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Cathodic Protection Co. Limited Project Ref: 12/P16227

CATHODIC PROTECTION

TETCO GADARIF STRATEGIC DEPOT PROJECT

EXTERNAL TANK BASE SYSTEM AND INTERNAL TANK SYSTEMS

 

DETAILED DESIGN CALCULATIONS

 

Document Number: 16227-CP-03-DD

   

0

28/03/2012

Issued for client approval

DM

SF

DM

   

Rev.

Date

Description

Prepared

Checked

Approved

   

No.

ORIGINATOR

 

CLIENT

Venture Way, Grantham, Lincs, NG31 7XS, UK. Tel: +44 (0) 1476 590666 Fax: +44 (0) 1476 570605 E-mail: cpc@cathodic.co.uk Website: www.cathodic.co.uk

Registered Office: Minalloy House, Regent Street, Sheffield S1 3NJ, UK Vat No. 116 8408 71 Registered in England No. 478098

Office: Minalloy House, Regent Street, Sheffield S1 3NJ, UK Vat No. 116 8408 71 Registered in

TETCO – Gadarif Strategic Depot Project

Tank External Base and Internal Cathodic Protection

Detailed Design Calculations

Internal Cathodic Protection Detailed Design Calculations TABLE OF CONTENTS 1 INTRODUCTION 3 1.1 GENERAL

TABLE OF CONTENTS

1

INTRODUCTION

3

1.1

GENERAL

3

1.2

REFERENCE DOCUMENTS

3

1.2.1

INTERNATIONAL STANDARDS

3

2

CORROSION CONTROL METHODS – EXTERNAL CP

4

2.1

GENERAL

4

2.2

COATING SYSTEMS

4

2.3

CATHODIC PROTECTION

4

2.3.1 DESIGN LIFE

4

2.3.2 COATING BREAKDOWN AND DESIGN CURRENT DENSITIES

4

2.3.3 CURRENT DRAIN

5

2.3.4 CURRENT DEMAND

5

2.3.5 CP PROTECTION POTENTIAL RANGES

5

3

DESIGN

CONSIDERATIONS – EXTERNAL CP

6

3.1

DESIGN

PARAMETERS

6

3.2

CATHODIC PROTECTION PHILOSOPHY

6

4

DESIGN CALCULATIONS – EXTERNAL CP

8

4.1

CURRENT REQUIREMENTS

8

4.2

MMO ANODE RIBBON CALCULATIONS

9

4.3

RIBBON ANODE BED RESISTANCE

11

4.4

Ti CONDUCTOR BAR CALCULATIONS

13

4.5

EQUIVALENT CIRCUIT RESISTANCE

14

4.5.1

GROUNDBED VOLT DROP CALCULATION

15

4.5.2

MMO RIBBON VOLT DROP

15

4.5.3

CONDUCTOR BAR VOLT DROP

16

4.5.1

CABLE VOLT DROP

17

4.6

CALCULATION SUMMARY

18

5

SUMMARY OF INSTALLATION – EXTERNAL CP

19

6

CORROSION CONTROL METHODS – INTERNAL CP

20

6.1

GENERAL

20

6.2

COATING SYSTEMS

20

6.3

CATHODIC PROTECTION

20

6.3.1 DESIGN LIFE

20

6.3.2 COATING BREAKDOWN AND DESIGN CURRENT DENSITIES

20

6.3.3 CURRENT DRAIN

21

6.3.4 CURRENT DEMAND

21

6.3.5 CP PROTECTION POTENTIAL RANGES

21

7

DESIGN

CONSIDERATIONS – INTERNAL CP

22

7.1

DESIGN

PARAMETERS

22

7.2

CATHODIC PROTECTION PHILOSOPHY

22

8

DESIGN CALCULATIONS – INTERNAL CP

23

8.1

CALCULATION SUMMARY

23

8.2

CURRENT REQUIREMENTS

24

8.3

NUMBER OF ANODES BY CURRENT OUTPUT

25

8.4

NUMBER OF ANODES BY WEIGHT

26

9

SUMMARY OF INSTALLATION – INTERNAL CP

27

Document Title

Detailed Design Calculations

Date

28/03/2012

Document No

16227-CP-03-DD

Revision

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CPCL Project No

12/P16227

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Tank External Base and Internal Cathodic Protection

Detailed Design Calculations

Internal Cathodic Protection Detailed Design Calculations 1 INTRODUCTION 1.1 GENERAL This document is the design

1

INTRODUCTION

1.1 GENERAL

This document is the design philosophy and detailed calculations that shall be adopted to

provide the permanent cathodic protection system installed to protect the new tanks at the

Gadarif Strategic Depot project.

The requirements in this document apply to permanent corrosion protection by impressed

current cathodic protection to the external surfaces of the tank base and by sacrificial anode

current cathodic protection to the internal surfaces of the tank.

1.2 REFERENCE DOCUMENTS

This section lists the codes, standards and project documents / drawings, which are

applicable to the detailed design.

1.2.1 INTERNATIONAL STANDARDS

All CP equipment shall be designed, manufactured, tested and supplied in accordance with

applicable codes of practice, British Standards, NACE and other applicable standards listed

below:

Document Number

Title

BS 7361:Part1

Cathodic Protection, Code of Practice for Land and Marine Applications

NACE-RP-0193:1993

External Cathodic Protection of On-Grade Metallic Storage Tank Bottom

EDS-508 Revision A

Cathodic Protection Specifications

Document Title

Detailed Design Calculations

Date

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Document No

16227-CP-03-DD

Revision

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Tank External Base and Internal Cathodic Protection

Detailed Design Calculations

Internal Cathodic Protection Detailed Design Calculations 2 CORROSION CONTROL METHODS – EXTERNAL CP 2.1

2

CORROSION CONTROL METHODS – EXTERNAL CP

2.1

GENERAL

The corrosion protection system selected shall be based on a high integrity coating system in

combination with a cathodic protection system.

2.2

COATING SYSTEMS

The tank base plates shall be coated in line with the project specification.

2.3

CATHODIC PROTECTION

The permanent CP system for the tank will be an impressed current cathodic protection

(ICCP) system. The design criteria for the cathodic protection system are outlined in the

sections below:

2.3.1 DESIGN LIFE

The design life shall be 25 years for permanent CP system.

2.3.2 COATING BREAKDOWN AND DESIGN CURRENT DENSITIES

The current density below is taken from CPCL experience and international specifications:

Structure Surface

Minimum Current Density (mA/m 2 )

Tank Bottom

20

For the protection of structure with elevated operating temperatures the minimum design current densities given above shall be increased by 25% per 10 °C rise in temperature above 30 °C. All tanks will be at an operating temperature at 48 o C therefore, a design current density of 31.25 mA/m 2 is considered suitable.

For the purposes of the design the coating breakdown has been assumed to be a maximum

of 50 %:

Structure Surface

Coating Breakdown (%)

Tank Bottom

50

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Detailed Design Calculations

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Tank External Base and Internal Cathodic Protection

Detailed Design Calculations

Internal Cathodic Protection Detailed Design Calculations 2.3.3 CURRENT DRAIN The tank does not need to be

2.3.3 CURRENT DRAIN

The tank does not need to be electrically isolated from any foreign structures using isolation joints / flanges and polarisation cells as this is a close anode system. Where possible the tank should be electrically isolated from earthing / grounding systems and any re-bar used in construction.

2.3.4 CURRENT DEMAND

The current demand for each tank is calculated based on the surface area and the applicable final current density for steel as given in section 2.3.2.

2.3.5 CP PROTECTION POTENTIAL RANGES

The effectiveness of the cathodic protection system should be determined by potential shift. The following “instant off” or IR free potentials should apply in the case of all tank bases.

The protection criteria for items in contact with soil are in line with international specifications and in summary:

Steel in Soil -0.850 to -1.200 Volts with respect to a Cu/CuSO 4 reference electrode.

100 mV polarisation shift.

All above potentials are IR free or “OFF” potentials.

Document Title

Detailed Design Calculations

Date

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Revision

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Tank External Base and Internal Cathodic Protection

Detailed Design Calculations

Internal Cathodic Protection Detailed Design Calculations 3 DESIGN CONSIDERATIONS – EXTERNAL CP   3.1

3

DESIGN CONSIDERATIONS – EXTERNAL CP

 

3.1

DESIGN PARAMETERS

Structure to be protected

:

Two Gas Oil Tanks

 

Two Gasoline Tanks

One Fire Water Tank

 

Diameter

:

25 m

 

17.5

m

17.5

m

 

Coating

:

50 % Coating Breakdown

Design Life

:

25 Years – Permanent CP

Design Current Density

:

31.25 mA/m²

CP Protection Criteria, E CU

:

-0.85 V (IR Free)

Soil Resistivity

:

100 Ohm.m

3.2

CATHODIC PROTECTION PHILOSOPHY

The cathodic protection system for all external surfaces will be based on an impressed current cathodic protection (ICCP) system and the design life for the permanent impressed current system shall be 25 years.

All cable will be XLPE/PVC where running underground. Structure to cable connections will be by bolted connections. All junction boxes will be GRP and have a minimum of IP67 protection and be ATEX certified for use in hazardous areas.

The permanent cathodic protection system for the tank base will be based by a “close” anode grid arrangement with a ribbon type anode. Temporary protection is not required as the permanent system can be energised upon completion of the tank.

Document Title

Detailed Design Calculations

Date

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Revision

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Tank External Base and Internal Cathodic Protection

Detailed Design Calculations

Internal Cathodic Protection Detailed Design Calculations The tank will be electrically continuous from the remainder

The tank will be electrically continuous from the remainder of any piping and earthing but as this

is “close” anode system and there will be a containment layer – hence will not be affected by any

current drains.

DC

Power supply shall be transformer rectifiers to CPCL specifications. The current required is

less

than 5 A for the 17.5 m tanks and 10 A for the 25 m tanks and it is recommended that a 5 A

or 10 A CP station is installed for each tank.

Due to the high surface soil resistivity anticipated it is recommended that a grid type anode is installed at a minimum depth of 300 mm and maximum depth of 550 mm below the tank base in

a mesh arrangement with MMO coated ribbon running in one direction and Titanium conductor

bar in the other. The maximum current output of the anode is based upon a soil resistivity of up

to 100 Ohm.m which would be as anticipated in this method of installation and backfilling.

Impressed current anodes shall consist of a Mixed Metal Oxide (MMO) / Titanium ribbon anode

with Titanium conductor bar to carry the current and connected via cable and a junction box to

the transformer rectifier. The MMO ribbon is to be spot welded to the conductor bar at each

intersection. Various power feed connectors are then connected to each of the conductor bars

and to a cable which exits the tank to the junction box.

The negative cable will be connected to tank via a junction box from the transformer rectifier unit

at two points 180 o from each other.

Permanent reference electrodes and slotted monitoring tube shall be installed under the tank to allow effective monitoring.

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Detailed Design Calculations

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Tank External Base and Internal Cathodic Protection

Detailed Design Calculations

Internal Cathodic Protection Detailed Design Calculations 4 DESIGN CALCULATIONS – EXTERNAL CP A grid of MMO

4

DESIGN CALCULATIONS – EXTERNAL CP

A grid of MMO / Ti ribbon and Ti conductor bar is the selected design for the installation of an anode below the bottom of the aboveground storage tank. The design of such a grid will be done by taking a simplified approach, which is based on the diameter of the tank, depth from the location of the anode bed, the ribbon anode width, and the cathodic protection current requirement for the given environment. The equations derived enabled the determination of the length of anodes and the anode bed resistance.

4.1

CURRENT REQUIREMENTS

The current required for the external tank bases to be protected is shown below.

The external surface area of the structure is calculated using the following formula:

SA = Π.r

2

Where for Gas Oil in first column then Gasoline and Firewater in second column:

Π

=

Pi

3.142

3.142

r

=

Radius

12.5

8.75

m

SA

=

Surface Area (m²)

490.87

240.53

The total current required can then be calculated using the following:

Itot = (SA.J.Fc)

Where,

SA

=

Surface Area

490.87

240.53

J

=

Current Density

31.25

31.25

mA/m²

F c

=

Coating Breakdown Factor

50

50

%

I tot

=

Total Current

7.67

3.76

A

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Detailed Design Calculations

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Tank External Base and Internal Cathodic Protection

Detailed Design Calculations

Internal Cathodic Protection Detailed Design Calculations 4.2 MMO ANODE RIBBON CALCULATIONS The minimal total ribbon

4.2 MMO ANODE RIBBON CALCULATIONS

The minimal total ribbon length, L, is determined by the current rating for the size and type of anode material selected:

L

min

=

I tot

I

a

Where,

I tot

=

Total Current

7.67

3.76

A

I a

=

Anode Current Output (A/linear m) 1

0.019

0.019

A

L min

=

Minimum Ribbon Length

410.0

201.0

m

The space between anodes should be adjusted to achieve uniform current distribution under the tanks. The MMO ribbon spacing is calculated by:

S

mmo =

I

a

J

1

Where,

 
 

I a

=

Anode Current Output (A/linear m)

12

12

mA

J 1

=

Applied Current Density

10

10

mA/m²

S 1

=

MMO Ribbon Spacing

1.20

1.20

m

MMO spacing restricted to 1.2 m for correct spacing.

1 The ribbon anode output is considered to be a maximum of 3 A / m 2 then for standard ribbon this is equivalent to 0.035 A (35 mA) / linear m for a lifetime of 25 years and therefore any value lower is acceptable.

Document Title

Detailed Design Calculations

Date

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16227-CP-03-DD

Revision

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Tank External Base and Internal Cathodic Protection

Detailed Design Calculations

Internal Cathodic Protection Detailed Design Calculations The lengths of the MMO ribbon anodes are calculated below

The lengths of the MMO ribbon anodes are calculated below using the following formula:

Initial Spacing = 0.5 x (MMO ribbon spacing m)

Subsequent Spacing = initial spacing + (MMO ribbon spacing m)

Where,

L 1

=

= initial spacing + (MMO ribbon spacing m) Where, L 1 = 4. S 1 .(

4.

S

1

.(

d S

1

)

S 1

=

0.5 x MMO Ribbon Spacing

0.6

0.6

m

D

=

Diameter of Tank

25

17.5

m

L 1

=

MMO Ribbon Length

7.65

6.39

m

The length of cord in each row is calculated from the above equation.

Row

Spacing

Length

Number

(m)

(m)

 

1 0.60

7.62

 

2 1.79

12.88

 

3 2.98

16.19

 

4 4.17

18.63

 

5 5.36

20.52

 

6 6.55

21.98

 

7 7.74

23.11

 

8 8.93

23.96

 

9 10.12

24.54

 

10 11.31

24.89

 

11 12.50

25.00

 

12 13.69

24.89

 

13 14.88

24.54

 

14 16.07

23.96

 

15 17.26

23.11

 

16 18.45

21.98

 

17 19.64

20.52

 

18 20.83

18.63

 

19 22.02

16.19

20 23.21

 

12.88

 

21 24.40

7.62

Total

 

413.65

Spacing

Length

(m)

(m)

0.58

6.28

1.75

10.50

2.92

13.04

4.08

14.80

5.25

16.04

6.42

16.87

7.58

17.34

8.75

17.50

9.92

17.34

11.08

16.87

12.25

16.04

13.42

14.80

14.58

13.04

15.75

10.50

16.92

6.28

 

207.26

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Detailed Design Calculations

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Tank External Base and Internal Cathodic Protection

Detailed Design Calculations

Internal Cathodic Protection Detailed Design Calculations 4.3 RIBBON ANODE BED RESISTANCE The total resistance

4.3 RIBBON ANODE BED RESISTANCE

The total resistance between the tank bottom and the bed of grid ribbon anodes without taking into account the mutual interference between the anodes is:

R =

ρ

2

L

π

(ln

2

4 L

hw

2)

Where

 
 

ρ

=

Soil Resistivity

100

100

Ohm.m

L

=

Length of Anode

7.62

6.28

m

h

=

Distance between Anode and Tank

0.5

0.5

m

w

=

Ribbon Anode Equivalent Diameter

0.005

0.005

m

R

=

Resistance

20.78

24.23

Ohm

The resistance of each cord is calculated from the above equation and the total resistance calculated by summing the resistance of each cord. Thus the total anode resistance is calculated:

Document Title

Detailed Design Calculations

Date

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Document No

16227-CP-03-DD

Revision

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Tank External Base and Internal Cathodic Protection

Detailed Design Calculations

Internal Cathodic Protection Detailed Design Calculations Row Spacing Resistance Spacing Resistance

Row

Spacing

Resistance

Spacing

Resistance

Number

(m)

(ohm)

(m)

(ohm)

1

0.60

20.78

0.58

24.23

 

2 1.79

13.59

1.75

16.05

 

3 2.98

11.26

2.92

13.45

 

4 4.17

10.03

4.08

12.13

 

5 5.36

9.26

5.25

11.35

 

6 6.55

8.74

6.42

10.89

 

7 7.74

8.38

7.58

10.64

 

8 8.93

8.13

8.75

10.56

 

9 10.12

7.97

9.92

10.64

 

10 11.31

7.88

11.08

10.89

 

11 12.50

7.85

12.25

11.35

 

12 13.69

7.88

13.42

12.13

 

13 14.88

7.97

14.58

13.45

 

14 16.07

8.13

15.75

16.05

 

15 17.26

8.38

16.92

24.23

 

16 18.45

8.74

   
 

17 19.64

9.26

   
 

18 20.83

10.03

   
 

19 22.02

11.26

   
 

20 23.21

13.59

   
 

21 24.40

20.78

   

Total (Ohm)

0.458

 

0.860

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Tank External Base and Internal Cathodic Protection

Detailed Design Calculations

Internal Cathodic Protection Detailed Design Calculations 4.4 Ti CONDUCTOR BAR CALCULATIONS The total length of

4.4 Ti CONDUCTOR BAR CALCULATIONS

The total length of titanium conductor bar is based upon an assumption that conductor bar separation should not exceed 4.0 m. The lengths of the individual Ti Conductor bar chords are calculated as below using the following formula:

Initial Spacing = 0.5 x (Conductor bar spacing m) Subsequent Spacing = initial spacing + (Conductor bar spacing m)

Where,

L

2

=

= initial spacing + (Conductor bar spacing m) Where, L 2 = 4. S 2 .(

4.

S

2

.(

d S

2

)

 

S 2

=

0.5 x Conductor Bar Spacing

 

1.75

1.75

m

d

=

Diameter of Tank

 

25

17.5

m

L 2

=

Initial Conductor Bar Length

 

12.88

10.5

m

The length of cord in each row is calculated from the above equation.

 
   

Row Number

Spacing (m)

Length (m)

 

Spacing (m)

 

Length (m)

 

1 1.79

12.88

 

1.75

 

10.5

 

2 5.36

20.52

 

5.25

 

16.04

 

3 8.93

23.96

 

8.75

 

17.5

 

4 12.50

25

 

12.25

 

16.04

 

5 16.07

23.96

 

15.75

 

10.5

 

6 19.64

20.52

   
 

7 23.21

12.88

   
 

Total (m)

86.6

   

70.6

Document Title

Detailed Design Calculations

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Detailed Design Calculations

Internal Cathodic Protection Detailed Design Calculations 4.5 EQUIVALENT CIRCUIT RESISTANCE This section proves

4.5 EQUIVALENT CIRCUIT RESISTANCE

This section proves through calculation that there is sufficient driving voltage in the CP circuit to enable the system to operate at its design current after the groundbed voltage, cable volt drops and other losses have been taken into consideration.

The total system volt drop is the sum of the following components:

 

Groundbed volt drop

 

MMO Ribbon volt drop

Conductor bar volt drop

Cable volt drop

Back EMF and other losses

For

the

CP to

be effective this

total must

be

equal to

or

less

than the

voltage of

the

Transformer Rectifier.

This can be expressed in the following formula:

Where,

V vd

(

1)

+V vd

(

2)

+V vd +V vd

(

3)

(

4)

+Vlosses VTR

 

V (vd1)

=

Groundbed Volt Drop

4.6

4.3

V

V (vd2)

=

MMO Ribbon Volt Drop

0.005

0.005

V

V (vd3)

=

Conductor Bar Volt Drop

0.192

0.092

V

V (vd4)

=

Cable Volt Drop

5.45

2.73

V

V losses

=

Back EMF and Structure Losses

4.0

4.0

V

V Total

=

Total Voltage

14.23

11.13

V

V TR

=

Transformer Rectifier Voltage

24

24

V

 

See below for calculations of each component

 

Document Title

Detailed Design Calculations

 

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Tank External Base and Internal Cathodic Protection

Detailed Design Calculations

Internal Cathodic Protection Detailed Design Calculations 4.5.1 GROUNDBED VOLT DROP CALCULATION The groundbed volt

4.5.1 GROUNDBED VOLT DROP CALCULATION The groundbed volt drop is a combination of the following components:

Groundbed to earth resistance

Groundbed current

This can be expressed in the following formula:

Where,

V (vd1) = RGB.Itot

R GB

=

Groundbed Resistance to Earth

0.458

0.860

Ohm

I tot

=

Total Current

10

5

A

V (vd1)

=

Groundbed Volt Drop

4.6

4.3

V

 

V (vd 2) = I.R.L

I

=

MMO Ribbon Load / m

0.021

0.02

A

R

=

Resistance of MMO Ribbon 2

0.138

0.138

Ohm/m

L

=

Length of MMO Ribbon

1.79

1.75

m

V (vd2)

=

MMO Ribbon Volt Drop

0.005

0.005

V

MMO RIBBON VOLT DROP The MMO ribbon volt drop is calculated using the following formula:

Where,

4.5.2

Where the load is the current required for half the distance between two conductor bars.

I

=

I

tot

/

L

1

/(0.5.

S

2

)

Where,

I tot

=

Total Current

10

5

A

L 1

=

Total Length of MMO Ribbon

413.65

207.26

m

S 2

=

Spacing of Conductor Bar

3.5

3.5

m

I

=

MMO Ribbon Load / m

0.014

0.014

A

2 Data from MMO anode manufacture

Document Title

Detailed Design Calculations

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Tank External Base and Internal Cathodic Protection

Detailed Design Calculations

Internal Cathodic Protection Detailed Design Calculations 4.5.3 CONDUCTOR BAR VOLT DROP The Conductor Bar volt drop

4.5.3 CONDUCTOR BAR VOLT DROP

The Conductor Bar volt drop is calculated using the following formula:

V (vd 3) = I.R.L

Where,

I

=

Load

0.223

0.152

A

R

=

Resistance of Conductor Bar 3

0.069

0.069

Ohm/m

L

=

Length of Conductor Bar

12.50

9.75

m

V (vd2)

=

MMO Ribbon Volt Drop

0.192

0.092

V

Where the load is the current required for half the length of the longest conductor bar (worst case).

I

=

I

tot

/

L

2

/(0.5.

L

3

)

Where,

I tot

=

Total Current

10

5

A

L

2

=

Total Length of conductor Bar

139.7

70.6

m

L

3

=

Length of Longest conductor Bar

25

17.5

m

I

=

Conductor Bar Load / m

0.006

0.008

A

3 Data from conductor bar manufacture

Document Title

Detailed Design Calculations

Date

28/03/2012

Document No

16227-CP-03-DD

Revision

0

CPCL Project No

12/P16227

Page

16 of 27

TETCO – Gadarif Strategic Depot Project

Tank External Base and Internal Cathodic Protection

Detailed Design Calculations

Internal Cathodic Protection Detailed Design Calculations 4.5.1 CABLE VOLT DROP Cable volt drops are calculated using

4.5.1 CABLE VOLT DROP Cable volt drops are calculated using the following formula:

V

(

vd

4)

=

V

1

+

V

2

+

V

3

+

V

4

Where,

V 1

=

Main Positive Cable Volt Drop

1.05

V

V 2

=

Main Negative Cable Volt Drop

1.05

V

V 3

=

Powerfeed Cable Volt Drop

2.3

V

V 4

=

Negative Cable Volt Drop

1.05

V

V (vd4)

=

Cable Volt Drop

5.45

V

Individual cable volt drops are calculated using the following formula:

Where,

V

vd

=

(

R

cab

/1000 .L

)

cab

.I

cab

R Cab

=

Resistance of Cable 4

0.524

0.524

Ohm/km

L cab

=

Length of Cable

200

200

m

I cab

=

Current in Cable

10

5

A

V vd

=

Cable Volt Drop

1.1

0.524

V

The volt drop of each cable is calculated from the above equation.

 

R Cab

L cab

I cab

V vd

V 1

0.524

100

10

1.05

V 2

0.524

100

10

1.05

V 3

1.15

100

10

2.3

V 4

0.524

100

10

1.05

4 From cable manufacturers

Document Title

Detailed Design Calculations

Date

28/03/2012

Document No

16227-CP-03-DD

Revision

0

CPCL Project No

12/P16227

Page

17 of 27

TETCO – Gadarif Strategic Depot Project

Tank External Base and Internal Cathodic Protection

Detailed Design Calculations

Internal Cathodic Protection Detailed Design Calculations 4.6 CALCULATION SUMMARY   Parameter   25 m

4.6 CALCULATION SUMMARY

 

Parameter

 

25 m

17.5 m

Unit

SA

=

Surface Area (m²)

490.87

240.53

I

tot

=

Total Current

10

5

A

L

min

=

Minimum Ribbon Length

414

208

m

L

1

=

Actual Ribbon Length

414

208

m

S

1

=

MMO Ribbon Spacing

1.2

1.2

m

L

2

=

Conductor Bar Length

139.7

70.6

m

S

2

=

Conductor Bar Spacing

3.6

3.5

m

V

Total

=

Total Voltage Drop

15

12

V

V

TR

=

Transformer Rectifier Voltage

24

24

V

Document Title

Detailed Design Calculations

 

Date

28/03/2012

Document No

16227-CP-03-DD

 

Revision

0

CPCL Project No

12/P16227

 

Page

18 of 27

TETCO – Gadarif Strategic Depot Project

Tank External Base and Internal Cathodic Protection

Detailed Design Calculations

Internal Cathodic Protection Detailed Design Calculations 5 SUMMARY OF INSTALLATION – EXTERNAL CP In summary the

5 SUMMARY OF INSTALLATION – EXTERNAL CP

In summary the CP system and groundbed will be sized as follows:

Item

25 m

17.5 m

Permanent CP Station

2

 

3

Transformer Rectifier Voltage

24

V

24 V

Transformer Rectifier Current

10

A

 

5 A

MMO Ribbon Length

414

m

208

m

Powerfeed Number

7

 

5

Powerfeed Cable Size

16

mm 2

16

mm 2

Powerfeed Cable Length

150

m

100

m

Feeder Cable Size

35

mm 2

35

mm 2

Total Feeder Length (including 20 % spare for routing)

200

 

200

Number of Reference Electrodes

5

 

5

Document Title

Detailed Design Calculations

Date

28/03/2012

Document No

16227-CP-03-DD

Revision

0

CPCL Project No

12/P16227

Page

19 of 27

TETCO – Gadarif Strategic Depot Project

Tank External Base and Internal Cathodic Protection

Detailed Design Calculations

Internal Cathodic Protection Detailed Design Calculations 6 CORROSION CONTROL METHODS – INTERNAL CP 6.1

6

CORROSION CONTROL METHODS – INTERNAL CP

6.1

GENERAL

The corrosion protection system selected shall be based on a high integrity coating system in

combination with a cathodic protection system.

6.2

COATING SYSTEMS

The tank shall be coated internally in line with project specifications.

6.3

CATHODIC PROTECTION

The permanent CP system for the tanks will be a sacrificial anode cathodic protection (SACP)

system. The design criteria for the cathodic protection system are outlined in the sections

below:

6.3.1 DESIGN LIFE

The design life shall be 25 years for sacrificial anodes.

6.3.2 COATING BREAKDOWN AND DESIGN CURRENT DENSITIES

The current density below is taken from CPCL experience and international specifications:

Structure Surface

Minimum Current Density (mA/m 2 )

Tank Internals

100

For the protection of structure with elevated operating temperatures the minimum design current densities given above shall be increased by 25% per 10 °C rise in temperature above 30 °C.

All tanks will be at an operating temperature at 48 o C therefore, a design current density of 156.25 mA/m 2 is considered suitable.

The current density below is taken from Project Document:

Structure Surface

Coating Breakdown (%)

Gasoline / Gas Oil

5

Firewater

10

Document Title

Detailed Design Calculations

Date

28/03/2012

Document No

16227-CP-03-DD

Revision

0

CPCL Project No

12/P16227

Page

20 of 27

TETCO – Gadarif Strategic Depot Project

Tank External Base and Internal Cathodic Protection

Detailed Design Calculations

Internal Cathodic Protection Detailed Design Calculations 6.3.3 CURRENT DRAIN The tanks do not need to be

6.3.3 CURRENT DRAIN

The tanks do not need to be electrically isolated from any foreign structures using isolation joints / flanges and polarisation cells as this is an internal system. Where possible the tank should be electrically isolated from earthing / grounding systems and any re-bar used in construction.

6.3.4 CURRENT DEMAND

The current demand for each tank is calculated based on the surface area and the applicable final current density for steel as given in section 6.3.2.

6.3.5 CP PROTECTION POTENTIAL RANGES

The effectiveness of the cathodic protection systems should be determined by potential shift. The following “instant off” or IR free potentials should apply in the case of all tank bases.

The protection criteria for items in contact with soil are in line with international specifications and in summary:

Steel in Water -0.800 to -1.050 Volts with respect to a Ag/AgCl reference electrode.

100 mV polarisation shift.

All above potentials are IR free or “OFF” potentials.

Document Title

Detailed Design Calculations

Date

28/03/2012

Document No

16227-CP-03-DD

Revision

0

CPCL Project No

12/P16227

Page

21 of 27

TETCO – Gadarif Strategic Depot Project

Tank External Base and Internal Cathodic Protection

Detailed Design Calculations

Internal Cathodic Protection Detailed Design Calculations 7 DESIGN CONSIDERATIONS – INTERNAL CP 7.1 DESIGN

7

DESIGN CONSIDERATIONS – INTERNAL CP

7.1

DESIGN PARAMETERS

Structure to be protected and Diameter / Height considered for CP

:

Coating

:

Design Life

:

Current Density

:

CP Protection Criteria, E ag

:

Water Resistivity

:

7.2

CATHODIC PROTECTION PHILOSOPHY

Gas Oil: 25 m / 1 m

Gasoline: 17.5 m / 1 m

Firewater: 17.5 m / 12.5 m

10 % Coating Breakdown Factor

5 % for Firewater only

25 Years – Permanent CP

156.25 mA/m² at 30 o C

-0.80 V (IR Free)

200 Ohm.cm or less

The cathodic protection system for the internal surfaces will be based on a sacrificial anode cathodic protection (SACP) system and the minimum design life for the permanent system shall be 25 years.

The permanent cathodic protection system for the internal of the tanks will be based on aluminium sacrificial anodes which shall be bolted to welded support brackets installed at various locations around the base of each tank.

Temporary protection is not required as the permanent system can be energised upon completion of the tank.

Document Title

Detailed Design Calculations

Date

28/03/2012

Document No

16227-CP-03-DD

Revision

0

CPCL Project No

12/P16227

Page

22 of 27

TETCO – Gadarif Strategic Depot Project

Tank External Base and Internal Cathodic Protection

Detailed Design Calculations

Internal Cathodic Protection Detailed Design Calculations 8 DESIGN CALCULATIONS – INTERNAL CP The design of

8

DESIGN CALCULATIONS – INTERNAL CP

The design of the system is based on the diameter and height of the tank bottom, anode size and weight, and the cathodic protection current requirement for the given environment. The equations derived enabled the determination of the number of anodes and the anode resistances.

8.1

CALCULATION SUMMARY

The table below is an executive summary of the calculations in this section:

 

Tank

Gas Oil

Gasoline

Firewater

Unit

SA

=

Surface Area (m²)

570

296

928

I

f

=

Current

8.90

4.62

7.25

A

I

a

=

Individual Anode Current

0.25

0.25

0.25

A

A

n1

=

Anode Number for Current

36

19

29

No

M

a

=

Individual Anode Mass

25.2

25.2

25.2

kg

A

n2

=

Anode Number for Mass

37

19

30

No

A

t

=

Anode Number Required

40

24

34

No

Document Title

Detailed Design Calculations

Date

28/03/2012

Document No

16227-CP-03-DD

Revision

0

CPCL Project No

12/P16227

Page

23 of 27

TETCO – Gadarif Strategic Depot Project

Tank External Base and Internal Cathodic Protection

Detailed Design Calculations

Internal Cathodic Protection Detailed Design Calculations 8.2 CURRENT REQUIREMENTS The current required for the

8.2 CURRENT REQUIREMENTS

The current required for the internal tank surface to be protected is shown below:

The internal surface area of the structure (GAS OIL TANK ONLY) is calculated using the following formula:

SA

=π

.r

2

+π

.d.h

Where for tank,

π

=

Pi

3.142

R

=

Radius

12.5

m

D

=

Diameter

25.0

m

H

=

Height

1.0

m

SA

=

Surface Area (m²)

569.41

The current required for GAS OIL TANK can then be calculated using the following:

If = (SA.J.Fc)

Where for tank,

SA

Surface Area

596.41

J

Current Density

156.25

mA

F c

Coating Breakdown Factor

10

%

I f

=

Final Current

8.90

A

Document Title

Detailed Design Calculations

Date

28/03/2012

Document No

16227-CP-03-DD

Revision

0

CPCL Project No

12/P16227

Page

24 of 27

TETCO – Gadarif Strategic Depot Project

Tank External Base and Internal Cathodic Protection

Detailed Design Calculations

Internal Cathodic Protection Detailed Design Calculations 8.3 NUMBER OF ANODES BY CURRENT OUTPUT The anode resistance

8.3 NUMBER OF ANODES BY CURRENT OUTPUT

The anode resistance is calculated using the following equation:

Where,

R

f

=

ρ

l

2

π

f

(ln

4

l

f

r

f

1)

ρ

=

Water Resistivity

2

Ohm.m

l f

=

Final Anode Length (90%)

112.5

cm

r f

=

Final Effective Anode Radius (50%)

49.2

cm

R f

=

Final Anode Resistance to Earth

1.19

Ohm

Then, the maximum current output per anodes is calculated using Ohm’s Law:

Where,

I