential (-1.75V)
ΔV = Driving voltage (-0.85) – (-1.75) (Volt)
Ra = Ground Bed / anodes to soil resistance (ohm)

6.8. Quantity of Anode Required Based on Current Output Method (NI)

The quantity of anode is also calculated based on total current required and individual
anode current output capacity as per following formula:
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(eq.8)

Where:
NI = Number of anode (pcs)
Ip = Protective current requirement (A)
Ia = Current output capacity of anode (A)

7. CALCULATION RESULT
7.1. Number of Anode (Mass Method)
The summary of calculation result based on Mass Method can be showed the table
below:
Table 1. Quantity of anode based on Mass Method
OD Pipeline L AP IP WT NW Test
Pipeline
Inch m (m) (m2) (A) (Kg) (pcs) Point
N2 8 0.219 576 396.293 0.515 106.188 8 1
N2 6 0.168 1344 709.346 0.922 190.071 14 1
H2 4 0.114 576 206.290 0.268 55.276 4 1
H2 3 0.089 1344 375.785 0.489 100.693 7 1
TOTAL 33 4

7.2. Number of Anode (Current Output Method)

The summary of calculation result based on Current Output Method can be showed the
table below:
Table 2. Quantity of anode based on Current Output Method
Pipeline OD Pipeline L AP IP IA NI Test
(KP) Inch m (m) (m2) (A) (A) (pcs) Point
N2 8 0.219 576 396.293 0.515 0.004 119 1
N2 6 0.168 1344 709.346 0.922 0.004 212 1
H2 4 0.114 576 206.290 0.268 0.004 62 1
H2 3 0.089 1344 375.785 0.489 0.004 112 1
TOTAL 505 4

7.3. Number of Test Point

Test Point shall be installed at pipeline. The test point shall enable to check both anode
potential and current output for maintenance wise. Test points shall be installed every 1
km each for pipeline are 4 pcs.
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OD Pipeline L Test Point

Area
Inch m (m) (pcs)

N2 8 0.219 576 1

N2 6 0.168 1344 1

H2 4 0.114 576 1

H2 3 0.089 1344 1

8. CONCLUSION
Based on above calculation result, it can be concluded that the required anode is taken
from quantity of Mass Method which is 33 pcs for pipeline. The number of test point used
is 6 pcs.
 APPENDIX-1

DETAIL CALCULATION CATHODIC PROTECTION FOR PIPELINE

QUANTITY OF ANODE REQUIRED BASED ON MASS METHOD QUANTITY OF ANODE REQUIRED BASED ON CURRENT OUTPUT METHOD

QTY OF ANODE
CURRENT PROTECION ANODE WEIGHT OF QTY OF ANODE PROPOSED CURRENT
OUTSIDE AREA TO BE OPERATING CURRENT COATING DESIGN BASED ON PROPOSED QTY
NO. PIPE LENGTH DENSITY CURRENT UTILIZATION CURRENT ANODE BASED ON QTY ANODE AVERAGE SOIL SOIL LAYER RESISTANCE OUTPUT
DIAMETER PROTECTED TEMPERATURE DENSITY BREAKDOWN LIFETIME CURRENT ANODE BY
(L) USED REQUIRED FACTOR CAPACITY REQUIRED MASS METHOD BY MASS RESISTIVITY* DEPTH OF ANODE CAPACITY
(D) (AP) (T) (CD) FACTOR (Y) OUTPUT CURRENT METHOD
(CDU) (IP) (U) (CAP) (WT) (NW) METHOD OF ANODE
(CBF) METHOD
(M) (INCH) (M) (M2) (ᵒC) (A/M2) (A/M2) (A) (YEAR) (Ah/Kg) (Kg) (Ea) (Ea) (Ohm.m) (m) (Ohm) (A) (NI) (Ea)

1 N2 576 8 0.219 396.293 25.0 0.02 0.065 0.00130 0.515 20 0.85 1100 106.188 7.32 8 568 1.2 - 2.4 206.173 0.004 118.0 119

2 N2 1344 6 0.168 709.346 25.0 0.02 0.065 0.00130 0.922 20 0.85 1100 190.071 13.11 14 568 1.2 - 2.4 206.173 0.004 211.2 212

3 H2 576 4 0.114 206.290 25.0 0.02 0.065 0.00130 0.268 20 0.85 1100 55.276 3.81 4 568 1.2 - 2.4 206.173 0.004 61.4 62

4 H2 1344 3 0.089 375.785 25.0 0.02 0.065 0.00130 0.489 20 0.85 1100 100.693 6.94 7 568 1.2 - 2.4 206.173 0.004 111.9 112

452.228 31.188 0.017 502.610

TOTAL QUANTITY OF ANODE 33 505

Note :
1 Design parameter of sand resistivity value, sand corrosivity level & req. current density are estimated and subject to revision based on actual site soil resistivity survey and actual pipe data.

2 Current Density of 20 mA/m2 is applied for bare steel pipes which buried in soil with "NORMAL" corrosiveness level (Estimate soil resistivity vary 2,000 ~ 10,000 ohm.cm)

3 The current density of bare steel shall be increased by 25% for each 10ºC of Fluid Temperature exceeding 30ºC (ISO 15589-1).

4 Estimate Coating Breakdown of 5% is assumed as per company approval