EPCC OF SARQALA GAS PIPELINE FROM

aggreko
dGAZPRDM SARQALA 1 CPF TO AGGREKO POWER
GENERATION PLANT
N E F T
'PetroWeld

DOCUMENT DETAILS

COMPANY CONTRACT NO. : 606-20-EB-GR

PROJECT : EPCC of Sarqala Gas Pipeline

COMPANY : Gazprom Nett Middle East B.V.

COMPANY JOB NO. : GM606

CONTRACTOR : Aggreko

CONTRACTOR JOB NO. : 60620

DOCUMENT NO. : GM606-60620-390-MT-CL-0001

REVISION NO. :0 I No. of pages (incl. cover): 13

DOCUMENT DESCRIPTION : CALCULATION FOR CATHODIC PROTECTION

0 Issued for Design 25 Aug 20 MANOLO NA NA Audie

D Issued for Approved 02 JUL 20 MANOLO NA NA / Audie

C Re-Issued for Review 15 JUN 20 MANOLO NA NA Audie

B Re-Issued for Review 23 Apr 20 MANOLO NA NA Audie

A Issued for Review 26 Mar 20 MANOLO NA NA Audie

Approved Approved
Rev Description Date Prepared Checked
(EM) (PM/ PD)
Electronic File Name: GM606-60620-390-MT-CL-0001 Doc size: A4
 
0 13

- Issued for Design

25 Aug 20
 CATHODIC PROTECTION SYSTEM
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Table of Contents
1. INTRODUCTION ............................................................................................................................... 3
2. REFERENCES .................................................................................................................................... 3
3. SCOPE OF WORK ............................................................................................................................. 3
4. STRUCTURE DESCRIPTION............................................................................................................... 4
5. DESIGN PROTECTION CRITERIA ....................................................................................................... 4
6. SOIL RESISTIVITY TEST RESULTS ...................................................................................................... 4
7. GUIDELINES FOR DESIGN OF CP SYSTEM ........................................................................................ 5
8. CALCULATIONS FOR BURIED PIPELINES .......................................................................................... 6
8.1 DESIGN PARAMETERS .................................................................................................................. 6
8.2 ANODE SELECTION ....................................................................................................................... 6
8.3 CURRENT REQUIREMENT ............................................................................................................. 6
8.4 RESISTANCE OF SINGLE VERTICAL ANODE TO SOIL: .................................................................... 7
8.5 SINGLE ANODE CURRENT OUTPUT: ............................................................................................. 8
8.6 NUMBER OF ANODES BASED ON CURRENT OUTPUT .................................................................. 8
8.7 NUMBER OF ANODES REQUIRED BASED ON WEIGHT ................................................................. 9
9. CP SYSTEM DESCRIPTION ................................................................................................................ 9
9.1 TEST STATIONS AND MONITORING FACILITIES .......................................................................... 10
9.2 TEST STATION-POTENTIAL MONITORING .................................................................................. 10
9.3 TEST STATION ISOLATION JOINT .............................................................................................. 10
9.4 TEST STATION-POLARIZATION COUPON TEST POINT ................................................................ 11
9.5 TEST STATION-UNCASED ROAD & WATER CANAL CROSSING ................................................... 11
9.6 CABLE CONNECTION TO PIPELINES ............................................................................................ 11
10. BILL OF MATERIALS .................................................................................................................... 12

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1. INTRODUCTION
Corrosion Technology Services LLC (CTS) has been appointed by Petroweld Services Ltd. (Vide
PO No. PO-CTS-E&I EPR NO:004-2020) as vendor to design, supply materials, supervise the
installation, test and commission the Sacrificial Anode Cathodic Protection Systems for external
surface of buried Gas Pipelines associated with Aggreko Gas pipelines, Iraq.
This document outlines the detailed design and calculations of the proposed Sacrificial Anode
CP System for the external surface of buried pipelines associated with the above
project.

2. REFERENCES
G32300291-Rev-B - Specification for Gas supply pipelines for Kurdistan
Project
G32300166-Rev-A - Specification for piping corrosion protection
AGG-8GL-S1-PP-AS-01_16 -
Report No.111 - Report on Soil resistivity tests for Sarqala pipeline
Project
NACE SP0169 - Control of external corrosion on Underground or
submerged metallic piping systems
ISO15589-1:2015 - Petroleum, petrochemical and natural gas industries-
Cathodic protection of pipeline systems part1: on land
pipelines.
NACE SP0177 - Standard Practice for Mitigation of Alternating Current
and Lighting Effects on Metallic Structure and Corrosion
Control Systems.
NACE SP0286 - Electrical Isolation of Cathodically Protected Pipelines

3. SCOPE OF WORK
The scopes of works identified to be performed by CTS under this contract are as follows:

Design and Engineering

Supply of Materials
Installation Supervision
Testing and Commissioning

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4. STRUCTURE DESCRIPTION
Table 1 (Structure Details)

Pipe
Operating
SL No. Line ID Service Diameter Length (m) Coating
Temp. (°C)
(Inch)
1. GAS 16 4850 80 3LPP
Pipe

5. DESIGN PROTECTION CRITERIA

In line with project specification requirements, sacrificial anode cathodic protection shall be
provided for the proposed buried metallic pipelines in Aggreko Gas Pipeline Project for the
design life of 10 years.

A minimum polarized potential of -850mV (Coupon OFF) with the cathodic protection current
applied to the structure with respect to a Cu/CuSO4 reference electrode (or -800mV with
respect to an Ag/AgCl reference electrode shall be considered as an alternate) is the protection
criteria for a sacrificial anode cathodic protection system using sacrificial anodes.

Or 100mV polarization shift criteria may also applicable in case above criteria is not able to
achieved.

6. SOIL RESISTIVITY TEST RESULTS

As per Report no.111 Report on Soil Resistivity test for Sarqala pipeline project wherein subject
pipeline is installed, Soil resistivity values in Field indicate the project pipeline traverse through
soil which of very high Very low -
3. Although the resistivity data index states as Slightly corrosive (100 Ohm-m & above), cathodic

the event of changes to the ground resistivity (i.e./. Due to various climatic conditions).

Table 2 (Resistivity Table)

Pipeline Description Resistivity

1 Gas Pipeline 273.2 Ohm-m to 423.9 Ohm-m

Table 3 below (ASTM Special Publication 741) can be used as guideline to evaluate the
corrosiveness of an environment with respect to the soil-resistivity values:

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Table 3 (Resistivity Reference Table)

Soil Resistivity In ohm-m Soil Corrosivity

Below 10 Very High Corrosivity

10 to 25 High Corrosivity

25 to 50 Moderate Corrosivity

50 to 100 Low Corrosivity

Above 100 Very Low Corrosivity

Based on past experience for similar terrain, we propose to use a soil resistivity of 10,000 Ohm-
cm for design calculation. If the installed number of anodes does not meet the protection
criteria then an additional anode shall be supplied and installed by the EPC contractor until the
protection criteria is met.

7. GUIDELINES FOR DESIGN OF CP SYSTEM

The following guidelines summarize the basic design concepts for SACP system:

The cathodic protection for the project pipelines shall be achieved by utilizing pre-
packaged magnesium anodes
Magnesium anodes shall be installed horizontally at 1.5 to 2m depth approximately
at 2m away from the pipeline
The anode cable tail shall be terminated in a test facility located adjacent to pipeline
and provided with shunts and variable resistors
At all test facilities, two cables shall be connected to pipeline. The size and type of
cables shall be as per construction drawing
All pipeline-to-cable connection shall be done by Thermite weld technique
All pipeline-to-cable connections shall be encapsulated using Intergard 821 compound
or equivalent
All CP cables shall be XLPE/PVC cables
In order to achieve adequate cathodic protection on the existing buried pipeline,
effective electrical isolation is mandatory which shall prevent leakage of cathodic
protection current to other buried metallic structures and earthing. The pipeline shall
be isolated from the concrete foundation reinforcement steel, foreign pipe Tap-
Off/Tie-in, valves, vents, chambers, stacks, scraper traps, casings, earthing and all
other locations as deemed necessary by suitable means
Protective Current density of 0.01mA/m2 as per ISO 15589-1:2015(table-3) shall be
applied for the subject pipeline

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8. CALCULATIONS FOR BURIED PIPELINES

This section outlines the design calculations and the parameters used in the design of the
Sacrificial anode cathodic protection system for the pipelines using 7.7Kg Magnesium Anode.

8.1 DESIGN PARAMETERS

The following design parameters are applicable:
CP system: Sacrificial anode cathodic protection system
Design life: 10 years for SACP (Buried Pipelines)
Coating of pipeline: 3LPP Coated
Current density: 0.01 mA/m² as per ISO 15589-1:2015 (table-3)
Soil resistivity for design: 10,000 ohm-cm
Anode: 7.7Kg Pre-packaged magnesium anode
Anode cable: 1 core x 10 mm2 XLPE/PVC copper cable
Anode consumption rate: 7.96 Kg/Ampere-Year for magnesium alloy
Anode utilization factor: 0.8(80%)
Anode installation: Horizontal
Anode backfill material: 75% Gypsum, 20 % Bentonite and 5% Sodium Sulphate
Cable to pipe connection for pipelines: Thermite Weld

8.2 ANODE SELECTION

7.7 kg net weight high potential magnesium alloy anodes are proposed for the sacrificial anode
cathodic protection system for the buried pipelines. The Anode shall be Pre-packaged with low
resistivity backfill comprising of Gypsum, Bentonite and Sodium sulphate and c/w require
length of 1C x 10Sqmm XLPE/PVC tail cable.
The calculations in the following sections are based on this anode.

8.3 CURRENT REQUIREMENT

The surface areas and the current required for the pipelines have been calculated as shown
below at a current density of 0.01mA/ m2 for SACP.
The following formula determines the surface area of the pipeline.
2)

Where:
SA - Surface Area (m2)
d - Diameter (m)
L - Pipeline length (m)
Current Requirement = SA x Current Density

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Where:
SA - Surface Area (m2)
Current Density = 0.01mA/m2
The temperature corrected current density is given by:

Where:
CDT = Temperature Corrected Current Density (mA/m2)
CD = Current Density (0.01 mA/m2)
T = Operating Temperature (80°C)
Therefore, the temperature corrected current density is 0.0351 mA/m2.
The current requirement for the piping is given by:

Where:
I = Current Demand (A)
SA = Surface Area (m2)
CDT = Temperature Corrected Current Density (mA/m2)

Table 4 (Calculation Details)

Temp
Pipe Pipeline Pipeline Surface Corrected Current
S.No.
Start and End points Length Diameter Area Current Required
(m) (m) (m2) Density (Amp)
(mA/m2)
1 4850 0.406 6186.1 0.0351 0.188

8.4 RESISTANCE OF SINGLE HORIZONTAL ANODE TO SOIL:

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Where:

L = Pre-Packaged Anode Length (0.762 m)

d = Pre-Packaged Anode Diameter (0.152 m)
h = Depth to Centre of Anode (1.5 m)
Therefore, the anode to earth resistance of a pre-packaged 7.7 kg Magnesium anode is 88.61
ohms.

8.5 SINGLE ANODE CURRENT OUTPUT:

The anode current output can be calculated by the following formula where anode and
structure potentials are measured with respect to a Cu/CuSO4 Reference Electrode:

Where:
AOCP = Anode Open Circuit Potential (-1.70 V)
SPP = Structure Protected Potential (-0.85 V)

Therefore, the calculated current output of a single 7.7 Kg magnesium anode to achieve a
structure protected potential of -850mV is 0.010A (10mA).

8.6 NUMBER OF ANODES BASED ON CURRENT OUTPUT

The anode quantity is calculated using the following formula:

Table 5 - Anode Requirement based on Current

SI. Piping Current Demand Anode Current
No. of Anodes
No Description (A) (A)
1 1 Gas Line 0.188 0.0101 18

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8.7 NUMBER OF ANODES REQUIRED BASED ON WEIGHT

The number of anodes required based on anode weight is calculated using the formula:

Where:
Design Life = 10 Years
Consumption Rate = 7.96 kg/Ay
I = Current Demand (A)
Utilization Factor = 0.8
The results of Equation are given below in Table 6.

Table 6 - Anode Requirement based on Weight

Anode Weight
Piping Anode Weight
SI. No Required No. of Anodes
Description (kg)
(kg)
1 1 Gas line 37.51 7.7 4.87

Table 7 - Anode Requirement Sufficiency

No. of Anodes No. of Anodes
Proposed
Piping Required Based Required Based Anode
SI. No No. of
Description on Current on Weight Sufficiency
Anodes
(No.) (No.)
1 1 Gas line 18 4.87 18 Yes

9. CP SYSTEM DESCRIPTION
A sacrificial anode cathodic protection system using sacrificial magnesium alloy is designed to
provide corrosion control to the external surface of the buried pipelines. The pre-packaged
magnesium anodes are designed to provide protection for a period of 10 years. For effective
functioning of CP System, the pipelines under the scope must be electrically isolated at the start
and end locations, any branches and from other metallic structures including earthing and rebar
in concrete.

The pipe-to-cable connections for the project pipes are to be carried out using thermite weld
for new pipelines. The test coupons, and cable connections on to the buried pipeline for the
test stations such as potential monitoring test stations, road crossing test stations, and
insulating joint test stations which are part of the cathodic protection system are recommended

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to be installed during the pipe construction phase, before backfilling the pipe in order to avoid
re-excavation.

The following section describes the purpose of the test facilities for the permanent cathodic
protection that are to be installed (cable to pipe connection in particular) as part of the SACP
system materials are installed.

The project pipelines traverses through various crossings such as roads, and water canal
crossing at different locations between the S1 to power plant.

9.1 TEST STATIONS AND MONITORING FACILITIES

The test stations are provided to facilitate the measurement of the protection level of the
pipeline. These test stations also facilitate the connections of galvanic anodes, coupons as a
part of SACP system.
Though there are several types of test stations based on its purpose, all the test stations will be
utilized for the purpose of potential monitoring. For this, a connection from the pipeline and a
contact for the reference electrode to the electrolyte (soil) near the pipeline will be made. The
different types of test stations and its purpose are stated in below sections. If test stations are

9.2 TEST STATION-POTENTIAL MONITORING

A standard type test station (CTS type) for pipe to soil potential measurement is to be installed
at every 1km along the pipeline route unless the position of this test station coincides with or
in close proximity (+/- 100m) to another type test point. Two test cables from the pipeline are
to be terminated inside this test station.
The Sacrificial CP anodes are to be connected to the pipeline via one of the test cables
terminated inside the test station.

9.3 TEST STATION ISOLATION JOINT

The isolation joint test station is of a standard type that will be provided at every isolation joint
location. Two cables from either sides of the isolation joint are to be routed to the test station
to facilitate future testing and to monitor the potential across the protected and unprotected
sections regularly to verify the condition of the IJ kit and to take corrective measures if found
damaged.

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9.4 TEST STATION-POLARIZATION COUPON TEST POINT

A standard type test station will be installed at Polarization coupon test point. Two test cables
along with a coupon to measure the off potential and the cables will be terminated inside the
test station for monitoring. The coupon is to be connected to the pipeline through a magnetic
reed switch.

9.5 TEST STATION-UNCASED ROAD & WATER CANAL CROSSING

A standard type test station to measure the pipe to soil potential for the uncased road crossing
is to be installed at every asphalt road crossing. Two test stations are to be installed for roads
having more than 10m width, one at each side of the road. Two test cables from the pipeline
are to be terminated inside the test station.

9.6 CABLE CONNECTION TO PIPELINES

All new pipelines to cable monitoring and drain point connections shall be thermite weld type.
All cable to pipe connections will be routed through test facilities. All above and below grade
cable connection to pipelines will be encapsulated using two-part epoxy compound to prevent
the moisture ingress.

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10. BILL OF MATERIALS

1 SACP Materials
SI.
Description Unit Quantity
No
Polarization Coupon Point Test Station with reed switch c/w
1 No. 2
uPVC conduit 2m long, 5 terminal board and lockable cap
Test Station for Magnesium Anode c/w Cott shunt & variable
2 No. 6
resistor, uPVC conduit 2m long, 5 terminal board, lockable cap
Isolation Flange Test Post c/w uPVC conduit 2m long, 5
3 No 2
terminal board, lockable cap
7.7kg Magnesium Anode c/w 10m of 10mm2 XLPE/PVC Red
4 No. 18
Cable
Polarization Coupon c/w 2 x 10mm2 XLPE/PVC Black/ Yellow
5 No. 2
Cable
Cu/CuSO4 Reference electrode c/w 10sqmm XLPE/PVC cable
D 6 No. 8
(Yellow/Blue)
7 Thermite Weld Charges (15g) with Mould (1 No.) No. 16
8 Intergard 821 L 5
2
9 10mm XLPE/PVC Black Monitoring black Cable m 180
10 16mm2 XLPE/PVC Black Monitoring black Cable m 40
11 Surge Diverter (SG4) No. 2
Items Supplied by Others
Welded Cleats for Isolation Flanges locations by (EPC
12 No. 8
Contractor)
13 Cable Lugs and Tagging by (EPC Contractor) lot 1
14 Concrete foundations (EPC Contractor) lot 1

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