CORROSION MATTERS

1.6 Sample Design Calculation for CP Station for Span Length from 0 to 28.9 Km

Equation Description Value unit

1.6.1 Sa Surface area 41165 m2

Sa = P x d x l d Dia 0.4534 m

l Length 28900 m

1.6.2 It Total Current requirement 1.33 Amps

It = Sa x Id x 1.3/1000 Sa Surface area 41165 m2

Id Current density 0.025 mA/mt2

1.6.3 W Total Anode Weight 0.062 grams

It Total Current 1.33 Amps

W = I t x Ct x L / U f Ct Consumption Rate 0.001 gm/A-Y

L Life 40 Years

Uf Anode Utilization factor 0.85

1.6.4 Nw No of Anode required by weight 0.25 Nos

W Total Anode Weight 0.062 grams

Nw = W/ Wa
Wa Weight of Anode 0.240 grams

(Thickness of MMO Coating 6gm/m2)

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 CORROSION MATTERS

1.6.5 Nt No of Anode required by current 0.44 Nos

Nt = It/ Ia It Total current 1.33 Amps

Ia Anode output current 3 Amps

GROUND BED RESISTANCE CALCULATION FOR SHALLOW HORIZONTAL ANODE BED

1.6.6 RS Individual anode to backfill resistance 0.806 Ohms

ohm-
PS Soil Resistivity 36 mtr

Rs = 0.159Ps/L Ln(4L2 + 4L (S2+L2) 0.5)/DS)+( S/L) – (S2+L2)0.5/L –1) N No of Anodes 8 Nos

L Active length of anode 51 mtr

D Active diameter of Pre-packed anode bed 0.4 mtr

S Twice the depth of Anode 6 mtr

1.6.7 Rbs Individual anode to backfill resistance 0.38 Ohms

ohm-
Rbs = 0.159 Pb/L Ln ( 8 L / d)-1  Pb Backfill Resistivity for Calcined Coke 0.5 mtr

L Length of anode 1 mtr

d Diameter of anode 0.025 mtr

1.6.8 Rtbs Total Anode to Backfill Resistance 0.047 Ohms

Rtbs = Rbs/N Rbs Individual anode to backfill resistance 0.38 ohms

N Number of Anodes 8 Nos

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 CORROSION MATTERS

1.6.9 Rgb = Rs + Rtbs Rgb Total Ground bed Resistance 0.853 Ohms

Rs Resistance of vertical Anode to earth 0.806 Ohms

Rtbs Total Anode to Backfill Resistance 0.047 Ohms

Rta = 1/(1/R1)+(1/R2)……..+1/R6 Rta Resistance of Anode Tail Cable 0.0552 Ohms

Ri = Li x R10
Li Length of Anode cable mtr
R1 & R5 = 8 x 0.001.73 = 0.015ohms
1.6.10
R2 & R6 = 15x0.001.73 = 0.028 ohms

R3 & R7 = 22x0.001.73 = 0.040 ohms

R4 & R8 = 29x0.001.73 = 0.053 ohms R25 Resistance of 10 mm2 cable 0.00115 Ohm/Mtr

1.6.11 Rac Resistance of Header cable 0.14 Ohms

R35 Resistance of 35 mm2 cable 0.00056 Ohm/mtr

Rac = R35 ( Lac + L cc )
Lac Length of Cathode cable 75 mtr

lcc Length of Anode cable 175 mtr

1.6.12 Rtc Total Reisistance offered by All cables 0.143 Ohms

Rtc = Rta + Rac Rac Resistance of Header cable 0.14 Ohms

Rta Resistance of Anode tail cable 0.00342 Ohms

1.6.13 Rtotal Total Circuit Resistance 0.997 Ohms

Rtotal = Rgb + Rtc Rgb Total Ground bed Resistance 0.853 Ohms

Rtc Total Reisistance offered by All cables 0.143 Ohms

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 CORROSION MATTERS

1.6.14 Vt Total Output Voltage 3.32 Volts

Rtotal Total Circuit Resistance 0.997 Ohms

Vt = (Rtotal x It)+ 2Volts
It Total Current 1.33 Amps

Back Voltage 2 Volts

1.6.15 Voltage rise in earth with respect to remote

Vx earth 0.401 Volts

Vx = I /2 L  Soil Resistivity 36 Ohms

L Distance between P/L and Anode bed 100 Mtr

I Maximum current output 7 Amps

From above electrically remoteness calculations for Anode bed, it can observed that Voltage raise in earth with respect to remote earth at a distance 100 is
less than to pipeline Voltage to earth (ie 0.45V) & Remoteness of anode ground bed can be achieved

1.6.16 Ap Cross section area of Pipe 0.0123 Mtr

D Diameter of Pipe (m) 0.4534 Mtr

Ap = P x t x ( D-t )
t Thickness of pipe 0.0087 Mtr

1.6.17 ohm/K
Rs Linear Resistance of pipeline 0.01.70 m

0.0000
s Resistivity of steel pipe 0022 ohm-mtr
Rs = s x l / Ap
I unit length of pipe 1000 mtr

Ap Cross section area of Pipe 0.0123 mtr

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 CORROSION MATTERS

1.6.1.7 ohm/K
Rl Coating Leakage Resistance for 3LPE 10.45 m

ohm-
Rl = Rp/Sa
Rp Coating Resistance 15000 mtr2

1435.7
Sa Surface area per Km 1 mtr2

1.6.1.7  attenuation Constant 0.0415

=( Rs/Rl )0.5 Rs Linear Resistance of pipeline 0.01.70 ohm/Km

Rl Coating Leakage Resistance for 3LPE 10.45 ohm/Km

1.6.20 Edp Maximum potential shift at drain point -1.05 V

P/s
Edp =P/s max - P/s nat max Least negative PSP at drain point -1.5 V

P/s
nat Natural PSP of pipeline -0.45 V

1.6.21 Ed Maximum potential shift at end point -0.5 V

P/s
Ed =P/s min - P/s nat min Least negative PSP at end point -0.95 V

P/s
nat Natural PSP of pipeline -0.45 V

1.6.22 Lp Length of P/L protected from drain point 33.12 Km

Edp Maximum potential shift at drain point -1.05 V

Lp=(1/) x Cosh-1(Edp/ Ed)
Ed Maximum potential shift at end point -0.5 V

 attenuation Constant 0.0415

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