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NEWCROSS Exploration and Production Limited

DESIGN, SUPPLY, INSTALLATION AND COMMISSIONING OF A SKIDDED 600#,


4 HEADER, 24 SLOTS SEGMENTED INLET MANIFOLD AT EKULAMA 1
FLOWSTATION

CATHODIC PROTECTION
DOCUMENT No: EKUF1-19001-FODE-QA-SP-1001

SAMSON
P 24/08/18 Issued for IDC AKI
O. FOSL
REV DATE ISSUE PURPOSE ORIG CHK APPR

APPROVED BY: COMPANY APPROVAL:

DATE: DATE:
Project Document Sequence
FODE Document Client Discipline Revision
Number Type Number
Control No.
19000 NWC ST DRD 1001 P
DESIGN OF SKIDDED 600#, 4 HEADER 24 SLOT SEGMENTED INLET
MANIFOLD
CATHODIC PROTECTION CALCULATIONS REPORT

TABLE OF CONTENTS
1 INTRODUCTION ................................................................................................................................ 3

1.1 OBJECTIVE OF THE REPORT .................................................................................................. 4

1.2 DESIGN CODE ............................................................................................................................ 4

1.3 SCOPE .......................................................................................................................................... 4

2 PROJECT OVERVIEW ....................................................................................................................... 5

2.1 EKULAMA FIELD OVERVIEW ................................................................................................ 5

3 DESIGN BASIS.................................................................................................................................... 6

3.1 MANIFOLD PIPING DATA........................................................................................................ 6

3.2 DESIGN DATA ............................................................................................................................ 6

3.3 DESIGN FORMULAE ................................................................................................................. 6

3.4 FLOWLINE LIGAMENT PIPING CATHODIC PROTECTION ............................................... 9

3.4.1 USING ALUMINUM ANODES .......................................................................................... 9

3.4.2 USING MAGNESIUM ANODES...................................................................................... 10

3.4.3 SACRIFICIAL ANODE DATA ......................................................................................... 11

3.4.4 CALCULATION RESULTS .............................................................................................. 12

3.4.5 REQUIRED NO OF ANODES SUMMARY ..................................................................... 12

3.5 MANIFOLD 8 INCH HEADER PIPING CATHODIC PROTECTION ................................... 14

3.5.1 USING ALUMINUM ANODES ........................................................................................ 14

3.5.2 USING MAGNESIUM ANODES...................................................................................... 15

3.5.3 SACRIFICIAL ANODE DATA ......................................................................................... 16

3.5.4 CALCULATION RESULTS .............................................................................................. 17

3.5.5 REQUIRED NO OF ANODES SUMMARY ..................................................................... 18

4 CONCLUSION AND RECOMMENDATIONS ................................................................................ 19


DESIGN OF SKIDDED 600#, 4 HEADER 24 SLOT SEGMENTED INLET
MANIFOLD
CATHODIC PROTECTION CALCULATIONS REPORT

1 INTRODUCTION
This document presents the design calculation for cathodic protection of the
proposed inlet piping at Ekulama Flowstation using Sacrificial Anodes.

In this document, the use of Magnesium was compared with Aluminum as


sacrificial anodes for both ligament section and the manifold header section.

Result shown that required number of Aluminum anodes for cathodic protection
over the stated design life of 15 years was lesser to a ratio of 5 as compared to
using Magnesium Anodes.

The use of Galvotec Aluminum Bracelet Anodes and Magnesium Anodes was
referenced to throughout the design and the selection process. This however was
used as a based guide as the design calculations and formulae being employed is
applicable to using other vendor anodes other than Galvotec.

Design calculation was performed in compliance with the recommendation of


DNV-RP-B401 (2017 Edition)
DESIGN OF SKIDDED 600#, 4 HEADER 24 SLOT SEGMENTED INLET
MANIFOLD
CATHODIC PROTECTION

1.1 OBJECTIVE OF THE REPORT


 To present the design calculations for the sacrificial anodes to be employed for the
cathodic protection of inlet manifold piping at Ekulama 1 Flowstation.

1.2 DESIGN CODE


DNV RP B401 - Recommended Practice - Cathodic Protection Design

1.3 SCOPE
The design Calculation is limited to cathodic protection of the ligament and header sections
of the inlet manifold piping as this does not include cathodic protection for piles and other
supporting structures.
DESIGN OF SKIDDED 600#, 4 HEADER 24 SLOT SEGMENTED INLET
MANIFOLD
CATHODIC PROTECTION

2 PROJECT OVERVIEW
COMPANY plans to replace the existing Inlet manifold that is severely corroded. This is a
measure to sustain continuous and safe production of the wells through the inlet manifold.
The corroded existing manifold shows possibilities of rupture and the decommissioning,
removal and replacement of the manifold will prevent and help safe guard people and the
environment. The new manifold shall not be a like for like, it shall be re-designed as an
upgrade of the existing manifold. The new manifold shall be rated at 600# with 4 Headers, 24
Slots and segmented in 6 slots each such that each segment can be fully and independently
isolated from the others by use of isolation valves installed on each 8” Header.

2.1 EKULAMA FIELD OVERVIEW


Ekulama-1 flow station is located on piles on Oil Mining License 24 approximately 45km
South West of Port Harcourt. It is bounded by Awoba field to the south, Soku field to the
South East and close to Belema field. The field is accessible by air and by water. A journey
from Port Harcourt by air takes approximately 40 minutes while boat transportation takes
2hours 15minutes.

The flow station is a single bank with vessels for a two-stage separation. The processed crude
is pumped with gas driven crude oil export reciprocating pumps into the trunk line, while
the separated gas is flared with horizontal flare unit located in a bunded area outside the flow
station. Ekulama-1 field consists of 11 wells flowing into its flow station. These wells are
located in swampy area with dredged slot to each well head for easy access during wellhead
activities. Ekulama-1 flow station is currently producing 17,000bbls/d gross with an average
water cut of 38.85%. It is design to handle a maximum capacity of approximately
30.000bbls/d.

Accommodation for dedicated teams of technical personnel who visit the Ekulama-1 flow
station is provided at the nearest base station on Ekulama-2.
DESIGN OF SKIDDED 600#, 4 HEADER 24 SLOT SEGMENTED INLET
MANIFOLD
CATHODIC PROTECTION

3 DESIGN BASIS
The following defines the basis of cathodic protection, design parameters and assumptions,
which shall be used to design the CP system sacrificial anodes for the new SKIDDED 600#,
4 HEADER 24 SLOT SEGMENTED INLET MANIFOLD

3.1 MANIFOLD PIPING DATA


Flowline Ligament Piping Diameter: 4 inch
Manifold Header Piping Diameter: 8 inch
Flowline Ligament Piping length: 10meters
Manifold Header Piping Length: 10 meters

3.2 DESIGN DATA


Location Ekulama
Terrain Shallow Water/Swampy
Water Depth <30 m
Temperature Tropical Zone (>200C)
Average Current Density 0.100 A/m2 Ref : DNV RP – B401 Table
10.8
Average Soil Resistivity (Sea 0.25 ohm m
Water)
Design Life 15 years

3.3 DESIGN FORMULAE


The following formulae are employed in the course of the design.

Piping Area Sr 𝑆𝑟 = 2𝜋𝑟𝑙

Total Area Stotal

Total Current
ltotal
required
DESIGN OF SKIDDED 600#, 4 HEADER 24 SLOT SEGMENTED INLET
MANIFOLD
CATHODIC PROTECTION CALCULATIONS REPORT

𝑊
Required 𝐷𝑒𝑠𝑖𝑔𝑛 𝐿𝑖𝑓𝑒 𝑥 𝐼𝑡𝑜𝑡𝑎𝑙 𝑥 𝐶𝑢𝑟𝑟𝑒𝑛𝑡 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦
W
anode weight =
𝐶𝑢𝑟𝑟𝑒𝑛𝑡 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑦 𝑥 𝑈𝑡𝑖𝑙𝑖𝑧𝑎𝑡𝑖𝑜𝑛 𝐹𝑎𝑐𝑡𝑜𝑟

Required 𝑇𝑜𝑡𝑎𝑙 𝑅𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑊𝑒𝑖𝑔ℎ𝑡


anode N
𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑂𝑛𝑒 𝐴𝑛𝑜𝑑𝑒
quantity

Protect area
Sanode
for one anode

Minimum
distances
LMIN
between
anodes
Protecting
Diameter for Danode
one anode

Anode to
As Per DNV RP B401 Table
Earth Ra
10.7
Resistance
Minimum
As per Vendor (Galvotec)
Protective Vmin
Specifications
Potential
Driving
Vd 𝑉 − 𝑉𝑚𝑖𝑛
Potential
Anode
𝐼𝑡𝑜𝑡𝑎𝑙
Current Io
Output 𝑅𝑎
Anode
Quantity (By 𝐼𝑡𝑜𝑡𝑎𝑙
Nc
Current 𝐼𝑜
Requirement)
Anode
𝑇𝑜𝑡𝑎𝑙 𝑅𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑊𝑒𝑖𝑔ℎ𝑡
Quantity By N
Weight 𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑂𝑛𝑒 𝐴𝑛𝑜𝑑𝑒
Selected
Number of
Ns Maximum (N, Nc)
Anodes
(+FOS)
Calculated
Number of
tactual 𝑁𝑠 × 𝑇𝑜𝑡𝑎𝑙 𝐴𝑛𝑜𝑑𝑒 𝑊𝑒𝑖𝑔ℎ𝑡 𝑥 𝑈𝑡𝑖𝑙𝑖𝑧𝑎𝑡𝑖𝑜𝑛 𝐹𝑎𝑐𝑡𝑜𝑟 𝑥 𝜇
Years Based
on Number of 𝐼𝑥𝐶
DESIGN OF SKIDDED 600#, 4 HEADER 24 SLOT SEGMENTED INLET
MANIFOLD
CATHODIC PROTECTION CALCULATIONS REPORT

Anodes being
Selected
DESIGN OF SKIDDED 600#, 4 HEADER 24 SLOT SEGMENTED INLET
MANIFOLD
CATHODIC PROTECTION

3.4 FLOWLINE LIGAMENT PIPING CATHODIC PROTECTION

3.4.1 USING ALUMINUM ANODES

3.4.1.1 INPUT DATA


Piping Inside Diameter D 0.102 m
Piping Length L 10 m
Resistivity ρ 0.25 Ωm
DNV-RP-B401,
Design Current density l 100 mA/m2
Table 10-4
Design Life time t 15 years
Current Capacity of anode 3.4 kg/A.year
Anode current efficiency 50 %
Utilization Factor U 90 %
Coating Breaking Factor (80% DNV-RP-B401,
fc 0.20
Coating Efficiency) Section 6.4.4

3.4.1.2 SACRIFICIAL ANODES DATA


Anode Type Aluminum Bracelet Anodes
Anode Manufacturer Galvotec
Bracelet I.D 114mm (4.5 inch) Ref : Galvotec Catalogue
Type T Ref : Galvotec Catalogue
Thickness 38mm (1.5 inch) Ref : Galvotec Catalogue
Length 305mm (12 inch) Ref : Galvotec Catalogue
Gap 32 mm (1.25 inch) Ref : Galvotec Catalogue
Weight 11.3 kg (25.1 lbs) Ref : Galvotec Catalogue
Anode Composition Rate 3 kg/A.yr
Utilization Factor 0.9 Ref : DNV RP – B401
Table 10.8
Anode Efficiency 85% Ref : Galvotec Catalogue
Anode Closed Circuit -(1.15V)
Potential
Anode Minimum Protection -(0.80V)
Potential

3.4.1.3 CALCULATION RESULTS


Designed As Per DNV-RP-B401
Piping Area Sr 3.2 m2

Total Area Stotal 3.2 m2

Total Current required ltotal 0.06 Amp


DESIGN OF SKIDDED 600#, 4 HEADER 24 SLOT SEGMENTED INLET
MANIFOLD
CATHODIC PROTECTION CALCULATIONS REPORT

Required anode weight W 8 kg

Required anode N 0.75 ea


quantity

Protect area for one Sanode 4.29 m2


anode

Minimum distances LMIN 2.07 m


between anodes

Protecting Diameter for Danode 1.17 m


one anode

Anode to Earth Ra 0.27 Ohms As Per DNV RP B401 Table


Resistance 10.7
Minimum Protective Vmin 0.80 V As per Vendor (Galvotec)
Potential Specifications

Driving Potential Vd 0.350 V


Anode Current Output Io 1.301 Amp

Anode Quantity (By Nc 1 ea


Current Requirement)

Anode Quantity By N 1 ea
Weight
Selected Number of Ns 1 Anodes
Anodes (+FOS)

Calculated Number of tactual 20 Years


Years Based on
Number of Anodes
being Selected

Anode Actual Design Life is greater than the stated design life, thus Required Anode Quantity is
Sufficient

3.4.2 USING MAGNESIUM ANODES


Piping Inside Diameter D 0.102 m
Piping Length L 10 m
Resistivity ρ 160.0 Ωm
DNV-RP-B401,
Design Current density l 100 mA/m2
Table 10-4
Design Life time t 15 years
Current Capacity of anode 7 kg/A.year
DESIGN OF SKIDDED 600#, 4 HEADER 24 SLOT SEGMENTED INLET
MANIFOLD
CATHODIC PROTECTION CALCULATIONS REPORT

Anode current efficiency 50 %


Utilization Factor U 90 %
Coating Breaking Factor (80% DNV-RP-B401,
fc 0.20
Coating Efficiency) Section 6.4.4

3.4.3 SACRIFICIAL ANODE DATA

Anode Type High Potential Magnesium


Anodes
Anode Manufacturer Galvotec
Product Number GA – MG – 9HP Ref : Galvotec Catalogue
Weight 4.1kg (9.1 lbs) Ref : Galvotec Catalogue
Width 89mm (3.50 inch) Ref : Galvotec Catalogue
Height 95 mm (3.75 inch) Ref : Galvotec Catalogue
Diameter 152 mm (6 inch) Ref : Galvotec Catalogue
Overall Length 432 mm (17 inch) Ref : Galvotec Catalogue
Anode Composition Rate 7 kg/A.yr
Utilization Factor 0.9 Ref : DNV RP – B401
Table 10.8
Anode Efficiency 50% Ref : Galvotec Catalogue
Anode Closed Circuit -(1.5V) Ref : Galvotec Catalogue
Potential
Anode Minimum Protection 55% of the Anode Closed Circuit Ref : Galvotec Catalogue
Potential Potential
DESIGN OF SKIDDED 600#, 4 HEADER 24 SLOT SEGMENTED INLET
MANIFOLD
CATHODIC PROTECTION

3.4.4 CALCULATION RESULTS


Results are presented below:

Designed As Per DNV-RP-B401


Piping Area Sr 3.2 m2
Total Area Stotal 3.2 m2
Total Current required ltotal 0.06 Amp
Required anode weight W 16 kg
Required anode
N 3.86 ea
quantity
Protect area for one
Sanode 0.83 m2
anode
Minimum distances
LMIN 0.91 m
between anodes
Protecting Diameter for
Danode 0.51 m
one anode
Anode to Earth As Per DNV RP B401 Table
Ra 0.20 Ohms
Resistance 10.7
Minimum Protective As per Vendor (Galvotec)
Vmin 0.83 V
Potential Specifications
Driving Potential Vd 0.700 V
Anode Current Output Io 3.582 Amp
Anode Quantity (By
Nc 1 ea
Current Requirement)
Anode Quantity By
N 4 ea
Weight
Selected Number of
Ns 5 Anodes
Anodes (+FOS)
Calculated Number of
Years Based on
tactual 19 Years
Number of Anodes
being Selected
Anode Actual Design Life is greater than the stated design life, thus Required Anode Quantity is
Sufficient

3.4.5 REQUIRED NO OF ANODES SUMMARY


Aluminum Magnesium
Number of Sacrificial Anodes 1 5
per Ligament
Required total number of 24 120
Anodes for the Entire Manifold
(x24)
DESIGN OF SKIDDED 600#, 4 HEADER 24 SLOT SEGMENTED INLET
MANIFOLD
CATHODIC PROTECTION CALCULATIONS REPORT

Design Life 15 years 15 years


Estimated Years based on 20 Years 19 Years
Number of Selected Anodes
DESIGN OF SKIDDED 600#, 4 HEADER 24 SLOT SEGMENTED INLET
MANIFOLD
CATHODIC PROTECTION

3.5 MANIFOLD 8 INCH HEADER PIPING CATHODIC PROTECTION

3.5.1 USING ALUMINUM ANODES


3.5.1.1 INPUT DATA
Piping Inside Diameter D 0.20 m
Piping Length L 10 m
Resistivity ρ 0.25 Ωm
DNV-RP-B401,
Design Current density l 100 mA/m2
Table 10-4
Design Life time t 15 years
Current Capacity of anode 3.4 kg/A.year
Anode current efficiency 50 %
Utilization Factor U 90 %
Coating Breaking Factor (80% DNV-RP-B401,
fc 0.20
Coating Efficiency) Section 6.4.4

3.5.1.2 SACRIFICIAL ANODES DATA


Anode Type Aluminum Bracelet Anodes
Anode Manufacturer Galvotec
Bracelet I.D 181mm (7.375 inch) Ref : Galvotec Catalogue
Type T Ref : Galvotec Catalogue
Thickness 57mm (2.25inch) Ref : Galvotec Catalogue
Length 241mm (9.5 inch) Ref : Galvotec Catalogue
Gap 25 mm (1.00 inch) Ref : Galvotec Catalogue
Weight 20 kg (44.1lbs) Ref : Galvotec Catalogue
Anode Composition Rate 3 kg/A.yr
Utilization Factor 0.9 Ref : DNV RP – B401
Table 10.8
Anode Efficiency 85% Ref : Galvotec Catalogue
Anode Closed Circuit -(1.15V)
Potential
Anode Minimum Protection -(0.80V)
Potential

3.5.1.3 CALCULATION RESULTS


Designed As Per DNV-RP-B401
Piping Area Sr 6.3 m2

Total Area Stotal 6.3 m2


Total Current required ltotal 0.13 Amp
DESIGN OF SKIDDED 600#, 4 HEADER 24 SLOT SEGMENTED INLET
MANIFOLD
CATHODIC PROTECTION CALCULATIONS REPORT

Required anode weight W 15 kg

Required anode N 0.75 ea


quantity

Protect area for one Sanode 8.33 m2


anode

Minimum distances LMIN 2.89 m


between anodes

Protecting Diameter for Danode 1.63 m


one anode

Anode to Earth Ra 0.23 Ohms As Per DNV RP B401 Table


Resistance 10.7
Minimum Protective Vmin 0.80 V As per Vendor (Galvotec)
Potential Specifications

Driving Potential Vd 0.350 V


Anode Current Output Io 1.554 Amp

Anode Quantity (By Nc 1 ea


Current Requirement)

Anode Quantity By N 1 ea
Weight
Selected Number of Ns 1 Anodes
Anodes (+FOS)

Calculated Number of tactual 20 Years


Years Based on
Number of Anodes
being Selected

Anode Actual Design Life is greater than the stated design life, thus Required Anode Quantity is
Sufficient

3.5.2 USING MAGNESIUM ANODES


Piping Inside Diameter D 0.102 m
Piping Length L 10 m
Resistivity ρ 0.25 Ωm
DNV-RP-B401,
Design Current density l 100 mA/m2
Table 10-4
Design Life time t 15 years
Current Capacity of anode 7 kg/A.year
DESIGN OF SKIDDED 600#, 4 HEADER 24 SLOT SEGMENTED INLET
MANIFOLD
CATHODIC PROTECTION CALCULATIONS REPORT

Anode current efficiency 50 %


Utilization Factor U 90 %
Coating Breaking Factor (80% DNV-RP-B401,
fc 0.20
Coating Efficiency) Section 6.4.4

3.5.3 SACRIFICIAL ANODE DATA

Anode Type High Potential Magnesium


Anodes
Anode Manufacturer Galvotec
Product Number GA – MG – 20HP Ref : Galvotec Catalogue
Weight 9.1kg (9.1 lbs) Ref : Galvotec Catalogue
Width 70mm (2.75 inch) Ref : Galvotec Catalogue
Height 76 mm (3.00 inch) Ref : Galvotec Catalogue
Diameter 127 mm (5 inch) Ref : Galvotec Catalogue
Overall Length 1676 mm (66 inch) Ref : Galvotec Catalogue
Anode Composition Rate 7 kg/A.yr
Utilization Factor 0.9 Ref : DNV RP – B401
Table 10.8
Anode Efficiency 50% Ref : Galvotec Catalogue
Anode Closed Circuit -(1.5V) Ref : Galvotec Catalogue
Potential
Anode Minimum Protection 55% of the Anode Closed Circuit Ref : Galvotec Catalogue
Potential Potential
DESIGN OF SKIDDED 600#, 4 HEADER 24 SLOT SEGMENTED INLET
MANIFOLD
CATHODIC PROTECTION

3.5.4 CALCULATION RESULTS


Results are presented below:

Designed As Per DNV-RP-B401


Piping Area Sr 3.2 m2

Total Area Stotal 3.2 m2

Total Current required ltotal 0.06 Amp


Required anode weight W 16 kg

Required anode
N 1.74 ea
quantity
Protect area for one
Sanode 1.84 m2
anode

Minimum distances
LMIN 1.36 m
between anodes

Protecting Diameter for


Danode 0.77 m
one anode
Anode to Earth As Per DNV RP B401 Table
Ra 0.09 Ohms
Resistance 10.7

Minimum Protective As per Vendor (Galvotec)


Vmin 0.80 V
Potential Specifications

Driving Potential Vd 0.700 V

Anode Current Output Io 8.065 Amp

Anode Quantity (By


Nc 1 ea
Current Requirement)

Anode Quantity By
N 2 ea
Weight

Selected Number of
Ns 3 Anodes
Anodes (+FOS)
Calculated Number of
Years Based on Number
tactual 26 Years
of Anodes being
Selected

Anode Actual Design Life is greater than the stated design life, thus Required Anode Quantity is
Sufficient
DESIGN OF SKIDDED 600#, 4 HEADER 24 SLOT SEGMENTED INLET
MANIFOLD
CATHODIC PROTECTION CALCULATIONS REPORT

3.5.5 REQUIRED NO OF ANODES SUMMARY


Aluminum Magnesium
Number of Sacrificial Anodes 1 3
per Ligament
Required total number of 16 48
Anodes for the Entire Manifold
(x16)
Design Life 15 years 15 years
Estimated Years based on 20 Years 26 Years
Number of Selected Anodes
4 CONCLUSION AND RECOMMENDATIONS
The use of Magnesium and Aluminum as sacrificial anodes has been evaluated for inlet piping manifold
design and their results are summarized below

4 INCH FLOWLINE LIGAMENTS

Aluminum Magnesium
Number of Sacrificial Anodes 1 5
per Ligament
Required total number of 24 120
Anodes for the Entire Manifold
(x24)
Design Life 15 years 15 years
Estimated Years based on 20 Years 19 Years
Number of Selected Anodes

8 INCH MANIFOLD HEADERS

Aluminum Magnesium
Number of Sacrificial Anodes 1 3
per Ligament
Required total number of 16 48
Anodes for the Entire Manifold
(x16)
Design Life 15 years 15 years
Estimated Years based on 20 Years 26 Years
Number of Selected Anodes

Thus based on the outcome of the results, it is recommended that the use of Aluminium Anodes should be
the preferred choice over Magnesium for longer duration of cathodic protection of the inlet piping at
Ekulama Flowstation. There should however be balance between cost and the design life for protection to
justify the use of Aluminum Anodes over Magnesium Anodes.