OM40-OPM-CRN-CAL-00001 Cathodic Protection Calculation Report

NIGERIAN PETROLEUM DEVELOPMENT COMPANY LIMITED

PROJECT TITLE:

FRONT END ENGINEERING DESIGN (FEED) FOR THE INSTALLATION OF

2NOS. x 1MW GAS GENERATORS AT OPUAMA FIELD AND
ELECTRIFICATION OF 2 OPUAMA FIELD HOST COMMUNITIES IN OML 40

DOCUMENT TITLE: CATHODIC PROTECTION CALCULATION REPORT

DOCUMENT NUMBER: OM40-OPM-CRN-RPT-00001

A01 02.10.20 ISSUED FOR APPROVAL J .BABALOLA S.OKELOLA O.ATTAH

R01 02.10.20 ISSUED FOR REVIEW J .BABALOLA S.OKELOLA O.ATTAH

K01 08.10.20 INTER-DISCIPLINE CHECK J .BABALOLA S.OKELOLA O.ATTAH

Rev Date Issued Purpose Originator Checker Approver

Company Approval: CONTRACTOR

Date:

Asset Location Discipline Designation Sequence Revision

Document No.
OM40 OPM CRN CAL 00001 A01

Page 1 of 21
OM40-OPM-CRN-CAL-00001 Cathodic Protection Calculation Report

Table of Contents
1.0 INTRODUCTION ............................................................................................................................................3
1.1 Background ..................................................................................................................................................3
1.2 Project objective.........................................................................................................................................3
1.3 Purpose of Document ...............................................................................................................................3
1.4 Definition .......................................................................................................................................................4
1.5 Abbreviations ...............................................................................................................................................4
2.0 REFERENCES ..................................................................................................................................................5
a. Nigerian regulations ...................................................................................................................................6
b. Codes and Standards ...............................................................................................................................6
3.0 DESIGN DATA ...............................................................................................................................................6
3.1 Design basis ..................................................................................................................................................6
Definition of zone ............................................................................................................................................7
Structures to be protected...........................................................................................................................7
3.2 Generator Platform structure data ........................................................................................................7
3.3 Sacrificial anode parameters..................................................................................................................9
3.4 Cathodic protection calculation parameters .................................................................................10
3.5 Design assumptions and considerations ............................................................................................10
4.0 CALCULATIONS METHODOLOGY .........................................................................................................12
4.1 Mean current demand ...........................................................................................................................12
4.2 Final current demand ..............................................................................................................................12
4.3 Mass requirement to meet mean current demand .......................................................................13
4.4 Anode dimensions to meet final current demand .........................................................................13
5.0 RESULTS SUMMARY, CONCLUSIONS AND RECOMMENDATIONS..................................................14
5.1 Results summary ........................................................................................................................................14
5.2 Conclusion ..................................................................................................................................................16
5.3 Recommendations...................................................................................................................................16
6.0 LIST OF attachments.................................................................................................................................17

Page 2 of 21
OM40-OPM-CRN-CAL-00001 Cathodic Protection Calculation Report

1.0 INTRODUCTION

1.1 Background

Nigerian Petroleum Development Company Limited (NPDC), a subsidiary of Nigerian

National Petroleum Corporation (NNPC) intends to increase the power generation at
Opuama flowstation by two (2) Megawatts. This is to provide power to two of its host
communities, Opuama and Tsekelewu which is one of NPDC’s Capacity Development
Initiatives (CDIs) for OML 40’s host communities. The power station will be located at
Opuama Flowstaion and this upgrade will also provide the additional power
requirements of the existing flowstation.

The power station will be a consolidated power system consisting of four existing
generators (1x 450KVA Gas Generator, 1x 350KVA Diesel Generator, 1x 500KVA Diesel
Generator) and two nos 1 MW Gas Generator (New).

The existing generators shall be relocated from the present position to a new location to
be determined by this project and synchronised with the incoming gas generators. This
new location will serve as the power station where power shall be transmitted to the flow
station after stepping down, to Opuama approximate five kilometers from the flow
station and Tsekelewu approximately nine kilometer from the flow station. Marine Cable
shall be used to transmit power to these two communities and connect to the existing
Power Supply Distribution Networks on ground.

1.2 Project objective

The objective of this project is to provide a Front-End Engineering and design (FEED) for
the installation of 2nos. x 1mw gas generators at Opuama field and electrification of 2
Opuama field host communities in oml 40.

1.3 Purpose of Document

The purpose of this report is to perform the analysis and present the FEED results of
cathodic protection for the Opuama Field and Electrification Project using galvanic
(sacrificial) anodes in accordance with the latest edition of the International Codes and
Standards per ref. [1].

Anode dimensions/weights provided in this Calculation Report are based on FEED design
and need to be confirmed by the Detailed Engineering contractor with exact anode
characteristics given by the anode VENDOR/SUPPLIER.

In compliance with ref. [1], the calculation report presents the assumptions taken at FEED
stage for the cathodic protection design and gives the quantity of anodes necessary for
the protection of the Gas plant at Opuama field.

Page 3 of 21
OM40-OPM-CRN-CAL-00001 Cathodic Protection Calculation Report

The scope of this report covers the design of Sacrificial Anode Cathodic Protection
(S.A.C.P.) system for the Generator Platform of Opuama Field and Electrification project,
providing the necessary current and anode mass needed for the protection of the
platform structure and its appurtenances from external corrosion throughout its design
life. Sacrificial anode system shall be used to provide Cathodic Protection (C.P.) for the
exposed parts (submerged and buried parts) of the Generator Platform.

1.4 Definition
The following definitions & abbreviations are used extensively throughout this document:
Definitions

COMPANY Nigerian Petroleum Development company Ltd

CONTRACTOR EPCI Contractor

CONTRACTOR’s scope of work as defined in the contract between

WORK
COMPANY and CONTRACTOR

Company to which CONTRACTOR has contracted part of WORK,

SUBCONTRACTOR
providing service(s) to CONTRACTOR

Company providing service(s) or item(s) to CONTRACTOR towards

VENDOR/SUPPLIER
performing WORK

1.5 Abbreviations
Abbreviations

ALARP As Low As Reasonably Practicable

CBF Coating Breakdown Factor

CD Current Density

CP Cathodic Protection

EPCIC Engineering, Procurement, Construction, Installation,

Commissioning

FEED Front End Engineering Design

HSE Health Safety Environment

Page 4 of 21
OM40-OPM-CRN-CAL-00001 Cathodic Protection Calculation Report

ITT Invitation to Tender

MSL Mean Sea Level

OGGS Offshore Gas Gathering System

OPEX Operating Expenditure

SACP Sacrificial Anode Cathodic Protection

UoM Unit of Measurement

WD Water Depth

2.0 REFERENCES
In case of any conflict between the requirements of this document, applicable code, standards
& specifications and other contract documents, the order of precedence shall be as follows:

 Statutory law and regulations of State of Nigeria

Page 5 of 21
OM40-OPM-CRN-CAL-00001 Cathodic Protection Calculation Report

 Nigerian National Codes and Standards

 This Document and its referenced documents
 International Codes and Standards
Any conflict between the applicable documents shall be referred to the CONTRACTOR for
clarification.

a. Nigerian regulations
All Nigerian regulations are applicable to this project.

b. Codes and Standards

The present document relates more specifically to the following CODES and STANDARDS.
Ref Document Number Document Title
[1] DNVGL-RP-B401 (June 2017) Cathodic Protection Design

3.0 DESIGN DATA

3.1 Design basis

The following defines the basis of cathodic protection, design parameters and assumptions used
for the design of sacrificial anodes cathodic protection system for Generator Platform.

Page 6 of 21
OM40-OPM-CRN-CAL-00001 Cathodic Protection Calculation Report

Definition of zone
The following defines the protection zones of the Generator Platform structures.

a. Zone 1: Submerged zone below the water depth, uncoated Steel surfaces.
b. Buried zone: Zone below the mudline. The surfaces are bare and buried in sediment.
Structures to be protected

The structure to be protected consists of an offshore jacket and ancillaries as listed below:

 The steel platform sub-structure, including steel piles,

 Piles in soil and
 Concrete reinforcement steels

3.2 Generator Platform structure data

Table 3.2 lists the principal particulars of the Generator platform structure and the protected
surface areas of the platform structure. Figure 5.2 shows the general view of the Generator
Platform.

Page 7 of 21
OM40-OPM-CRN-CAL-00001 Cathodic Protection Calculation Report

Table 3.2:Generator Platform data

Generator Platform
Sections Zone 1 Buried Zone
Design Life(Years) 25
323.9 @ the pier and
406.4
Pile Diameter (mm) 406.4 @ the platform
Surface Area (m2)
Platform Sub-
576.38 (Structural members below the water)
Structure
Piles 1930.43 (Below the mudline)
Total Surface Area
576.38 1930.43
(m2)
Total Surface Area
(m2) with 10%
contingency 634.02 2123.48

Page 8 of 21
OM40-OPM-CRN-CAL-00001 Cathodic Protection Calculation Report

3.3 Sacrificial anode parameters

Table 3.3 lists the Aluminium (Al-Zn-In) alloy sacrificial anode parameters used for the analysis.

Table 3.3: Sacrificial Anode Data

Platform Sections Zone 1 Buried Zone

Anode Type/Material Al-Zn-In Long Flush Mounted Anode

Anode Utilisation 0.85

Factor

Anode Net Weight, 108.9

(kg)

Anode Gross Weight 109.81

(kg)

Anode Length (m) 0.610

Anode thickness (m) 0.254

Anode Width (m) 0.254

Anode energy 2000 (Seawater)

capacity (A-hr. /kg)
(This can be more than 2500 A-hr./kg depending on the
VENDOR/SUPPLIER 1-year anode capacity test)

Anode Consumption 3.5

Rate, (kg/A.Year)

Anode Density, 2750

(kg/m3)

Design Protective
Potential, (V)
-0.8
(w.r.t
Ag/AgCl/seawater)

Design Closed Circuit

Anode Potential, (V)
-1.05
(w.r.t
Ag/AgCl/seawater)

Anode Core 1/2” rod

Specification

Page 9 of 21
OM40-OPM-CRN-CAL-00001 Cathodic Protection Calculation Report

3.4 Cathodic protection calculation parameters

Table 3.4 lists the platform cathodic protection calculation parameters used for the analysis,
the current demands, and outputs.

Table 3.4: Cathodic Protection Calculation Parameters

Platform Sections Zone 1 Buried Zone

Seawater Temp., (0C) 20.5

Seawater Resistivity 0.21 0.24 (Seabed

(Ωm) Temp. of 13 0C)

Design Life(Year) 25

Design CD for Jacket 0.15, 0.07, 0.1 0.02, 0.02, 0.02

Sub-structure (ici,icm,
icf), (A/m2)

CBF for jacket Sub- 1, 1, 1

structure, (fci,fcm, fcf),
(Bare surface)

Curent Demand 95.1, 42.5,

(Ici, Icm, Icf), (A) 44.4, 42.5,

63.4 42.5

Current Output 2.662, 1.578 2.329, 1.381

(Iai,Iaf), (A)

3.5 Design assumptions and considerations

The following assumptions have been adopted:
 The design current density is based on TablesA-1 and A-2 of DNVGL-RP-B401, ref. [9].
 Exposed parts and buried portions of the platform structures are not coated.
 Seawater resistivity is 0.21 Ohms-m, ref. [1].
 The choice Al-Zn-In anode is based on the higher electrical capacity and lower density,
translating into lesser weight and lesser anode numbers and is less expensive.
 Mean seawater salinity is 35 ‰, ref. [1].

Page 10 of 21
OM40-OPM-CRN-CAL-00001 Cathodic Protection Calculation Report

 Anodes required for destructive testing are not included in the design quantity; these shall
be provided separately by the anode VENDOR/SUPPLIER.
 Current drains from any adjoining structure are factored in the surface area
calculations.
 The surface area of the platform structure exposed to water is the total surface area from
the HWL down to the seabed.
 It is assumed that the sea level does not go beyond the H.A.T.at any time.
 Anodes shall be welded on the piles.
 Anodes shall not be welded on any surface below the mud line e.g. the piles driven below
the mudline.
 The anode shall be custom made. Anode VENDOR/SUPPLIER shall manufacture the
anodes to the dimensions stated in Section 5.3.
 Only the external surface areas of the exposed parts are used for the cathodic protection
analysis.
 1/2” rod shall be considered for the anode core.

Page 11 of 21
OM40-OPM-CRN-CAL-00001 Cathodic Protection Calculation Report

4.0 CALCULATIONS METHODOLOGY

The methodology used for the calculation of the mean current demand, final current demand
and total anode mass required are according to the recommended practice described in
DNVGL-RP-B401.

4.1 Mean current demand

The mean current demand throughout the jacket structure lifetime is calculated by multiplying
the contributions of the exposed surface areas to seawater and design mean current density,
eqn. (1).

Icm =Ac x fcm x Icm ……………………………………………………………….…………………………(1)

Where:
Icm= Mean current demand
Ac= Exposed area to be protected
fcm= Mean coating breakdown factor
icm= Design mean current density

tf
fcm =a+b ……………………………………………………………….……………………………..(2)
2

Where, a and b are constants in Table A-4, ref. [9].

4.2 Final current demand

The final current demand is calculated in a similar way to the mean current demand, eqn. (3).

Icf =Ac x fcf x Icf ……………………………………………………………..………………………………(3)

Where:
Icf= final current demand
Ac= Exposed area to be protected
fcm= final coating breakdown factor
icf= Design final current density

fcf =a+b tf …………………………………………………………………………………………………...(4)

Page 12 of 21
OM40-OPM-CRN-CAL-00001 Cathodic Protection Calculation Report

4.3 Mass requirement to meet mean current demand

The net anode mass required to maintain cathodic protection throughout the design life has
been calculated for the exposed jacket areas using the formula below.

Icm x tf x 8760
M= …………………………………………………………………………………………….(5)
uxε

Where:
M = Total net anode mass (kg)
Icm= Total mean current demand (A)
tf= The design life (year)
u = Utilization factor
ε= Electrochemical al c capacity (A-hr/kg)

4.4 Anode dimensions to meet final current demand

The final anode current output of the selected anode has been calculated using (6).

Eoc - Eoa
Iaf = …………………………………………………………………………………………………………… 6
Raf

Where:

(Eoc - Eoa) = The design driving voltage (V)

Raf = The final anode resistance (Ω)

The final anode resistance for long stand-off anodes have been calculated from (7).

ρ 4L
Raf = Ln -1 ……………………………………………………………………………………………….
2πL r

(7)

Where:
ρ Environmental resistivity (Ohms-m)
L Length of anode (m)
r Final anode radius (m)
The required number (N) of anodes can be calculated from eqn. (8) using the final anode current
output (Iaf) and the total final current demand (Icf).

I
N= Icf ………………………………………………………………………………………………………………. (8)
af

Page 13 of 21
OM40-OPM-CRN-CAL-00001 Cathodic Protection Calculation Report

5.0 RESULTS SUMMARY, CONCLUSIONS AND RECOMMENDATIONS

5.1 Results summary

The cathodic protection design analysis has been carried out in accordance with the
methodology given in section 6. Table 5.1 shows the result of the design calculations. The detailed
calculations including the required number of anodes and the required anode mass for the
protection of the exposed areas against corrosion are given in the Attachment 2.
Table 5.1 Summary of cathodic protection detailed calculations for piled platform

Zones of protected piled Zone 1 Buried Zone

structure
Parameters Unit Value
Total anode mass kg 5717.36 5471.08
required (Eqn. 5)
Calculated Quantity Nos. 53 51
of anodes
Individual Anode kg 107.87 107.28
mass required (net
wt.)
Available anode net Kg 108.9
weight- individual
Available anode Kg 109.81
gross weight-
Individual
Final current output A 1.578 2.662
(Individual)
Total final current A 63.4 42.5
demand
Design protective V -0.8
potential
Design Closed Circuit
Anode Potential V -1.05
Design driving V 0.25
voltage

Page 14 of 21
OM40-OPM-CRN-CAL-00001 Cathodic Protection Calculation Report

Total protection m2 634.02 2123.48

surface area

Zones of protected pile d Zone 1 Buried Zone

structure
Parameters Unit Value
Qty of Anode Nos. 5 5
overage (10%)
Total available net kg 5771.7 5553.9
anodic weight
(Excluding anode
overage)
Total available kg 5819.93 5600.31
anode gross weight
(Excluding anode
overage)

The protected areas shall be within the water depth including the Lowest Astronomical Tide (LAT)
and the Highest Astronomical Tide (HAT) and the buried portions of the piled structure.

The flush mounted sacrificial anodes to be provided are designed to be Aluminium (Al-Zn-In)
based alloy. The flush mounted anode consisting of tubular rod (tubular inserts) made of carbon
steel shall be welded to a doubler(wrap)plate which is then welded to the piles. Figure 7.1shows
a typical long flush mounted anode.

Figure 7.1: Typical Pier and Pile Anode with Pipe Rod or Pipe
Anode overage of 10% of the anode quantity has been considered for the Piled Platform in order
to establish the total number of anodes to be manufactured by the anode VENDOR/SUPPLIER.

Page 15 of 21
 OM40-OPM-CRN-CAL-00001 Cathodic Protection Calculation Report

5.2 Conclusion
The cathodic protection design calculations show that 104nos of 108.9kg (net weight) of Al-Zn-In
sacrificial stand-off anodes are adequate for the external corrosion protection of the piled
platform over the design life. Table 5.2 shows the anode distribution with respect to the protection
zones and the total net weight of the anodes.

Anode map showing locations of anode on the structure shall be in accordance with Cathodic
Protection Layout Drawing Doc. No OM40-OPM-CRN-LAY-00001.

Table 5.2: Anode Distribution per Zone

Piled Platform Zone 1 Buried Zone
Sections
Quantity of 53 51
Anodes
Total Number of 104nos X 108.9 kg
Anode required
Net Weight of 5771.7 (5.78) 5553.9 (5.554)
Anodes, kg
(tonnes)
Total Net Weight 11325.6(11.326)
of Anodes, kg
(tonnes)
Minimum Anode 0.5
Spacing, m

5.3 Recommendations
Long flush mounted type sacrificial anodes (Figure 7.1) with parameters as stated in Table 5.3 are
recommended for the exposed parts of piled Platform. The anodes shall only be welded on the
piles.

The distance between adjacent anodes shall be at a minimum of 0.5m in order to avoid
interference and shielding.

Anodes shall be installed on piled structure by welding of the anode cores to doubler (wrap) plates
which is then welded to the piles. Welding ensures the closest electrical contact between the
anodes and surfaces to be protected, thus ensuring good conductivity between anodes and the
protected surfaces through the tubular insert material (anode core).

Page 16 of 21
OM40-OPM-CRN-CAL-00001 Cathodic Protection Calculation Report

6.0 LIST OF attachments

Attachment 1- Standard Sizes of Pier and pile Sacrificial Anode (typical - GALVOTEC)

Attachment 2 - Surface Area Calculation Report

Attachment 3- Piled Platform Detailed Cathodic Protection Calculation

Page 17 of 21
OM40-OPM-CRN-CAL-00001 Cathodic Protection Calculation Report

Attachment 1 –Standard sizes of sacrificial anode (typical - GALVOTEC)

Page 18 of 21
OM40-OPM-CRN-CAL-00001 Cathodic Protection Calculation Report

Attachment 2 –Surface Area Calculation Report

PIER PLATFORM Surface Area Calculation

SPLASH ZONE (LWL-HWL)

Perimete
Section Dimension Length Total Area
r Zone 1
(Below
Item Descr Qt
Breadt splash zone
Number iption y
h/Wall Section Ar to W.D.
Breadth/D Thickne Perimet ea 30m
iameter ss er m Area
mm mm mm mm m2 ft2 Area m2
GRIDS A,B, C, D, E, F
Pier Piles
Below
Water
323.9m
m
diam.X8
.74mm
WT 965 1017.5 58,916,8 633.8 58.916831
1 CPIP 2 6 323.9 8.74 0 6186 31.72 5084 72 NC
GRIDS G, H, I, J, K, L, M
Platform
Piles
Below
Water
406.4m
m
diam.X8
.74mm
WT 965 1276.7 517,464, 5567. 517.46404
1 CPIP 1 42 406.4 8.74 0 43254 041.02 0851 1 NC

576.38087
TOTAL SURFACE AREA (BELOW WATER) 27 NC
TOTAL SURFACE AREA (BELOW WATER )+10% 634.01896
APPURTENANCES

TOTAL SURFACE AREA APPURTENANCES (BELOW THE SPLASH ZONE) 0

576.38
TOTAL AREA 0873
TOTAL AREA + 10% 634.01
Contigengy 896

Page 19 of 21
OM40-OPM-CRN-CAL-00001 Cathodic Protection Calculation Report

HI PP Surface Area Calculation

ZONE 2- BELOW SEABED
Len Perime
Section Dimension Total Area
gth ter Zone 1
Item Breadt Sectio (Below
Descript Qt
Num h/Wall n splash zone
ion y
ber Breadth/Dia Thickne Perime to W.D.
meter ss ter Area Area 30m
mm mm mm mm mm2 ft2 Area m2
PILE
Pile
below
seabed
360 1276.7 1930435 20768 1930.4358
1 406.4m 42 406.4 8.74
00 43254 801 .401 01
m diam.
X
8.74mm

1930.4358
TOTAL SURFACE AREA- PILE (BELOW SEABED) 01
1930.4
TOTAL AREA 358
TOTAL AREA + 10% 2123.4
Contigengy 7938

Page 20 of 21
OM40-OPM-CRN-CAL-00001 Cathodic Protection Calculation Report

Attachment 3 - Production platform jacket detailed cathodic protection calculation

3.1 Submerged zone 1 (Piled Structure between LWL and HWL)

Page 21 of 21