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Group Practice

GP 06-31

Cathodic Protection (CP) Design for Onshore


and Offshore Facilities

Copyright © 2013 BP International Ltd. All rights reserved.


This document and any data or information generated from its use are classified, as a minimum,
BP Internal. Distribution is intended for BP authorised recipients only. The information contained
in this document is subject to the terms and conditions of the agreement or contract under which
this document was supplied to the recipient's organisation. None of the information contained in
this document shall be disclosed outside the recipient's own organisation, unless the terms of such
agreement or contract expressly allow, or unless disclosure is required by law.

25 October 2013
Engineering Technical Practice
Engineering
Cathodic Protection (CP) Design for Onshore and Offshore Facilities

Table of Contents
Page
Foreword ........................................................................................................................................ 4
Introduction ..................................................................................................................................... 5
1 Scope .................................................................................................................................... 6
2 Normative references............................................................................................................. 6
3 Terms and definitions............................................................................................................. 7
4 Symbols and abbreviations .................................................................................................. 11
5 General................................................................................................................................ 12
5.1 Application ................................................................................................................ 12
5.2 Cathodic protection (CP) principles........................................................................... 12
5.3 Corrosion control....................................................................................................... 13
5.4 Hazards identification and mitigation......................................................................... 14
5.5 Order of precedence for conformance....................................................................... 14
6 Health, safety, security, and environmental (HSSE)............................................................. 14
6.1 Factors effecting design ............................................................................................ 14
6.2 Impressed current cathodic protection (ICCP) systems............................................. 15
7 Personnel qualifications ....................................................................................................... 15
7.1 Competent person .................................................................................................... 15
7.2 Technical staff qualifications ..................................................................................... 16
8 CP System design ............................................................................................................... 16
8.1 General..................................................................................................................... 16
8.2 Principle design objectives........................................................................................ 18
8.3 Coatings ................................................................................................................... 20
8.4 Earthing (grounding) ................................................................................................. 21
8.5 Effective analysis ...................................................................................................... 21
8.6 Reference electrodes................................................................................................ 22
9 Cathodic Protection Criteria ................................................................................................. 23
9.1 Onshore cathodic protection (CP) criteria ................................................................. 23
9.2 Offshore cathodic protection (CP) criteria ................................................................. 25
9.3 Internal steel surfaces criteria ................................................................................... 26
10 Galvanic (sacrificial) anodes systems .................................................................................. 26
10.1 General..................................................................................................................... 26
10.2 Marine and offshore galvanic anodes........................................................................ 27
10.3 Onshore galvanic anodes ......................................................................................... 28
10.4 Low voltage cathodic protection (CP) for subsea applications................................... 29
10.5 Risk of failure ............................................................................................................ 29
11 Impressed current cathodic protection (ICCP) anode systems............................................. 29
11.1 General..................................................................................................................... 29

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Cathodic Protection (CP) Design for Onshore and Offshore Facilities

11.2 Marine and offshore applications .............................................................................. 30


11.3 Onshore applications ................................................................................................ 31
11.4 Risk of failure of impressed current cathodic protection (ICCP) system .................... 32
12 Hybrid systems .................................................................................................................... 33
13 Design considerations for offshore cathodic protection (CP) retrofit systems ....................... 33
13.1 General..................................................................................................................... 33
13.2 Impressed current cathodic protection (ICCP) retrofit systems.................................. 33
Annex A (Informative) Basics of corrosion................................................................................... 35
A.1 General................................................................................................................................ 35
A.2 Anodic and cathodic reactions ............................................................................................. 35
A.3 Electrolytes .......................................................................................................................... 36
A.4 Resistivity ............................................................................................................................ 36
A.5 Bimetallic corrosion (galvanic) ............................................................................................. 37
A.6 Microbial corrosion (MIC) ..................................................................................................... 37
A.7 Stray current corrosion......................................................................................................... 38
A.8 Electrochemical series ......................................................................................................... 39
Annex B (Informative) Advantages and disadvantages of galvanic and impressed current cathodic
protection (ICCP) systems ................................................................................................... 40
B.1 Galvanic cathodic protection (CP) systems.......................................................................... 40
B.2 Impressed current cathodic protection (ICCP) systems........................................................ 41
Bibliography .................................................................................................................................. 42

List of Tables

Table 1 - CP topics by application................................................................................................... 5


Table 2 - Technical staff qualifications .......................................................................................... 16
Table 3 - Technical staff competency by qualification level ........................................................... 16
Table 4 - CP design international standards.................................................................................. 20
Table 5 - Approved reference electrodes ...................................................................................... 23
Table 6 - Recommended potential criteria in seawater.................................................................. 25
Table 7 - Galvanic anodes ............................................................................................................ 27
Table 8 - Galvanic anode resistivity limitations.............................................................................. 29
Table A.1 - Soil resistivity.............................................................................................................. 37
Table A.2 - Galvanic and electrochemical series of metals ........................................................... 37

List of Figures

Figure A.1 - Electrochemical corrosion schematic......................................................................... 36

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Cathodic Protection (CP) Design for Onshore and Offshore Facilities

Foreword

This is a revised issue of Engineering Technical Practice (ETP) GP 06-31. This Group Practice (GP)
incorporates changes resulting from a reorganisation of the cathodic protection (CP) ETPs from asset
types to topics.

Due to extensive changes, revisions are not identified by a bar in the left margin, as is normal practice.

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Cathodic Protection (CP) Design for Onshore and Offshore Facilities

Introduction

CP of assets and facilities is a key component of integrity management. CP is used to supplement


corrosion protection of onshore and offshore buried and submerged metallic structures. This GP
explains the importance of CP and provides requirements on how to apply CP in accordance with
applicable codes.

This GP falls within the corrosion series of ETPs and is one of the documents related to CP. These
ETPs provide detailed information on all aspects of CP design. CP ETP document structure is
separated into four distinct topics by application and is not based on asset type. The four topics and
associated information are listed in Table 1.

Table 1 - CP topics by application

Topic Topic description ETP ETP title


What What are the basics of CP and GP 06-31 Cathodic Protection for Onshore and
how to design and apply CP for Offshore Facilities
a structure?
When When to perform CP monitoring GP 06-36 Cathodic Protection Monitoring,
and maintenance activities, Inspection, and Maintenance
intervals, and requirements.
How How to perform CP surveys and ETP to be
guidance on data interpretation. completed in the
future
Materials Which materials to use for CP GIS 06-311 Cathodic Protection - Procurement
systems.

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Cathodic Protection (CP) Design for Onshore and Offshore Facilities

1 Scope

a. This GP provides requirements, recommendations, and permissions for design and


application of CP to mitigate external and internal corrosion of the following equipment in
electrolytic (i.e., aqueous or soil) environment (referred to as structure going forward):
1. Buried, immersed, or ongrade pressure containing vessels and devices.
2. Fixed and floating structures (not including ships).
3. Critical communications and electrical equipment.
b. This GP provides requirements for designing and constructing facilities to prevent injury to
people or damage to the environment. The objective is to prevent loss of containment,
structural failure, or unintended release of stored energy.
c. This GP covers application of CP on the following materials:
1. Carbon steel and ductile iron.
2. Stainless steel, including duplex and super duplex.
3. Copper.
4. Aluminium.
5. High strength steels, including martensitic and corrosion resistant alloys (CRA).
d. This GP covers buried and immersed or ongrade metallic infrastructure that supports the
following hazardous material tasks:
1. Production.
2. Transportation.
3. Refining.
4. Storage.

2 Normative references

The following documents are referenced in one or more requirements in this document. For dated
references, only the edition cited applies. For undated references, the latest edition (including
amendments) applies.

BP
GDP 3.1-0001 Assessment, Prioritization and Management of Risk
GDP 5.0-0001 Integrity Management (IM).
GIS 06-311 Procurement of Cathodic Protection Goods and Services.
GIS 06-402 Fusion Bonded Epoxy Powder External Pipeline Coatings
GIS 06-601 Coating of Metal Surfaces and Equipment.
GP 06-36 Monitoring, Inspection, and Maintenance of Cathodic Protection (CP)
Systems.
GP 06-40 Pipeline Coating Selection.
GP 06-60 Coating Systems for Metal Surfaces.
GP 06-63 Internal Coatings.
GP 58-10 Above Ground Welded Steel Atmospheric Tanks for Oil Storage.

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Cathodic Protection (CP) Design for Onshore and Offshore Facilities

American Petroleum Institute (API)


API RP 651 Cathodic Protection of Aboveground Storage Tanks.

Det Norske Veritas (DNV)


DNV RP-B401 Cathodic Protection Design.
DNV RP-F103 Cathodic Protection of Submarine Pipelines by Galvanic Anodes.

European Standards (EN)


EN 12473 General principles of cathodic protection in sea water.
EN 12499 Internal cathodic protection of metallic structures.

International Organisation for Standardization (ISO)


ISO 15589-1 Petroleum and natural gas industries - Cathodic protection of pipeline
transportation systems - Part 1: Onland pipelines.
ISO 15589-2 Petroleum and natural gas industries - Cathodic protection of pipeline
transportation systems - Part 2: Offshore pipelines.

NACE International (NACE)


NACE RP0193 External Cathodic Protection of On-Grade Carbon Steel Storage Tank
Bottoms.
NACE SP0169 Control of External Corrosion on Underground or Submerged Metallic
Piping Systems.
NACE SP0176 Corrosion Control of Submerged Areas of Permanently Installed Steel
Offshore Structures Associated with Petroleum Production.
NACE SP0186 Application of Cathodic Protection for External Surfaces of Steel Well
Casings.
NACE SP0196 Galvanic Anode Cathodic Protection of Internal Submerged Surfaces of
Steel Water Storage Tanks.
NACE SP0285 Corrosion Control of Underground Storage Tank Systems by Cathodic
Protection.
NACE SP0286 Electrical Isolation of Cathodically Protected Pipelines.
NACE SP0388 Impressed Current Cathodic Protection of Internal Submerged Surfaces
of Carbon Steel Water Tanks.
NACE SP0492 Metallurgical and Inspection Requirement for Offshore Pipeline Bracelet
Anodes.
NACE SP0572 Design, Installation, Operation and Maintenance of Impressed Current
Deep Anode Beds.
NACE SP0575 Internal Cathodic Protection (CP) Systems in Oil Treating Vessels.
NACE SP0607 Petroleum and natural gas industries - Cathodic protection of pipeline
transportation systems

NORSOK
NORSOK Std M-503 Cathodic Protection.

3 Terms and definitions

For the purpose of this GP, the following terms and definitions apply:

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Anaerobic
Absence of air or free (molecular) oxygen.

Anode
Electrode of an electrochemical cell at which oxidation occurs.

Anode backfill
Material with low resistivity, which may be moisture retaining, immediately surrounding a buried
anode for the purpose of decreasing effective resistance of anode to electrolyte.

Back electromotive force (EMF)


Naturally occurring open circuit potential difference between anode and cathode in seawater or soil.

Bond
Intentional metallic connection between metallic systems in contact with a common electrolyte
designed to control electrical current interchange between systems.

Buried structure
Metallic structure laid beneath or built on ground level and covered with earth.

Calcareous deposit
Layer consisting of calcium carbonate and other salts deposited on surface. When the surface is
cathodically polarised as in CP, this layer is the result of increased pH adjacent to the protected
surface.

Cathode
Electrode of an electrolytic cell at which reduction is the principal reaction.

Cathodic protection (CP)


A technique to reduce corrosion rate of a metal surface by making that surface the cathode of an
electrochemical cell.

Cell
Electrochemical system consisting of an anode and cathode in metallic contact and immersed in an
electrolyte. (The anode and cathode may be different metals or dissimilar areas on same metal surface.

Coating defect or coating holiday


A small defect in a coating system where the substrate is exposed.

Discontinuity in a protective coating that exposes unprotected surface to environment.

Copper/saturated copper sulphate (Cu/CuSO4) reference electrode (CSE)


Reference electrode consisting of copper in saturated solution of Cu/CuSO4 used primarily for onshore
or freshwater applications.

Coupon

Representative metal sample used to quantify the extent of corrosion or the effectiveness of applied
cathodic protection.

Critical Bond

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An interference bond between two structures that if it fails would jeopardize protection of one or both
structures.

Current density
Electric current to or from a unit area of an electrode surface.

Driving voltage
Anode closed circuit potential, minus polarised cathode (steel) potential, expressed in volts.

Earthing (grounding)
System of electrical connections to general mass of earth. Resistance is the characteristic that primarily
determines effectiveness of an earth (ground) electrode, which is provided between earthing
(grounding) system and general mass of earth.

Electrical isolation
Condition of being electrically separated from other metallic structures or environment.

Electrolyte
Chemical substance containing ions that migrate in an electric field. This refers to the soil or liquid
adjacent to structure.

E-log-I modelling
Method of measuring CP potentials along the length of well casing, as described in NACE SP 0186.

Electrolyte resistivity
Electrical resistance of electrolyte, assuming electrolyte is homogeneous, expressed in Ohm-cm.

Electromotive force (EMF)


Naturally occurring open circuit electrical potential difference between anode and cathode.

Galvanic anode (sacrificial anode)


Metal that provides sacrificial protection to another metal that is more noble when electrically coupled
in an electrolyte.

Groundbed
System of buried or immersed galvanic or impressed current anodes used to supply CP.

Hybrid system
CP system that uses a combination of galvanic and impressed current anodes to protect a structure
(refer to 12).

Impressed current anode


Electrode that supplies current for CP by an impressed current source.

Ion
Electrically charged atom or group of atoms.

Interference
Electrical disturbance on a metallic structure as a result of stray current.

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Instant off potential


Structure to electrolyte potential measured immediately after synchronous interruption of all sources
of applied CP current, which closely approximates potential without IR drop (polarised potential)
when current is flowing.

Isolating joint (IJ)


Electrically discontinuous connection between two lengths of pipe, inserted to provide electrical
discontinuity between the two pipes (e.g., monolithic IJ, isolated flange).

Natural potential (native potential)


Structure to electrolyte potential measured with no CP applied.

On potential
Structure to electrolyte potential measured with CP current flowing.

Permanent reference electrode


Permanently buried or immersed reference electrode designed for long life and installed close to
structure.

pH
Measure of activity of hydrogen ions (H+) in electrolyte/solution, and, therefore, its acidity or
alkalinity: acidic (0 to 7), neutral (7), or alkaline (7 to 14).

Polarisation
Change from open circuit potential as a result of current across electrode/electrolyte interface.

Protected structure
Structure to which CP is effectively applied.

Protection current
Current made to flow into a metallic structure from its electrolytic environment in order to affect CP
of the structure.

Protection potential
Structure to electrolyte potential for which metal corrosion rate is acceptable.

Silver/silver chloride (Ag/AgCl) reference electrode (SSC)


Reference electrode consisting of silver, coated with silver chloride, in an electrolyte containing a
fixed concentration of chloride ions.

Structure to electrolyte potential


Potential difference between surface of a buried or submerged metallic structure and electrolyte,
measured with reference to electrode in contact with electrolyte.

Stray current corrosion


Corrosion that results from direct current (DC) flow through paths other than circuit intended.

Sulphate reducing bacteria (SRB)


Organisms found in most soils and natural waters that reduce sulphate to sulphide in absence of
oxygen. Sulphide that is liberated reacts with iron in typically tubed culture medium to form iron
sulphide, thus, accelerating corrosion.

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Transformer rectifier
Device that converts alternating current (AC) to DC. DC voltage is used as the power source for
impressed current cathodic protection (ICCP) systems.

Voltage drop (IR drop)


Voltage across a resistance (such as an electrolyte) when a current is applied in accordance with
Ohm’s Law (U (voltage) = I (current) x R (resistance)).

Zinc (Zn) reference electrode (ZRE)


A reference electrode consisting of solid zinc that is more robust than silver/silver chloride but with
less stability

4 Symbols and abbreviations

For the purpose of this GP, the following symbols and abbreviations apply:

AC Alternating current.

ACVG Alternating current voltage gradient.

Ag/AgCl Silver/silver chloride.

AST Aboveground storage tank.

CIPS Close internal potential survey.

CP Cathodic protection.

CRA Corrosion resistant alloy.

CSE Copper sulphate electrode.

DCVG Direct current voltage gradient.

EMF Electromotive force.

HSSE Health, safety, security, and environmental.

ICCP Impressed current cathodic protection.

IJ Isolating joint.

IR Current × resistance.

MIC Microbial corrosion.

RCP Resistor controlled CP.

ROV Remotely operated vehicle.

SHE Standard hydrogen electrode.

SRB Sulphate reducing bacteria.

SSC Silver/silver chloride.

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TA Technical authority.

UST Underground storage tank.

ZRE Zinc reference electrode.

5 General

5.1 Application
CP shall be applied to a wide variety of production, pipeline, and process equipment for onshore
and offshore, including:
a. Onshore
1. ASTs, USTs, and vessels when installed in a conductive electrolyte.
2. Buried and immersed pipelines (gathering and transmission).
3. Buried process and utility pipelines.
4. Well casings.
5. Shell and tube heat exchangers using cooling water.
6. Buried and immersed fixed structures (metallic supports, ground grids, tower legs).
b. Offshore
1. Fixed and floating production facilities.
2. Storage tanks (product, water, and drilling fluid).
3. Subsea systems (e.g., wellheads, risers, mooring systems, flowlines, and pipelines).
4. Firewater and seawater pump caissons.
5. Coastal and marine terminals (e.g., wharfs, jetties, mooring, and breasting dolphins).

5.2 Cathodic protection (CP) principles

5.2.1 General
a. CP consists of:
1. Connecting an external anode to the metallic structure to be protected.
2. Passing of an electrical current such that all areas of the metallic surface becomes
cathodic and, therefore, does not corrode.
b. The external anode may be either:
1. A galvanic anode (the current is a result of the potential difference between the two
metals).
2. An impressed current anode (the current is impressed from an external DC power
source).

5.2.2 Polarisation
a. Polarisation is the change in potential (becoming more negative) of an electrode as the
result of CP current flow. As more current is applied, the level of polarisation increases.
Over time, polarisation may occur on anode and cathode.
b. After polarisation has been achieved, rate of electrochemical reactions slows down and
causes a reduction of:

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Cathodic Protection (CP) Design for Onshore and Offshore Facilities

1. Corrosion currents.
2. Corrosion rate.
Degree of polarisation at structure to electrolyte interface is measured in terms of
potential difference between the surface of a structure and the electrolytic
environment of the structure.

5.2.3 Voltage (IR) drop - onshore cathodic protection (CP)


a. In onshore CP, potential measurement between a metal surface and electrolyte interface
can be affected by potential drop due to the resistance of the surrounding electrolyte and
the protection current flowing through it to the structure. This loss in potential is known as
IR drop, and the following principles are the components of IR Drop:
1. IR drop has the effect of making measured potential appear more negative than the
actual potential at the metal/electrolyte interface.
2. IR drop is directly related to the electrolyte resistivity and resistance of any coatings
used.
b. Methods for consideration of IR drop that may be used include:
1. Measuring or calculating IR drop to ensure that only potential across structure to
electrolyte boundary is achieved.
2. Reviewing historical performance of the CP system, including:
a) Potentials over time (several years).
b) Number of years with adequate CP.
c) Remedial CP activities.
d) Consistency of CIPS.
e) Leak history.
3. Determining if evidence of corrosion exists by:
a) Direct examination.
b) Correlation of indirect inspection techniques, including:
1) CIPS.
2) DCVG.
3) ACVG.
4. Reviewing results of inline inspections showing no active corrosion.

5.3 Corrosion control


a. To achieve effective corrosion control from an asset lifetime perspective, corrosion
mitigation shall conform to engineering principles and procedures that ensure an
acceptable mitigation level using an appropriate design method.
Complete elimination of corrosion is rarely practical or possible.
b. Corrosion shall be prevented by removing one or more of the following elements of a
corrosion cell (refer to Annex A):
1. Anode.
2. Cathode.
3. Electrolyte.

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Cathodic Protection (CP) Design for Onshore and Offshore Facilities

4. Metallic path.
c. The following principles shall be considered in designing an adequate corrosion control
system:
1. Structure design considerations for corrosion control and CP.
2. Coating selection.

5.4 Hazards identification and mitigation


a. If hazards have been identified, mitigation by modifications to CP systems shall be
implemented as soon as reasonably practical.
b. Mitigation plan shall be executed by the more stringent time interval of the following:
1. Guidance from GP 06-36
2. Time interval mandated by local laws or regulations.

5.5 Order of precedence for conformance


a. CP system shall comply with local government regulations.
b. In the event of a conflict between this GP and a relevant law or regulation, the relevant law
or regulation shall be followed.
c. Requirements in this GP which are more stringent than a relevant law or regulation shall be
followed, provided that these requirements achieve compliance with the law or regulation.

6 Health, safety, security, and environmental (HSSE)

6.1 Factors effecting design


a. Because entanglement of divers or ROV umbilicals on anodes or anode supports is a major
risk with marine and offshore CP systems, anode support design should exclude:
1. Sharp edges.
2. Corners.
3. Protruding assemblies.
b. If a possibility exists of AC induced currents on a structure or pipeline, appropriate
mitigation measures shall be executed to safeguard personnel. Mitigation measures may
include:
1. Grounding cells.
2. Grounding mats.
3. Decouplers.
4. Parallel grounding anodes.
c. Galvanic or impressed current anodes containing toxic elements shall not be used to
protect potable water tanks (refer to 10.3g. for additional requirements).
d. Installation of electrical earthing (grounding) devices on structure to be protected shall be
considered for safety reasons.
e. Hydrogen gas
1. Buildup of hydrogen gas in confined spaces may present risk of explosion. To avoid
potential hazards, the following measures should be taken:

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Cathodic Protection (CP) Design for Onshore and Offshore Facilities

a) Structure to electrolyte potential shall be kept less negative than threshold value
at which hydrogen evolution could damage the structure.
b) Include adequate venting to prevent buildup of hydrogen.
c) Magnesium alloy anodes should not be installed in areas where hydrogen
buildup may occur.
2. Because high levels of hydrogen gas can cause embrittlement of certain materials,
measured potentials shall be kept within safe range for these materials to prevent
cracking.
Hydrogen gas limit requirements are specified in9.1.1c.1 and 9.1.9c.
f. Chlorine gas should not be allowed to collect in confined spaces, which may present a
hazard to personnel and materials.
Electrochemical reactions at the surfaces of impressed current anodes in seawater
can result in evolution of chlorine gas, which is highly toxic and corrosive.
Long term integrity of galvanic and ICCP systems is dependent on regular
maintenance and monitoring throughout the life of the system (refer to GP 06-36 for
additional requirements).
g. There are documented instances where pipelines parallel to high voltage AC transmission
lines can have induced AC voltage on structures. AC mitigation shall be considered,
preferably at design stage, to mitigate effects due to induced AC to protect personnel safety
and integrity of structures.
h. AC potential of cathodically protected structures should always be measured.
i. If AC potential measurement is:
1. Greater than 15 VAC, structure should be considered hazardous, and steps should be
taken to reduce AC potential level.
2. Less than 15 VAC, no specific action shall be necessary.

6.2 Impressed current cathodic protection (ICCP) systems


a. If diver intervention or inspection work is required on structure with ICCP systems,
applicable transformer rectifier providing current to anodes in area where diver is working
shall be switched off to prevent electric shock.
b. For onshore ICCP systems, transformer rectifier DC voltage should not exceed 50 VAC
for safety reasons.
c. ICCP systems shall not be used for internal protection of tanks containing hydrocarbons,
including galvanic anodes with alloying elements that could cause incendive sparking if hit
by a foreign metallic object or dropped from a height.

7 Personnel qualifications

7.1 Competent person


a. Any of the following professional recognitions, including suitable experience, shall
constitute a competent person for the purpose of designing, installing, testing or analysing
a CP system:
1. Chartered engineer status (UK).
2. Professional engineer (U.S. or Canada).
3. NACE international corrosion specialist.

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Cathodic Protection (CP) Design for Onshore and Offshore Facilities

4. NACE international CP specialist.


5. Institute of Corrosion (ICorr) fellow.
6. Individual with demonstrated 12 yr of practical knowledge and experience in CP
design and maintenance.

7.2 Technical staff qualifications


a. Recommended qualifications necessary for technical staff performing CP tasks shall
conform to Table 2.

Table 2 - Technical staff qualifications

Technical staff ICorr certification NACE certification Industry experience


Corrosion TA ICorr fellow CP Level 4 CP specialist 12 yr of CP experience

Corrosion engineer Senior CP engineer - CP Level 3 CP technologist 8 yr of CP experience


Level 3
Senior corrosion Senior CP technician - CP Level 2 CP technician 8 yr of CP experience
technician Level 2
Corrosion technician CP technician - CP Level 1 CP tester 2 yr of CP experience
Level 1

b. Common task categories and level of qualifications recommended to perform CP tasks


shall conform to Table 3.

Table 3 - Technical staff competency by qualification level

Task category ICorr and NACE ICorr and NACE ICorr Level 2 and ICorr Level
CP Level 1 or CP Level 2 or NACE CP Level 3 3/fellow and
equivalent equivalent or equivalent NACE CP Level 4
or equivalent
Design of CP systems X
Interpret data gathered
X X
during maintenance
Determine mitigation
X X
action plans
Perform CP surveys X X X X
Collect comprehensive
X X X
data for CP designs
Installation of CP systems X X X X
CP system
X X X X
troubleshooting
CP troubleshooting -
X X X
advanced
CP quality assurance X X X X

8 CP System design

8.1 General
a. CP systems shall be designed in accordance with principles in GDP 5.0-0001.

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Cathodic Protection (CP) Design for Onshore and Offshore Facilities

b. During design of new structure/asset, a competent person in CP design, as defined in 7.1,


shall be consulted during the entire project lifecycle, including all phases of design and
construction, to ensure that proper corrosion control measures are followed.
c. To ensure that corrosion control can be achieved, structure design shall address the
following considerations:
1. Dissimilar metals (identify locations where they are metallically connected)
2. Electrical continuity.
3. Electrical isolation.
d. Structure to be protected shall:
1. Be electrically continuous.
2. Have properly designed electrical isolation where needed for CP to be applied
effectively.
High resistance connections restrict amount of current available to structure being
protected. In areas of discontinuity, corrosion can occur, and, therefore, CP would
not be available to arrest corrosion cell.

Note: If CP is applied to a metal surface (the cathode), the


chemical reaction can form a scale or deposit that increases
the electrical resistance and reduces the flow of current.
Consequently, current required to achieve CP initially is
more than that required to maintain protection after
polarisation has been achieved. Annex A contains basic
principles of corrosion, including anodic and cathodic
reactions, electrolytes, and forms of corrosion.

e. Electrical continuity
1. Non-welded mechanical connections on a structure to be cathodically protected shall
be bonded in an effective manner (e.g., bell and spigot, screwed collars, and
couplings).
f. Electrical isolation
1. Structure to be protected shall not be electrically connected to a facility that would
prevent application of adequate corrosion control CP.
2. Isolation device shall be properly selected for application and properties to be
considered include:
a) Operating temperature.
b) Pressure.
c) Mechanical strength.
d) Chemical resistance.
e) Dielectric resistance.
3. Locations where electrical isolation shall be evaluated for use include:
a) Wellheads.
b) Casings or sleeves.
c) Custody transfer to another entity.
d) Junction of dissimilar metals.

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Cathodic Protection (CP) Design for Onshore and Offshore Facilities

e) Locations that have electrical grounding connected.


f) Stray current areas (static and dynamic stray currents), such as DC rail systems
and induced AC power systems.
g) Storage tank to pipeline connections.
4. To ensure a large current drain is not imposed on CP system, pipeline installations
shall not have non-designed direct contact with other foreign metallic structures,
including:
a) Pipelines.
b) Pumping stations.
c) Dissimilar metals.
d) Other CP systems.
e) Storage tanks.
f) Electrical earths (grounds).
5. Electrical isolation may be required to limit effects of interaction or stray currents by
installation of one of the following:
a) Monolithic IJ, a factory prefabricated joint welded directly into a pipeline that
should be used for locations where repair and replacement is extremely difficult,
such as high pressure lines or offshore installations.
b) Flange isolation kit, which consists of an insulation flange gasket, insulating
sleeves placed over studs, and insulating washers under nuts. If an interior liquid
is found to be conductive, causing possible interference at flange isolation kit,
isolation kit shall be subject to approval by Company responsible engineer.
The use of isolation kits needs to take into consideration the conductivity of the
product inside the pipe to ensure the isolation kit will be effective.
Company responsible engineer may consult the corrosion TA for assistance in
selecting an isolation kit.
c) Isolating joint (IJ)
1) IJ (flange connected, nonmetallic, or internally lined spool piece) with a
length at least 10 times greater than the outer diameter of the pipeline.
2) This joint may be used if pipeline is carrying a conductive
electrolyte/liquid.
d) Pipelines entering buildings or valve chambers, including aboveground sections
of pipelines supported on steel or concrete racks or bridges, which shall be
electrically isolated from concrete steel reinforcement by applying a suitable
nonconductive material over pipe part that passes over concrete.

8.2 Principle design objectives


a. Basic design objectives and considerations are generally common to galvanic and ICCP
systems for offshore or onshore applications. Principle design objectives are that the CP
system shall:
1. Conform to applicable codes and standards (e.g., certifying authority, local
government, and ETPs).
2. Ensure potentials are:
a) At protection values.

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b) Uniform as possible over entire structure.


3. Ensure CP system does not introduce adverse effects or interference currents on
associated or adjacent structures.
4. Consider sectioning large onshore systems to be protected (e.g., multiple gathering
lines) in electrically isolated parts, which may allow system to be maintained and
monitored in a more efficient manner.
5. Model and mitigate effects on pipelines from high voltage power lines or direct
electrical heating systems, as large AC voltages can:
a) Be induced and cause accelerated corrosion.
b) Compromise personnel safety.
6. Ensure pipeline crossings under roads or railway tracks, normally through steel
casings, have additional insulating material (coating) with at least twice the normal
thickness for crossing section, plus 3 m (10 ft) in each direction from edge of casing.
7. Ensure if high probability exists of lightning to strike structure, lightning protection is
provided to protect ICCP equipment, such as output terminals of DC voltage sources
and IJs.
b. For marine and offshore structures, additional corrosion protection to metallic surfaces in
tidal and splash zones of structures shall be provided.
CP current requirements are much higher in marine and offshore locations and may
not be able to provide adequate protection without additional corrosion protection
systems. For details on proper coating systems in tidal or splash zones (refer to
GP 06-60).
c. Secondary effects of CP system shall be considered. The application of CP might cause
development of alkalinity or the evolution of hydrogen at the protected surface. The effects
that might occur include:
1. Paint or other coatings that might become disbonded by CP. Coatings should be
tested to ensure good resistance to cathodic disbonding.
2. In seawater, alkalinity that generates a white calcareous deposit (chalking). This
deposit can be beneficial because current density needed to maintain CP is reduced.
3. Hydrogen evolved at very negative potentials, which could create an explosion hazard
in enclosed spaces.
4. Hydrogen embrittlement of high tensile steels or stainless steels (duplex, martensitic
and ferritic, not austenitic), which is a possible danger.
5. CP systems connected to existing steel structures not previously protected could cause
the following problems:
a) Rust or scale might detach from surface during initial period of operation, which
could result in blocked water passages for a short period.
b) If steel surfaces have been seriously corroded, removal of rust that is plugging
holes might cause leaks to become apparent during this period.
6. If the electrolyte contains chlorides, chlorine may be evolved at anodes of ICCP
installation, which could:
a) Create a hazard.
b) Cause excessive wear rate of some types of impressed current anode materials.

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d. Relevant CP system design equations for the structure to be protected shall be used.
Relevant equations that shall be used are contained in the international standards listed in
Table 4, which is separated into asset type with applicable standards for each asset.

Table 4 - CP design international standards

Onshore ASTs USTs Internal CP for Well casings Offshore pipelines


pipelines and storage tanks and structures
structures and vessels
EN 12473 API RP 651 NACE SP0285 EN 12499 NACE SP0186 DNV RP-B401
ISO 15589-1 NACE RP0193 NACE SP0196 DNV RP-F103
NACE SP0169 NACE SP0388 EN 12473
NACE SP0286 NACE SP0575 ISO 15589-2
NACE SP0572 NACE SP0607
NACE SP0176
NORSOK Std M-503

8.3 Coatings
a. CP shall be designed as part of corrosion protection system in conjunction with corrosion
control provided by coatings, as applicable.
b. Coating systems and the application methods that can be deployed on cathodically
protected steel structures shall conform to the following, as applicable:
1. GP 06-40.
2. GP 06-60.
3. GP 06-63.
4. GIS 06-402.
5. GP 58-10.
c. Surface preparation before applying any coating system shall conform to GIS 06-601.
Correct surface preparation is vital for coating systems and often governs service
life of the coating system.
d. To use CP in a corrosion protection system, the following coatings principles shall be
considered:
The primary corrosion control principle for the use of coatings is to provide an
isolating barrier between the metal surface and its surrounding electrolyte and to
reduce the flow of corrosion currents (including stray currents). However, coatings
unfortunately always can contain defects and further flaws will develop as the
system ages.
1. A combination of applying a coating and CP results in the most effective overall
corrosion protection system. This combination is the primary principle for corrosion
protection of ongrade, immersed, and/or buried structures operated by Company.
2. The primary corrosion protection barrier is provided by the coating, while CP
provides protection to deficiencies in the coating and ensures the integrity of the
associated structure.
3. Coatings are not perfect isolators and will become damaged or degraded over time.
4. As the coating degrades or becomes damaged, the CP system will provide more
protective current to ensure continued efficient protection of the coating defects.

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Provision of a protective, insulating coating to the structure greatly reduces the


current demand for CP of the metallic surface.
Use of a well applied and suitable coating increases the effective spread of CP
current.
5. Important principles for any coating are surface preparation and application. Without
proper procedures and control in these two areas, effectiveness of coating would be
severely reduced.
6. Nonbonded or disbonded coatings can cause shielding of CP, which can cause
corrosion without CP able to arrest the corrosion due to coating failure.
e. Coatings shall have:
1. High electrical resistance.
2. Continuous coverage.
3. Strong adherence to surface to be protected.
f. Coating characteristics shall include:
1. Stability in the environment.
2. Abrasion resistance.
3. Compatibility with alkaline environment created by CP.

8.4 Earthing (grounding)


a. Consider installing electrical earthing (grounding) devices for safety reasons (AC
discharge) on a structure to be cathodically protected.
b. If earthing (grounding) is required to mitigate the effect of induced electrical voltages, the
following shall be considered:
1. Making earthing (grounding) compatible with the CP system by installing either:
a) Polarisation cells or diode circuits, suitably specified and rated for the purpose,
in the earthing (grounding) circuit or
b) Separate earthing (grounding) electrodes, buried in low resistivity backfill and
not in direct electrical continuity with other earthing (grounding) systems.
2. Earthing (grounding) installations to mitigate the effect of AC induced voltages on
pipelines should be where:
a) Anticipated or measured earth (ground) voltages are highest.
b) Pipeline is exposed and can be touched by personnel.
3. To ensure personnel safety:
a) Induced AC voltages, lightning, and fault current protection shall be considered.
b) If short term, high current loading is anticipated, isolating or fault current
devices shall be designed to handle anticipated loads.

8.5 Effective analysis


To analyse effectiveness of CP system to prevent loss of primary containment, the following
shall be documented:
a. Detailed operating history.
b. Locations of corrosion control systems.
CP is one mitigation method that can prevent corrosion on a structure.

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Cathodic Protection (CP) Design for Onshore and Offshore Facilities

Corrosion related to lack of or insufficient CP can have catastrophic consequences


on hydrocarbon production and treatment facilities.
Corrosion damage causing loss of containment may seriously harm environment,
personal health and safety, production, revenue, and reputation of Company, locally
and globally.

8.6 Reference electrodes


a. To measure performance and effectiveness of a CP system, reference electrodes shall be
used to assess structure to electrolyte potentials.
b. Reference electrodes shall be isolated from structure.
c. Reference electrodes have a limited life, and procedures for regular calibration and
maintenance shall be established.
For bare steel structures, reference electrodes are best placed at positions remote
from anodes, where the effect of CP is the least, to ensure that structure to
electrolyte potential at all points is within set limits.
d. Permanent reference electrodes used in seawater for potential control transformer rectifiers
should be zinc or SSC.
e. Reference electrodes shall be used to measure structure to electrolyte potential.
f. Conversion factors and approved usage for the following shall conform to Table 5:
1. CSE.
2. SSC.
3. SHE.
4. Saturated calomel.
5. ZRE.
6. Temperature correction.
7. Equivalent measured value to -0,850 V CSE.
g. Portable reference cells shall be properly calibrated to ensure accurate measurements.
h. For offshore applications, the most common reference electrodes are SSC and ZRE. ZRE
electrodes are more robust, but SSC electrodes are more accurate.
i. For onshore applications in which permanent potential monitoring is required to control
current output, CSE electrodes, which are specifically designed for long term buried
applications, shall be used (refer to GP 06-36).
j. Locations should be determined by calculations or experience to ensure potential of
structure is maintained within design set limits.
Location of reference electrodes is very important, especially if used to control CP
system.
k. Portable reference electrodes should:
1. Be placed as close as possible to structure to reduce possible error in measurement.
2. Have no direct electrical contact between reference electrodes and structure.

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Table 5 - Approved reference electrodes

Reference Potential at Potential at Temperature Equivalent value Approved usage


o o o o
electrode 25 C/75 F 25 C/75 F coefficient to -0 850 V CSE
o
(V/SHE) (V/CSE) mV/ C (V)
CSE +0.320 0.000 0.900 ---- Soil, under AST
bottoms, fresh water
SSC +0.256 -0.050 -0.330 -0.800 Seawater, brackish
water
Standard 0.000 -0.320 ---- -0.530 Laboratory
hydrogen
(SHE)
Saturated +.244 -0.070 -0.700 -0.780 Laboratory
calomel
Zn (ZRE) -0.800 -1.100 ---- +0.250 Under AST bottoms,
seawater

9 Cathodic Protection Criteria

9.1 Onshore cathodic protection (CP) criteria

9.1.1 General
a. CP criteria for the following buried or submerged onshore steel structures shall be as
defined in b.:
1. Pipelines.
2. Flowlines.
3. Communications and electrical tower legs.
4. Firewater and suppression systems.
5. Metallic support structures.
b. For the structures listed in a., one of the following CP criteria shall be achieved:
1. -0,850 V or more negative polarised instant off potential, with respect to CSE
reference electrode.
2. 100 mV of cathodic polarisation, with respect to CSE reference electrode, measuring
either formation or decay of polarisation.
3. In anaerobic conditions, -0,950 V or more negative polarised potential, with respect to
CSE reference electrode.
4. At temperatures greater than 60°C (140°F), a polarised potential of -0,950 V, with
respect to CSE reference electrode.
c. CP potential levels
1. CP potential levels that result in excessive hydrogen generation should be avoided on
materials susceptible to hydrogen embrittlement.
2. Carbon steel potentials should be more positive than -1,200 V, with respect to CSE.
3. Potential limits of stainless steel, duplex, super duplex, or other CRA materials should
be determined by a testing regime during CP system design.

9.1.2 Aboveground storage tanks (AST) - steel bottom


For steel bottom ASTs, one of the following CP criteria shall be achieved:

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a. -0,850 V or more negative polarised instant off potential, with respect to CSE reference
electrode.
b. 100 mV of cathodic polarisation, with respect to CSE reference electrode, measuring either
formation or decay of polarisation.
c. For temperatures greater than 60°C (140°F), 200 mV of cathodic polarisation, with respect
to CSE reference electrode.

9.1.3 Underground storage tanks (USTs) - steel


For steel USTs, one of the following CP criteria shall be achieved:
a. -0,850 V or more negative polarised instant off potential, with respect to CSE reference
electrode.
b. 100 mV of cathodic polarisation, with respect to CSE reference electrode, measuring either
formation or decay of polarisation.
c. If MIC (SRB or acid producing bacteria) is present, -0,950 V or more negative polarised
potential shall be measured, with respect to CSE reference electrode.

9.1.4 Onshore steel well casings


CP current applied to well casing shall be considered suitable if a net current flow to the casing
eliminates all anodic areas using one of the following CP criteria:
a. -0,850 V or more negative polarised instant off potential, with respect to CSE reference
electrode.
b. Casing potential profile internal inspection tool.
c. Current density calculations based on well completion practices.
d. Current attenuation modelling.
e. E-Log-I modelling.

9.1.5 Stainless steel piping


For stainless steel piping, one of the following CP criteria shall be achieved:
a. 100 mV of cathodic polarisation, with respect to CSE reference electrode, either formation
or decay of polarisation shall be measured.
b. -0,450 V or more negative polarised instant off potential, with respect to CSE reference
electrode.

9.1.6 Aluminium piping


For aluminium piping, 100 mV of cathodic polarisation, with respect to CSE reference
electrode, either formation or decay of polarisation shall be measured, observing the following
cautions:
a. Because aluminium can corrode in acidic (i.e., pH is less than 4) and alkaline (i.e., pH is
greater than 8,5) environments, the electrolyte should be tested to ensure protection will
not damage the material.
b. Potentials should not be more negative than -1,200 V, with respect to CSE reference
electrode.

9.1.7 Copper piping


For copper piping, 100 mV of cathodic polarisation, with respect to CSE reference electrode,
shall be achieved, measuring either formation or decay of polarisation.

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9.1.8 Mixed metal piping systems


a. Mixed metal piping systems are:
1. Different metals that are coupled together and
2. Electrically continuous.
b. For adequate protection of mixed metal piping systems, the criterion that shall be achieved
is -0,850 V or more negative polarised instant off potential, with respect to CSE reference
electrode.
Carbon steel is the most common material used for onshore structures.

9.1.9 Overprotection and under protection


For onshore CP design, the following should be reviewed:
a. Overprotection occurs if excessive current levels are applied by the CP system, promoting
an increase in electrolyte pH at metal surface.
b. Overprotection can damage a coated system and is often called “cathodic disbondment”.
Cathodic disbondment is normally not found until polarised potentials are -1,150 V CSE or
more negative.
c. At excessive negative potential levels, mono-atomic hydrogen is also evolved. Hydrogen
can damage a coating and can also result in hydrogen embrittlement of high strength
metals. This condition depends on the:
1. Metal being protected.
2. Environment.
3. Polarised potential.
d. Under protection occurs if measured potentials are less negative than acceptable limits
(criterion), resulting in the inability to mitigate corrosion.

9.2 Offshore cathodic protection (CP) criteria


The following submerged, fixed, or floating offshore steel structures shall have measured
potential values that conform to Table 6:
a. Pipelines.
b. Structures.
c. Equipment.
d. Well casings.

Table 6 - Recommended potential criteria in seawater

Material Minimum negative Maximum negative


potential (V) potential (V)
Ag/AgCl/seawater (4) Ag/AgCl/seawater (1)
Carbon steel
Aerobic environment. -0,800 -1,100
Anaerobic environment. -0,900 -1,100
Austenitic steels
o o
Npre ≥ 40 C (104 F), both aerobic and -0,300 -1,100
anaerobic conditions (2).
o o
Npre < 40 C (104 F), both aerobic and -0,500 -1,100
anaerobic conditions (2).

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Cathodic Protection (CP) Design for Onshore and Offshore Facilities

Duplex stainless steel (both aerobic and -0,500 -0,800 (3)


anaerobic conditions).
Martensitic stainless (13%Cr) steel (both -0,500 -0,800 (3)
aerobic and anaerobic conditions).
Notes:
1. Maximum potential limits ensure negligible impact on coatings from CP.
2. Npre = %Cr + 3,3% (Mo+0,5W) + 16%N.
3. Depending on strength, specific metallurgy, and stress level encountered in service, these alloys can be
susceptible to hydrogen embrittlement. If this risk exists, potentials more negative than -0,800 V should be
avoided.
4. Current attenuation calculations along pipeline to be protected can be used to ensure that protection is
provided along entire length. This technique uses the basic design method that checks suitability of anode
distribution, ensuring that pipe is adequately protected over its length. By adapting this technique, it is
possible to reduce or eliminate anode distribution on pipe, relying on external sources (anodes on adjacent
structures) to protect pipeline over its length.

9.3 Internal steel surfaces criteria


For internal steel surfaces of applicable storage tanks and vessels, one of the following CP
criteria shall be achieved:
a. -0,850 V polarised instant off potential, with respect to CSE reference electrode.
b. -0,850 V on potential for galvanic anode protection, where reference cell is placed as close
as possible to the structure in the water layer to reduce IR drop error.
c. 0,100 mV of cathodic polarisation, with respect to CSE reference electrode, and either
formation or decay of polarisation shall be measured.

Note: Potentials of -1,150 V CSE polarised or more negative can


cause disbonding of internal coating.

10 Galvanic (sacrificial) anodes systems

10.1 General
a. Galvanic anode design shall meet or exceed life expectancy required for structure (refer
to 8.2 for additional design considerations of galvanic CP systems).
b. If the galvanic anode design life does not exceed the life expectancy for the structure,
provisions for meeting this requirement shall be provided.
c. Refer to Annex B for a list of galvanic anode advantages and disadvantages.
d. Galvanic anodes shall be able to continuously supply maximum current required to
maintain protection levels during CP system life expectancy.
e. Current requirements shall be determined for CP design life of structure to ensure that
anode design conforms to initial, mean, and/or final current demand requirements.
f. Anode alloy composition, connections, and installation methods shall conform to
GIS 06-311.
g. Galvanic anodes should be made of alloys based on magnesium, zinc, and aluminium.
h. Galvanic (sacrificial) anodes shall:
1. Protect structure to which anodes are connected by corroding (sacrificing) in an
electrolyte.
2. Be more electronegative than material to be protected.

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3. Not require an external power source.


i. Other types of galvanic anodes can be used for specialised applications (e.g., iron anodes
commonly used to protect CRAs, such as in heat exchangers).
j. Galvanic anode systems shall be designed by locating properly shaped and sized anodes
along structure to be protected.
k. Active surface of sacrificial anodes shall not be:
1. Painted.
2. Isolated from electrolyte.
l. Efficiency of anode should be determined by a number of factors, including:
1. Nature of environment.
2. Operating current density.
3. Metallurgical microstructure.
m. Common galvanic anode materials and primary installation locations shall conform to
Table 7.

Table 7 - Galvanic anodes

Anode material Primary application Design limitations


Aluminium Marine and offshore Only offshore
Zinc Offshore and onshore Low driving voltage
Magnesium Onshore High consumption rate
Iron Heat exchangers Only use on process equipment

n. Diesel storage tanks in downstream application should not be cathodically protected by


zinc anodes.

10.2 Marine and offshore galvanic anodes


a. For marine and offshore applications, aluminium or zinc anodes should be used.
b. Aluminium anodes are the preferred option because aluminium has approximately three
times greater current capacity than zinc (refer to Table 7).
c. Zinc anodes shall be considered only for systems operating at ambient temperature due to a
reverse in potentials, which causes structure to become the anode.
d. Magnesium should not be used offshore due to:
1. High driving potential of alloy.
2. Consumption rate in seawater.
Driving potentials of aluminium and zinc anodes are considered to be relatively low,
which minimises risk of:
 Cathodic disbondment of high performance coatings.
 Thermite or incendive sparking when in contact with steel.
e. Offshore pipelines
1. Maximum spacing between anodes shall be 300 m (975 ft).
2. If maximum spacing between anodes is exceeded, to support longer spacing,
attenuation calculations shall be provided as proof of adequate protection along
pipeline.

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f. Stainless steel piping systems


1. In some cases, sacrificial anodes shall be required to protect stainless steel piping
systems against corrosion in chlorinated seawater.
2. To avoid high anode consumption rates, RCP systems should be considered.
RCP arrangement ensures anodes are controlled by a specific resistor. Limited
current density requirement for CP of stainless steel should be 1 mA/m2
(0,09 mA/ft2) to 2 mA/m2 (0,19 mA/ft2), which allows for longer life and a long
protective range for RCP anodes.

Note: RCP method is based on patent claim number 91.0093 from


The Foundation for Scientific and Industrial Research at the
Norwegian Institute of Technology (SINTEF), which is a
Scandinavian research and development body.

g. Offshore substructure seawater and firewater lift caissons


1. Sacrificial anodes shall be used to protect offshore substructure seawater and
firewater lift caissons (refer to NSSPU-GP 66-00-2).
2. Corrosion resistant alloys (CRAs)
a) The riser main and pump is often a CRA and should be coated to prevent
excessive current drain from anodes mounted on riser main (high exchange
current density for stainless steel).
b) If CRA components are effectively coated, internal diameter of carbon steel
caisson can also be coated, further reducing current drain.

10.3 Onshore galvanic anodes


a. For protection of onshore structures, galvanic anodes should be made of alloys based on
magnesium, zinc, and aluminium.
b. Galvanic anodes should only be used for:
1. Small diameter pipelines (less than 300 mm [12 in] diameter).
2. Short lengths of larger diameter pipelines in low resistivity:
a) Soils.
b) Water.
c) Swamps.
d) Marshes.
c. Galvanic anodes may also be used to protect:
1. Buried tanks or bases of ASTs.
2. Other types of storage vessels.
3. Fixed structures.
d. Galvanic anodes shall be used to provide:
1. Temporary protection of newly laid pipelines.
2. Localised (hot spot) protection to supplement ICCP systems.
e. Anode alloy selection
1. Selection of anode alloy for a particular application shall be restricted by the
resistivity of the electrolyte.

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2. Maximum resistivity restrictions for magnesium and zinc anodes shall conform to
Table 8.

Table 8 - Galvanic anode resistivity limitations

Magnesium (6% Al-3% Zn) < 5 000 Ohm-cm (164 Ohm-ft)


Magnesium (high purity) < 10 000 Ohm-cm (328 Ohm-ft)
Zinc - Type 1 < 500 Ohm-cm (16 Ohm-ft)
Zinc - Type 2 < 3 000 Ohm-cm (98 Ohm-ft)

f. For onshore applications in soil, prepackaged anodes with specially formulated backfill
shall be used in accordance with GIS 06-311.
g. Only magnesium alloys should be used in potable water, due to nontoxic corrosion
products.

10.4 Low voltage cathodic protection (CP) for subsea applications


Design of CP systems for low voltage subsea applications is a specialised activity and should
only be performed and approved by a qualified CP specialist.

10.5 Risk of failure


If monitoring reveals insufficient protection, appropriate corrective measures
should be performed as soon as reasonable in accordance with GP 06-36.
a. A risk analysis of the failure of the CP system shall be in accordance with GDP 3.1-0001.
b. The following risks shall be considered:
1. If CP design has not been accurately calculated, structure might not achieve full
polarisation or meet required design life of system.
2. If anodes become detached from structure or electrical continuity is lost, a reduction
in protection levels could occur.
3. Incorrect or deviating alloy composition can result in complete passivation of anode
under certain operating conditions.

11 Impressed current cathodic protection (ICCP) anode systems

11.1 General
ICCP can be applied if metal to be protected is coupled to the negative pole of an
external DC power source, while the positive pole is coupled to a more
electropositive anode material. Because driving voltage is provided by DC power
source, the anode does not need to be more active than structure to be protected.
Anodes may be:
 Nonconsumable anodes that can remain inert.
 Semiconsumable anodes (e.g., graphite and high silicon iron).
 Consumable anodes (e.g., scrap iron).
a. ICCP systems shall be designed:
1. To satisfy all statutory electrical and hazardous area requirements.
2. For specific structure to be protected.
b. Design should meet or exceed life expectancy required for structure.

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Cathodic Protection (CP) Design for Onshore and Offshore Facilities

c. To determine CP effectiveness and life expectancy, designs should have all associated
groundbed resistance and current requirement calculations.
d. To ensure all points are properly protected, current attenuation calculations may be
required for structures in which groundbed placement is extremely remote from structure
to be protected.
e. Measures shall be taken to ensure the necessary isolation between anodes and structure.
f. Total current capacity of ICCP system shall have 1,25 times current required for
groundbed to produce.
g. Excess capacity in the CP system design shall help meet additional current requirements of
structure as structure ages and coating deteriorates.
1. DC power source monitoring requirements shall conform to GP 06-36.
Current delivered by DC power source should be monitored throughout design life
of CP system to achieve and maintain an adequate protection potential over surface
of structure.
Monitoring requirements should conform to GP 06-36.
h. In addition to DC power source, a properly designed ICCP system shall consist of the
following components:
1. ICCP anodes.
2. Cables (anode and negative [current drain]).
3. Reference electrode and cable (if required).
4. Specialised and engineered backfill (as required).
i. ICCP system components shall conform to GIS 06-311.
Annex B provides advantages and disadvantages for ICCP systems.

11.2 Marine and offshore applications


A wide range of marine and offshore structures can be protected using ICCP
systems. An ICCP system generally consists of:
 One or more transformer rectifiers.
 Several anodes.
 A number of fixed reference electrodes.

11.2.1 General
a. If environment, structure configuration, and service conditions vary frequently,
transformer rectifiers with automatic potential control should be used. Otherwise,
fluctuations in current demand required to maintain polarisation can occur.
Fluctuations in current demand can be caused by several factors, including:
 Variations in salinity (as for estuaries).
 Change in electrolyte flow rates.
 Large fluctuations in submerged steel areas caused by tidal variations.
 Wetted surface areas of mobile units, depending on loading condition.

11.2.2 Current distribution


a. Specific areas may require a multizone control system to optimise current distribution to
CP demand.

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Cathodic Protection (CP) Design for Onshore and Offshore Facilities

b. To optimise current distribution, protection of each zone should:


1. Be designed individually.
2. Have an ICCP system.

11.2.3 Impressed current anodes


a. Due to higher current output of impressed current anodes compared to that of galvanic
anodes, impressed current anodes should be located remote from steel surface at least
1,5 m (5 ft), if possible.
b. If maintaining distance in a. is not practical, a special dielectric shield shall be applied to
adjacent support surface to prevent localised high current densities.
1. Dielectric shields may consist of:
a) Thick, applied coatings.
b) Prefabricated plastic.
c) Elastomeric sheets.
d) Miscellaneous other types.
2. Material should be considered for:
a) Service intended.
b) Life of system.
c) Resistance to chlorine, hydrocarbons, and deleterious chemicals, which can
cause disbonding or degradation of shield material.
High current densities can induce local overpolarisation with potentials outside
acceptable limits.

11.3 Onshore applications


a. ICCP systems may be used on a number of onshore structures, including:
1. Pipelines.
2. AST bottoms.
3. USTs and well casings.
b. ICCP systems should be designed:
1. For each structure to be protected.
2. To provide adequate current distribution to structure.
c. ICCP system design factors shall include:
1. Stray currents, which minimise effects on foreign structures due to ICCP system.
2. Configuration and location of ICCP groundbed.
3. Proximity to structure to be protected.
4. Configuration of anodes to be installed.
5. Groundbeds
a) Overprotection can occur if groundbed is too close to structure to be protected
and can cause cathodic disbondment.
b) Groundbeds should not be installed closer than 30 m (100 ft) for well coated
structures or 0,3 m (1 ft) for bare structures.

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Cathodic Protection (CP) Design for Onshore and Offshore Facilities

6. Calculations for the following groundbed resistances:


a) Anode materials.
b) Cables
c) Soil resistivity.
d) Backfill resistance to determine output from groundbed.
e) Back EMF between anode and cathode.
7. Anode groundbeds should be sited where soil resistivity is as low as possible and
compatible in a suitable position in relation to structure to be protected.
8. Power source type.
Possible options for power sources are:
 Local AC.
 Solar.
 Wind.
 Thermoelectric.
 Generator.
Selection criteria may include the options for output control for manual or
automatic (constant current and constant potential) ICCP systems.
Selection criteria of the power source may also include the consideration of the
surge protection capabilities associated with the particular source.
9. Location of the unit housing in classified areas.
10. Buried connections for integrity of connections to be considered in location and type
of groundbed installed.
d. Internal storage tank ICCP systems
1. Internal storage tank ICCP systems shall not be installed on tanks that contain
hydrocarbons.
2. Distributed anodes should be used and are either:
a) Suspended/tethered from roof of tank.
b) Surface mounted.
3. Surface mounted anode systems shall require dielectric shields to:
a) Prevent localised overpolarisation.
b) Assist in achieving uniform current distribution.
4. Internal storage tanks being protected shall be vented to prevent buildup of hydrogen
and chlorine.
e. If an extended period is necessary before ICCP system can be energised, a temporary
galvanic anode system shall be installed.
f. Remote monitoring and current interruption system for each transformer rectifier should be
considered, which assists in obtaining accurate instant off for an ICCP protected structure.

11.4 Risk of failure of impressed current cathodic protection (ICCP) system


If monitoring reveals insufficient protection, appropriate mitigation actions should
be performed in a timely manner to reinstate integrity in accordance with CP
mitigation requirements and frequencies clause in GP 06-36.

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Cathodic Protection (CP) Design for Onshore and Offshore Facilities

a. A risk analysis of the failure of the CP system shall be in accordance with GDP 3.1-0001.
b. The following ICCP system risks shall be considered:
1. Generally, risks of failure to ICCP systems are much greater than those of a galvanic
system.
2. Type of installation and attachment devices used for impressed current anodes and
groundbeds are, therefore, critical, with respect to mechanical damage, because fewer
anodes or groundbeds are involved at relatively high output currents.
3. Loss of an impressed current anode or groundbed may significantly reduce
performance of CP system.

12 Hybrid systems

a. Many onshore, marine, and offshore structures that are protected by ICCP systems may
also have a number of galvanic anodes installed.
b. Hybrid impressed current and galvanic anode system design should have a managed
interface to ensure compatibility.
c. Galvanic anodes shall be used in a hybrid system to provide:
1. Temporary protection to structure before power supply to transformer rectifiers can
be energised.
2. Supplemental protection levels for parts of structure shielded or remote from
impressed current anodes or anode groundbeds.
3. Permanent protection for deepwater components, even though impressed current is
supplied for adjacent floating structure.

13 Design considerations for offshore cathodic protection (CP) retrofit systems

13.1 General
a. If design life of existing CP system is exceeded and can no longer maintain desired levels
of protection or the system fails prematurely, retrofit CP systems shall be considered.
b. Galvanic anodes or ICCP systems shall be used to supplement or replace existing
protection systems.
c. Bracelet anode assemblies
1. Bracelet anode assemblies that have flush mounted or standoff galvanic anodes may
be retrofitted to offshore structures by divers or ROVs.
2. Effective, long term electrical continuity between steel hoops of anode bracelet and
structural member shall be ensured.
d. Galvanic anodes
1. Galvanic anodes mounted on sleds may also be used to supplement protection of
offshore structures and submarine pipelines.
2. Electrical continuity between anode sled and structure shall be provided using at least
two armoured cables.

13.2 Impressed current cathodic protection (ICCP) retrofit systems


a. ICCP systems may also be retrofitted to offshore structures or pipelines.

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Cathodic Protection (CP) Design for Onshore and Offshore Facilities

b. ICCP systems are usually deployed as sleds or tethered and pod configurations on the
seabed that are remote to structure or pipeline.
c. Location of seabed impressed current anode assemblies shall be evaluated to avoid
interaction with foreign metallic structures in the vicinity.
d. Typically, impressed current anode assemblies should be located between 50 m (164 ft)
and 100 m (330 ft) from structure to be protected to ensure uniform current distribution is
achieved.
e. Underwater cable connections (splices) shall be avoided for ICCP installations.

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Cathodic Protection (CP) Design for Onshore and Offshore Facilities

Annex A
(Informative)
Basics of corrosion

A.1 General

a. Metal that has been extracted from its primary ore (metal oxides or other free radicals) has
a natural tendency to revert to that state under the action of oxygen and water. This action
is called corrosion and the most common example is the rusting of steel. Corrosion is an
electro-chemical process that involves the passage of electrical currents on a micro or
macro scale.
b. Where metal is lost, it converts to positive ions and loses electrons through the metal. The
electrons travel through the metal to an area where they react with the environment to
balance the charge by forming negative ions in solution.
c. This corrosion process is initially caused by:
1. Difference in natural potential in galvanic (bimetallic) couples.
2. Metallurgical variations in the state of the metal at different points on the surface.
3. Local differences in the environment, such as variations in the supply of oxygen at the
surface (oxygen rich areas become the cathode and oxygen depleted areas become the
anode).

A.2 Anodic and cathodic reactions

a. Corrosion area in which metal is lost by conversion to positive ions is the anode. The area
in which electrons react with environment is the cathode.
b. Corrosion takes place in an electrochemical cell, provided that following four events occur
(refer to Figure A.1):
1. An anodic reaction (e.g., oxidation which produces free electrons that pass within the
metal to another site on the metal surface [cathode]).
 M  Mn+ + ne- __metal dissolution.
A common example is:
 Fe  Fe2+ + 2e- __iron dissolution.
2. A cathodic reaction (e.g., reduction that consumes electrons produced at anode).
In acid solution, cathodic reaction is as follows:
 2H+ + 2e-  H2 (gas) __ hydrogen reduction.
In neutral solution, cathodic reaction involves consumption of oxygen:
 O2 + 2H2O + 4e-  4OH- (alkali) __ oxygen reduction.
3. Presence of a conductive electrolyte to allow flow of ionic current between anode and
cathode.
4. Metallic connection (path) that completes corrosion circuit, allowing electric current
flow from the anode to the cathode.

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Cathodic Protection (CP) Design for Onshore and Offshore Facilities

Figure A.1 - Electrochemical corrosion schematic

A.3 Electrolytes

a. An electrolyte is a chemical substance or mixture, usually liquid that contains ions which
migrate in an electric field.
b. Electrolytes encountered in relation with CP are water based, typically:
1. Seawater, brackish, or fresh water.
2. Water in soil, clay, mud, concrete, etc.
c. Corrosiveness of electrolyte depends on physical conditions and constituents, for example:
1. pH, temperature, pressure, etc.
2. Oxygen content.
3. Bacteria concentration.
4. Salinity.
Wet concrete does not usually corrode steel due to high alkalinity and passivation of
the steel surface. Corrosion occurs, however, if concrete becomes contaminated
with chlorides or alkalinity reduces.

A.4 Resistivity

a. Soil acts as a reservoir for water and soluble salts, and corrosiveness can be assessed by
measuring electrical resistance of soil.
b. Resistivity measurements provide a good indication of aggressiveness of soil (refer to
Table A.1).
c. Electrolyte resistivity is essential for CP design and controls the amount of current that can
be passed into electrolyte from anode/groundbed.
Exceptions exist to Table A.1 For example, sandy soil in low marshy area is wet and
exhibits low resistivity. Therefore, sandy soil may be more corrosive than many clay
soils.
Resistivity of seawater may also vary with depth and global location.

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Cathodic Protection (CP) Design for Onshore and Offshore Facilities

Table A.1 - Soil resistivity

Resistivity Resistivity Corrosiveness Typical soil conditions


Ohm-m Ohm-ft

<5 16 Very aggressive


Clay
5 to 10 16 to 33 Aggressive
Chalky
10 to 30 33 to 98 Moderately corrosive

Sandy
30 to 100 98 to 328 Mildly corrosive

Unlikely to be
>100 >328
corrosive

A.5 Bimetallic corrosion (galvanic)

a. Bimetallic corrosion refers to corrosion damage induced if two dissimilar materials are
coupled in a corrosive electrolyte. Bimetallic corrosion occurs if two (or more) dissimilar
metals are brought into electrical contact under water.
b. Galvanic corrosion is often caused by inappropriate design.
c. The driving force for corrosion is potential difference between different materials.
d. Relative nobility of a material can be predicted by measuring its corrosion potential. The
well known galvanic series (refer to Table A.2) lists relative nobility of certain materials
versus common reference electrodes.
To avoid metal contact and corrosion between dissimilar metals, an IJ is normally
fitted to electrically separate the two metals.

Table A.2 - Galvanic and electrochemical series of metals

Material Potential (V) vs. Potential (V) vs.


SSC seawater CSE
Magnesium anode alloy -1,70 -1,75 ACTIVE
Magnesium anode alloy -1,50 -1,55 Anodic
Zinc (e.g., zinc anode) -1,05 -1,10 electronegative
Aluminium, zinc, indium anode -1,05 to -1,10 -1,10 to -1,15
Carbon steel (clean and shiny) -0,45 to -0,75 -0,50 to -0,80
Carbon steel (rusted) -0,15 to -0,45 -0,20 to -0,50
Cast iron -0,45 -0,50
Lead (e.g., crimp connection) -0,45 -0,50
C steel in concrete (corroding) -0,30 -0,35
C steel in concrete (not corroding) -0,15 -0,20
Mill scale on steel -0,15 -0,20
Copper, brass, bronze (e.g., cabling) -0,15 -0,20 NOBLE
Austenitic stainless steel -0,05 to +0,20 -0,10 to +0,15 Cathodic
Carbon, graphite, coke (e.g., anode backfill) +0,35 +0,30 electropositive

A.6 Microbial corrosion (MIC)

a. MIC refers to corrosion that is influenced by the presence and activities of microorganisms
and/or their metabolites.

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Cathodic Protection (CP) Design for Onshore and Offshore Facilities

Spectacularly rapid corrosion failures have been observed in soil due to microbial
action.
b. Microbial environment
1. Anaerobic conditions may be created in the micro environmental regime, even if bulk
conditions are aerobic.
2. pH conditions and availability of nutrients also play a role in determining which types
of microorganisms can thrive in a soil environment.
c. Sulphate reducing bacteria (SRB)
1. SRB reduces sulphate to sulphide.
2. The change from sulphate to sulphide usually shows up as:
a) Hydrogen sulphide, which can be recognised from its “rotten egg” odour.
b) Black ferrous sulphide, if iron is available.
3. Most common strains of SRB grow best at temperatures from 25°C (77°F) to 35°C
(95°F).
4. A few thermophilic strains of SRB that can function efficiently at more than 60°C
(140°F) have been reported.
5. SRB have been implicated in corrosion of:
a) Cast iron.
b) Steel.
c) Ferritic stainless steels.
d) 300 series stainless steels.
e) Very highly alloyed stainless steels.
f) Copper nickel alloys.
g) High nickel molybdenum alloys.

A.7 Stray current corrosion

Stray current corrosion occurs if current flows through paths other than the
intended circuit. Stray current corrosion is usually associated with DC systems.
a. Stray current corrosion is normally mitigated by eliminating or reducing stray current by
one of the following methods:
1. Increasing metal/electrolyte interface resistance by coating structure.
2. Inserting IJs between distinct parts of structure.
b. AC corrosion can be induced by proximity and parallelism to high voltage overhead power
lines, which can be caused by:
1. Long term imbalance in transmission system.
2. High voltages near earthing (grounding) systems, resulting from lightning strikes and
faults.
c. Induced voltage and current
1. Interference between pipeline and power supply phases causes induced voltages and
currents.
2. Induced AC voltages can be very dangerous.

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Cathodic Protection (CP) Design for Onshore and Offshore Facilities

3. Induced AC currents can cause very rapid corrosion, particularly on well coated
pipelines.
4. Mitigation is important to reduce both safety and corrosion risk.

A.8 Electrochemical series

Electrochemical series of metals are listed in Table A.2, which shows natural potentials of
metals (metals commonly referred to or related to CP), with respect to standard reference
electrodes.

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Cathodic Protection (CP) Design for Onshore and Offshore Facilities

Annex B
(Informative)
Advantages and disadvantages of galvanic and impressed
current cathodic protection (ICCP) systems

B.1 Galvanic cathodic protection (CP) systems

Galvanic Advantages Disadvantages


anode
Environment Depending on alloy, can be used onshore and Not practical for use in high resistivity conditions.
offshore. Restricted to well coated structures because
limited current available.

Installation Straight forward installation. Often bulky. Large quantity of anodes required
for uncoated structures.

Power source Independent of any power source. Hydrodynamic loadings may be high. Anodes
may restrict water flow in water system (e.g., for
pump casing systems offshore). Anodes may be
required at a large number of positions.

Interference Less likely to affect neighbouring structures,


because current output at any point is low.

Control Tendency for current to be self-adjusting. Lifespan varies with local conditions.
Replacements may be required at different
times.

Maintenance Generally maintenance free. No ability to measure current flow to determine


remaining life.

Damage Robust, not very susceptible to mechanical Anode weight may not be supported by structure
damage. to be protected.

Connection Designed mechanical connection or welded Not able to determine if connection is solidly
directly to surface of structure to be protected. made.
Connections are cathodically protected.

Hazards Magnesium anodes can be used in potable Magnesium should only be used in confined
water tanks. spaces that are well vented and not in areas
containing hydrocarbons. Aluminium and zinc
anodes should not be used in potable water
tanks. Zinc anodes should not be used in diesel
storage tanks that supply dual fuel gas turbines.

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Cathodic Protection (CP) Design for Onshore and Offshore Facilities

B.2 Impressed current cathodic protection (ICCP) systems

Impressed Advantages Disadvantages


current
Environment Not restricted by high resistivity May cause overprotection, coating disbondment, or
conditions. hydrogen induced cracking of high tensile steels.

Installation Good flexibility. Can be applied to a Requires high level of detail design and installation
wide range of structures. expertise.

Power source Controllable current output requiring External power source necessary with continuous power
fewer anodes due to higher current supply. DC polarity needs to be checked during
output. Controlled current output commissioning, because misconnection with reversed
caters for changing conditions. polarity will accelerate corrosion on structure.

Anodes/ Generally requires a small number of Effects on other structures that are near anode locations of
interference anodes. Lighter and has the least protected structures should be assessed (but any interaction
effect on water flow. may be readily corrected).

Control Simple controls, which can be made Monitoring and control required at regular intervals.
automatic to maintain potential within
close limits. Ability to switch current off to measure IR free potentials.

Maintenance Inspection can be maintained at Though designed for long life, requires regular inspection,
relatively few points of structure. monitoring, and control.
Large capacity, long life systems.

Damage Anodes can be located in a single Lighter anodes less resistant to mechanical damage and,
location. therefore, loss of anodes more critical.
History of use on offshore structures shows that anodes are
susceptible to damage during installation.

Connection Fewer connections required. Can be Connection more complex and requires high integrity
flush mounted to structure, preventing insulation. Susceptible to water ingress at anode termination
turbulence or water flow restriction. points, resulting in premature failure. Requires high integrity
insulation on connection to positive side of transformer
rectifier, which is in contact with soil or water. Otherwise,
connection will corrode.

Diver risk from electric shocks. Impressed current anodes


Hazards need to be switched off if divers are in vicinity.
Overprotection can result in coating disbondment and
hydrogen induced cracking of high strength steels.

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Cathodic Protection (CP) Design for Onshore and Offshore Facilities

Bibliography

BP
[1] GP 32-30, Inspection and Testing of Equipment In Service - Management Principles.

[2] GP 43-49, Pipeline Integrity Management System (PIMS).

[3] NSSPU-GP 66-00-2 Caisson Integrity Management Strategy

American Petroleum Institute (API)


[4] API Std 570, Piping Inspection Code: In-service Inspection, Rating, Repair, and Alteration of Piping
Systems.

[5] API RP 1632, Cathodic Protection of Underground Petroleum Storage Tanks and Piping Systems.

European Standards (EN)


[6] EN 12954, Cathodic Protection of Buried or Immersed Metallic Structures. General Principles and
Applications for Pipelines.

International Organization for Standardization (ISO)


[7] ISO 9001, Quality Management Systems - Requirements.

[8] ISO 10005, Quality Management System - Guidelines for Quality Plans.

[9] ISO/TS 29001, Petroleum, petrochemical and natural gas industries - Sector-specific quality
management systems - Requirements for product and service supply organizations.

NACE International (NACE)


[10] NACE 7L192, Cathodic Protection Considerations for Deepwater Projects.

[11] NACE No. 2/SSPC-SP 10, Near-White Metal Blast Cleaning.

[12] NACE TM0190, Impressed Current Test Method for Lab. Testing of Aluminium Anodes.

[13] NACE/ASTM G193-09, Standard Terminology and Acronyms Relating to Corrosion.

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25 October 2013

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