Beruflich Dokumente
Kultur Dokumente
DESIGN CALCULATION
FOR EXTERNAL SACP FOR BURIED FUEL TANKS
Table of Contents
1. Introduction ................................................................................................................................ 3
2. Abbreviations .............................................................................................................................. 3
3. Codes and Standards .................................................................................................................. 4
4. Structure Details ......................................................................................................................... 5
5. Scope of Work............................................................................................................................. 5
6. Soil Resistivity ............................................................................................................................. 5
7. Engineering Design ..................................................................................................................... 6
7.1. CP Current Density .................................................................................................................. 6
7.2. CP Design Life.......................................................................................................................... 6
7.3. Coating Breakdown................................................................................................................. 6
7.4. Electrical Isolation ................................................................................................................... 6
7.5. Anode Type ............................................................................................................................. 6
7.6. Design Calculations for SACP System ...................................................................................... 7
7.6.1. Area to Be Protected .......................................................................................................... 7
7.6.2. CP Current Requirement ..................................................................................................... 9
7.6.3. Anode Quantity Requirement by Weight ......................................................................... 10
7.6.4. Anode Quantity Requirement by Current ......................................................................... 12
7.6.5. Design Anode Quantity per Tank ...................................................................................... 15
8. Cathodic Protection Monitoring Facilities ................................................................................ 15
8.1. Test Station (STP) .................................................................................................................. 15
8.2. Junction Box (JB) ................................................................................................................... 16
9. Bill of Materials ......................................................................................................................... 16
10. List of Drawings..................................................................................................................... 17
Main contractor Project no.
STFA DENIZ INSAATI INSAAT SAN. VE TIC. A.S. 366010033
Cathodic protection vendor KOC document no.
DONG YANG CORROSION ENGINEERING CO.
Project Rev. Page
SMALL BOAT HARBOR FUEL SYSTEM A 3 OF 18
Document title Document no.
P-RFC19-KW-0008-DC-
DESIGN CALCULATION FOR EXTERNAL SACP SYSTEM FOR BURIED FUEL TANKS
1_TANK.DOCX
1. Introduction
Dong Yang Corrosion Engineering Co. (DYCE) has been retained by STFA Deniz Insaati Insaat
Sanayi Ve Ticaret Anonim Sirketi (STFA) to revise the design, supply materials, supervise the
installation, test and commission the external sacrificial cathodic protection system for the
underground fuel tanks associated with the project “Small Boat Harbor Fuel System”.
This document outlines the detailed design, engineering & BOQ calculation for the external
sacrificial cathodic protection system for the underground fuel tanks associated with the subject
project.
2. Abbreviations
The following definitions and abbreviations has been used in this document:
CP : Cathodic Protection
SACP : Sacrificial Cathodic Protection
Mg : Magnesium
Cu/CuSO4 : Copper-Copper Sulfate
NACE : National Association of Corrosion Engineers
KOC : Kuwait Oil Company
AJB : Anode Junction Box
TP : Test Post
ASTM : American Standards for Testing Materials
DC : Direct Current
RE : Reference Electrode
Main contractor Project no.
STFA DENIZ INSAATI INSAAT SAN. VE TIC. A.S. 366010033
Cathodic protection vendor KOC document no.
DONG YANG CORROSION ENGINEERING CO.
Project Rev. Page
SMALL BOAT HARBOR FUEL SYSTEM A 4 OF 18
Document title Document no.
P-RFC19-KW-0008-DC-
DESIGN CALCULATION FOR EXTERNAL SACP SYSTEM FOR BURIED FUEL TANKS
1_TANK.DOCX
4. Structure Details
Project tank details
Operating
Diameter Length T-T External Surface
Quantity Head Capacity Temperature
(m) (m) Coating (*)
(*)
1 Bumped 25000 3.35 12.0 High Performance 30°C
5. Scope of Work
The following activities are covered under the scope of work to be performed by DYCE:
• Revise the cathodic protection design calculation as per actual site conditions.
• Supply of additional materials.
• Revise the construction drawings.
• Supervision during installation.
• Testing & Commissioning of CP system.
• Preparation of as-built drawings.
6. Soil Resistivity
For a satisfactory cathodic protection system design, it is necessary to determine the resistivity of
the electrolyte (backfill). This resistivity is used to calculate anode to electrolyte resistance and thus
has an effect on the quantity of anodes. The resistivity is also an indication of the aggressiveness of
the environment.
As per project specifications cleaned washed sand shall be used as backfill for the underground fuel
storage tanks. The clean washed sand backfill material is generally characterized by a very high
resistivity. For contingency Soil resistivity value of 100 Ωm is considered for the design purposes.
Prior to backfilling a sample of sand shall be tested for contamination (chlorides, sulphates, etc.).
Proposed sand shall have a pH value between 6 and 11.5.
Main contractor Project no.
STFA DENIZ INSAATI INSAAT SAN. VE TIC. A.S. 366010033
Cathodic protection vendor KOC document no.
DONG YANG CORROSION ENGINEERING CO.
Project Rev. Page
SMALL BOAT HARBOR FUEL SYSTEM A 6 OF 18
Document title Document no.
P-RFC19-KW-0008-DC-
DESIGN CALCULATION FOR EXTERNAL SACP SYSTEM FOR BURIED FUEL TANKS
1_TANK.DOCX
7. Engineering Design
Considering the operating temperature of the tanks (See above section 2.0), correcting the CP
Current Density stated above is not required.
𝐴 " = 𝐴$ + 𝐴&
𝜋𝑂𝐷, 1 𝜀+1
𝐴 " = 𝜋 × 𝑂𝐷 × 𝑙 + × .1 + × ln 4 89
2 8𝜀 √3
1− 2
Where:
4𝑧 ,
𝜀 = :1 −
𝑂𝐷,
4 × (0.22𝑚),
𝜀 = :1 −
(3.35𝑚),
Substituting data for 25,000 USG fuel tank dimensions (See Section 4):
𝜋 × (3.35), 1 1.987137
𝐴 " = 𝜋 × 3.35𝑚 × 12𝑚 + × .1 + × ln 4 89
2 7.85094 √3
1−
2
𝐴 " = 149.921𝑚, + 0.12𝑚,
𝐴 " = 150.04𝑚,
Area to be protected is the metal bare area exposed to the soil due to the coating deterioration
(Coating Breakdown):
𝐴E = 𝐴 " × 𝐶𝐵
Where:
𝐴E = 15.004𝑚,
Considering that the fixing bolts of the tanks installed without insulation washer, the addition
surface area for the 16 bolts is 0.001 m2. Hence, the total area to be protected shall be considered
as 15.005 m2.
Then, the minimum anode quantity based on the weight requirement is calculated as follows:
𝑊QRS
𝑁d =
𝑊d
Where:
Output current of the anode is calculated considering the polarized potential criterion and the open
circuit potential value for the magnesium anode as follows:
𝐸lE − 𝐸ml
𝐼d =
𝑅f
Where:
The following table summarize the number of anodes to be installed to meet the total anode weight
required per tank.
CP Current Anode
Anode Per Vessel
Capacity Requirement Weight
(nos.)
(mA) (kg)
25000 US Gal. 300 14.5 18
Main contractor Project no.
STFA DENIZ INSAATI INSAAT SAN. VE TIC. A.S. 366010033
Cathodic protection vendor KOC document no.
DONG YANG CORROSION ENGINEERING CO.
Project Rev. Page
SMALL BOAT HARBOR FUEL SYSTEM A 15 OF 18
Document title Document no.
P-RFC19-KW-0008-DC-
DESIGN CALCULATION FOR EXTERNAL SACP SYSTEM FOR BURIED FUEL TANKS
1_TANK.DOCX
Total
Length Anode Anode
Diameter Anode
Qty. Capacity T-T per Tank Weight
(m) Quantity
(m) (nos.) (kg)
(nos.)
16 25000 US Gal. 3.35 12.0 18 288 14.5
Magnesium anodes shall be installed vertically and spaced as per above table at each tank location.
Anode lead cab les shall arrive to a junction boxes consisting of a copper bar and shunt to provide
electrical connection to the buried tank.
Test station shall be fabricated in GRP material, IP55 rated, and supp lied with terminals to connect
tank monitoring cables and reference electrode lead cable. Test station shall be provided with a 3"
G.I. conduit.
Main contractor Project no.
STFA DENIZ INSAATI INSAAT SAN. VE TIC. A.S. 366010033
Cathodic protection vendor KOC document no.
DONG YANG CORROSION ENGINEERING CO.
Project Rev. Page
SMALL BOAT HARBOR FUEL SYSTEM A 16 OF 18
Document title Document no.
P-RFC19-KW-0008-DC-
DESIGN CALCULATION FOR EXTERNAL SACP SYSTEM FOR BURIED FUEL TANKS
1_TANK.DOCX
9. Bill of Materials
Item
Drawing no. Drawing title
no.
Sample Drawing of CP System General Arrangement Drawing
1 366010033-14-DRW-001-01 for North Harbor Building (FT) Underground Fuel Tanks Fuel
System
Sample Drawing of CP System General Arrangement Drawing
2 366010033-14-DRW-001-02 for North Harbor Building (FT) Underground Fuel Storage Tank
Section & Details
Sample Drawing of CP System General Arrangement Drawing
3 366010033-14-DRW-001-03 for North Harbor Building (FT) Underground Fuel Storage Tank
Typical Magnesium Anode Details
Sample Drawing of CP System General Arrangement Drawing
4 366010033-14-DRW-001-04 for North Harbor Building (FT) Underground Fuel Storage
Tanks Anode Junction Box Details
Sample Drawing of CP System General Arrangement Drawing
5 366010033-14-DRW-001-05 for North Harbor Building (FT) Underground Fuel Storage
Tanks Anode Test Station Details
Sample Drawing of CP System General Arrangement Drawing
6 366010033-14-DRW-005-01 for North Harbor Building (P) Substation & Generator – ‘PA’
Ground Floor Plan – Fuel System
Sample Drawing of CP System General Arrangement Drawing
7 366010033-14-DRW-005-02 for North Harbor Building (P) Substation & Generator – ‘PA’
Underground Fuel Storage Tank & Sections
Sample Drawing of CP System General Arrangement Drawing
8 366010033-14-DRW-005-03 for North Harbor Building (P) Substation & Generator – ‘PA’
Typical Magnesium Anode Details
Arrangement Drawing for North Harbor Building (P) Substation
9 366010033-14-DRW-005-04
& Generator – ‘PA’ Anode Junction Box Details
Arrangement Drawing for North Harbor Building (P) Substation
10 366010033-14-DRW-005-05
& Generator – ‘PA’ Test Station Details
Sample Drawing of CP System General Arrangement Drawing
11 366010033-14-DRW-004-01 for North Harbor Building (P) Substation & Generator – ‘PB’
Ground Floor Plan – Fuel System
Sample Drawing of CP System General Arrangement Drawing
12 366010033-14-DRW-004-02 for North Harbor Building (P) Substation & Generator – ‘PB’
Underground Fuel Storage Tank & Sections
Sample Drawing of CP System General Arrangement Drawing
13 366010033-14-DRW-004-03 for North Harbor Building (P) Substation & Generator – ‘PB’
Typical Magnesium Anode Details
Arrangement Drawing for North Harbor Building (P) Substation
14 366010033-14-DRW-004-04
& Generator – ‘PB’ Anode Junction Box Details
Arrangement Drawing for North Harbor Building (P) Substation
15 366010033-14-DRW-004-05
& Generator – ‘PB’ Test Station Details
Sample Drawing of CP System General Arrangement Drawing
16 366010033-14-DRW-003-01 for North Harbor Building (UB) - Ground Floor Plan – Fuel
System
Main contractor Project no.
STFA DENIZ INSAATI INSAAT SAN. VE TIC. A.S. 366010033
Cathodic protection vendor KOC document no.
DONG YANG CORROSION ENGINEERING CO.
Project Rev. Page
SMALL BOAT HARBOR FUEL SYSTEM A 18 OF 18
Document title Document no.
P-RFC19-KW-0008-DC-
DESIGN CALCULATION FOR EXTERNAL SACP SYSTEM FOR BURIED FUEL TANKS
1_TANK.DOCX
Item
Drawing no. Drawing title
no.
Sample Drawing of CP System General Arrangement Drawing
17 366010033-14-DRW-003-02 for North Harbor Building (UB) Utility Building Fuel System
Underground Fuel Storage Tank & Sections
Sample Drawing of CP System General Arrangement Drawing
18 366010033-14-DRW-003-03 for North Harbor Building (UB) Utility Building Fuel System
Typical Magnesium Anode Details
Sample Drawing of CP System General Arrangement Drawing
19 366010033-14-DRW-003-04 for North Harbor Building (UB) Utility Building Fuel System
Anode Junction Box Details
Sample Drawing of CP System General Arrangement Drawing
20 366010033-14-DRW-003-05 for North Harbor Building (UB) Utility Building Fuel System Test
Station Details
Sample Drawing of CP System General Arrangement Drawing
21 366010033-14-DRW-002-01 for North Harbor Building (FT) Underground Fuel Tanks Fuel
System
Sample Drawing of CP System General Arrangement Drawing
22 366010033-14-DRW-002-02 for North Harbor Building (FT) Underground Fuel Storage Tank
Section & Details
Sample Drawing of CP System General Arrangement Drawing
23 366010033-14-DRW-002-03 for North Harbor Building (FT) Underground Fuel Storage Tank
Typical Magnesium Anode Details
Sample Drawing of CP System General Arrangement Drawing
24 366010033-14-DRW-002-04 for North Harbor Building (FT) Underground Fuel Storage Tank
Anode Junction Box Details
Sample Drawing of CP System General Arrangement Drawing
25 366010033-14-DRW-002-05 for North Harbor Building (FT) Underground Fuel Storage Tank
Test Station Details