Paper No.

01500

2001

CORROSION

CORROSION PROTECTION PROGRAM FOR HIGH TEMPERATURE SUBSEA PIPELINE

Mike Surkein and Steve Leblanc

ExxonMobil Upstream Development Company
Post Office Box 4876
Houston, Texas 77210
Shannon Richards
ExxonMobil Production Company
1555 Poydras Street
New Orleans, Louisiana 770112
John P. La Fontaine
Deepwater Corrosion Services, Inc.
6830 N. Eldridge Parkway
Suite 211
Houston, Texas 77041
ABSTRACT
A subsea pipeline has been installed with a novel corrosion protection scheme. The pipeline
and associated components have been protected from corrosion with a combination of a high
temperature pipeline fusion bonded epoxy coating, a thermal spray aluminum coating and sacrificial
cathodic protection anodes. Due to the high operating temperature of the pipeline, anode bracelet
installation on the pipeline was not desirable. A cathodic protection attenuation model was used to
design the anodes for the pipeline. The model indicated that the sacrificial anodes could be installed at
either end of the two-mile pipeline. To assure adequate corrosion control was achieved by the cathodic
protection system, a sophisticated in-situ monitoring system was installed. Also, a diver inspection was
conducted to measure cathodic protection performance. This paper presents the corrosion control
design approach used for each of the major components including the risers, pipeline and buried
expansion boxes. The design basis will be compared to the results of the in-situ and diver gathered
monitoring data.
Copyright
2001 by NACE International. Requests for permission to publish this manuscript in any form, in part or in whole must be in writing to NACE
International, Publications Division, 1440 South Creek Drive, Houston, Texas 77084-4906. The material presented and the views expressed in this paper are
solely those of the author(s) and not necessarily endorsed by the Association. Printed in U.S.A.

INTRODUCTION
A typical one-well development for a high-temperature well in shallow water includes a three or
four-pile platform, wellhead coolers, and utilities. These facilities are required to protect the flowline
from the increased corrosion rates and mechanical difficulties that it will experience at full wellstream
temperatures. For the development being discussed, wellhead temperatures range from 265 F (129 C)
to 315 F (157 C). The challenge of this design was to minimize the wellhead facility by eliminating
the cooler and its associated utilities, while addressing the corrosion and mechanical difficulties.
The mechanical design concerns for high-temperature, buried flowlines are thermal expansion and
upheaval buckling. Thermal expansion will occur when the flowline operating temperature is higher
than its as-installed temperature. In buried environments, natural flowline expansion is constrained by
the axial and lateral loads of the soil on the flowline. Where there are imperfections in the flowline
profile, the line will tend to experience lateral or upheaval movement.
To overcome the thermal expansion challenges; the flowline was designed with expansion
doglegs. The doglegs were housed in expansion boxes (Figure 1). The expansion boxes allowed
lateral growth of the flowline
Corrosion concerns at elevated temperatures include high cathodic protection consumption and
coatings degradation. Anodic current density increases and its capacity decreases with increasing
temperatures. Both of these conditions work against a standard system of bracelet anodes installed
directly onto the flowline. The challenge in selecting a suitable coating is to find a system that stands
up to high temperatures and resists cathodic disbondment.
T E M P E R A T U R E EFFECTS ON CATHODIC P R O T E C T I O N
In general corrosion is arrested when the current density on the cathode exceeds the oxygen
replenishment rate, according to the equation:
0 2 + 4 e - + 2HaO .-> 4(OH)-

(1)

This reaction raises the pH at the boundary, and if calcium carbonate concentration in the electrolyte is
near the solubility limit, it will precipitate out on the cathode, restricting oxygen diffusion to the
cathode, and current density decreases.
Cathodic protection anode consumption increases drastically at the design temperatures of this
flowline. The current density required to protect buried bare steel at 77 F is 2 mA/ft 2 (1). As
temperature increases, the current density requirement increases at a rate of 0. lmA/ft 2 per 1.8F
increase above 77F (0.1 mA/m 2 as temperature increases above 25 C). Conversely, the anode current
capacity decreases as the temperature increases as shown in Figure 2 (2). Since no industry data was
found at the design temperatures for this flowline, the anode properties were extrapolated.

CORROSION CONTROL FOR THE PIPELINE

Coatings
Corrosion control of marine pipelines is usually achieved through the use of protective coatings
and supplemental cathodic protection. When selecting a coating system for a pipeline or structure
several considerations must be made including:

1.
2.
3.
4.

Effect of cathodic protection

Temperature
Life
Cost

Marine coatings must be suitable for service with cathodic protection. Specifically, they must be
resistant to cathodic disbondment. Cathodic disbondment is the destruction of the adhesion between
coating and the surface due to cathodic protection. The coating system must be suitable for the service
temperature of the pipeline, in this case up to 150 C (300 F). The coating chosen for this application
was a dual coat system of fusion-bonded epoxy and chemically modified polypropylene (FBE/CMPP).

Cathodic Protection
Several basic designs were considered for providing cathodic protection to this line:
1. Standard bracelet anode mounted directly on the pipeline
2. Impressed current
3. Remote A1-Zn-In anode sleds mounted on the platforms at either end of the flowline
The reduction in anode efficiency due to elevated temperature eliminates the first strategy. Impressed
current cathodic protection was feasible, however such a system would require periodic maintenance
through the service life of the pipeline. At the anticipated high temperatures, strategy 3 was most
appropriate. Using galvanic anodes from a remote location allows the anodes to operate in ambient
temperatures where they are most efficient. It also becomes logistically easier than placing anodes on
the pipeline itself. Aluminum anodes alloyed with zinc and indium are commonly used for marine
applications due to their reliability and high efficiency and potential.

Design
To consider placing the anodes at either end of the flowline, it was essential to conduct a
cathodic protection attenuation model of the flowline. The cathodic protection potential
attenuation profile of the pipeline, and total current output required from the CP system were
calculated based on the following relationships.
V = Ki

(2)

V = Change in pipeline potenial from native state

i = Applied current density
K = Constant for any temperature

0
n

En I = Total current picked up by the line between midpoint and segment " n "
V(n+O - V(n) = Change in potential along a short incremental length of pipeline
R = Linear Resistance of incremental length of pipeline

Design Procedure
From the attenuation model the total current required was calculated. Assuming (-) 1.00 Volt
vs. Ag/AgC1 (silver / silver chloride) polarization potential at the end points of the pipeline (drain
points for the anode sleds), and (-) 0.800 V at the mid point, a successive iteration solution to this
model is valid for a 5% bare surface area. This bare surface or coating breakdown value is considered
conservative for a new pipeline. The required current predicted by this model was used to size the
anode sleds. Provision was made for the installation of one mixed metal oxide impressed current
anode on each sled in case additional current is required. A standard weight/current solution design
can be performed to determine anode number and weight for anode sleds at each end of the pipeline.
Anode current output is determined by ohm's law:
I = E/R

(4)

I = current output
E = driving potential
R = circuit resistance

Anode-to-electrolyte resistance was calculated according to Dwight's equation for long slender
standoffs:
R a = ( p 121rL)(In(4L / r) - 1)

(5)

p = Sea water resistivity (ohm - cm)

L = A n o d e length
r = Equivalent radius

A mutual interference factor was used to account for the reduced current output caused by anodes
arranged in parallel at close distances:
C.F. = 1 + In[(Cot82 / 2)(CottY 3 / 2) .... (Cot8 n / 2)]/[In(4L / r)]-

(6)

e n = A r c Cot(L/ns)
L = Length of a n o d e
s = Spacing between a n o d e s
n = n u m b e r of anodes in p a r a l l e l
r = radius

Anodes must have adequate weight to satisfy the equation:

w / c > IL

(7)

w = a n o d e weight
C = a n o d e c o n s u m p t i o n rate (Ibs/Amp X Year)
I = a n o d e current output in a m p s
L = desired design life in years

The anodes were arranged in a sled frame. One frame was mounted on the well caisson and the other
was mounted on the production platform (Figure 3.). The sleds were electrically isolated from the
structures by placing neoprene underneath the clamps. Continuity with the pipeline was established
through a cable jumper.

CORROSION CONTROL FOR THE PIPELINE INSIDE THE EXPANSION BOXES

Coatings
The coating system on the pipeline inside the expansion boxes must meet the same criteria as
the rest of the line. Hence, the FBE/CMPP system used on the rest of the pipeline was the coating of
choice.
Cathodic Protection
The expansion boxes shield the pipeline inside from receiving cathodic protection from the
anode sleds. Therefore in the CP design of the pipeline, these segments were assumed to be isolated
from the rest of the line. To protect this portion of the pipeline an independent CP system was
necessary. Limited accessibility to these locations made galvanic sacrificial anodes the most
appropriate option.
Design
The metallic resistance in the pipeline inside the boxes is relatively insignificant. As a result
potential attenuation is not a concern. The use of truly remote anodes to avoid the effect of elevated
temperature was not viable due to the physical restriction of the box. The best option was to use a
composite bracelet anode design (Figure 4). In this approach, the anode segments are actually small
standoff anodes arranged radially 4" (10 cm) off the pipe. Offsetting the anodes from the pipe allows
the anodes to operate in a reduced temperature environment.
In this elevated temperature environment the current capacity of the anodes is devalued such
that anode weight is the limiting design parameter (as opposed to current), hence this design was a
weight-based solution. A coating efficiency of 0.9 was used was used for the chosen coating system.
This value may be considered conservative but had limited impact on the final system layout.

CORROSION CONTROL FOR THE EXPANSION BOXES

Coatings
Thermal spray aluminum (TSA) was chosen as the coating system for the boxes. TSA differs
from organic coatings in several areas:
1. It is conductive
2. Higher impact resistance
3. Higher service temperature range

Cathodic Protection
The large surface area of the boxes, and the fact that they are electrically isolated from the
pipeline make it important to install a separate CP system for the boxes. Flush mounted anodes were
selected because their low profile decreased the chance of damage during installation.
Design
The cathodic protection requirements for the inside and outside surface were calculated
independently. This approach was necessary because each surface is in a different environment (mud
and seawater), and geometric shielding restricts electrochemical communication. A weight-based
solution calculation was performed to calculate the quantity of anodes required. As with the pipeline,

the design current density and current capacity was adjusted for temperature effects. The coating
efficiency factor used for the TSA coating system was 0.9. This number is conservative, as field data
on TSA is limited.
MONITORING
In order to verify the performance of the cathodic protection system, an online fixed monitoring
system was designed and installed on the pipeline and boxes.

Potential
For cathodic protection to be achieved, the electrochemical potential of steel vs. Ag/AgC1
electrode must be more negative than (-) 0.800 volts. The optimum protective potential range is
between approximately (-) 0.900 to (-) 1.050 Volts. Reference electrodes are required at several
locations to verify protective levels. The location of reference electrodes at the following points were
selected:

On the riser just above the mudline

Away from the riser in the sand (distance based on thermal gradients)
Inside the boxes
On the current density sensors
Outside surface of the boxes

Current Density
Current density monitors (coated/uncoated) were installed on the pipe at the following
locations:
On the risers above the mudline
On the pipeline just below the mudline
On the pipeline inside the boxes
These monitors provide additional data that will be valuable in future designs, i.e. the polarization
behavior of bare and coated steel at elevated temperatures. Each instrument combines, current density,
potential, and temperature measuring capabilities (Figure 5). The CD plates included bare steel, the
FBE/CMPP, and TSA coated surfaces. For each set of CD plates there was an Ag/AgC1 reference cell,
and temperature probe.

Anodes
The remote anode sleds as well as the individual bracelets on the line inside the boxes were
monitored for current output using shunted sensors. In addition to topside data acquisition, diver/ROV
accessible current measuring boxes were installed on the sleds (Figure 6.). These devices can be read
manually using a Diver/ROV probe (Figure 7).

Temperature
In addition to the combination sensors, independent temperature probes were installed on the
risers, and inside the boxes. These sensors are integrated circuit temperature transducers that produce
an output current proportional to absolute temperature. The data acquisition unit supplies power, and

output current is passed through a resistor. The voltage drop is measured across the resistor and
recorded by the data acquisition unit.

Data Acquisition
A remote monitoring system was used to record the signal output. The system is a modular
design based on 2, 19" rack mounted chassis that are daisy chained together (Figure 8.). All channels
are full differential with ranges of +/- 4000 mV DC for the reference cells, and 80+/- mV DC for all
others. The system recorded stored signals at programmed intervals. The PLC system on the
production facility interfaced with the system and recorded signals directly.
RESULTS

Pipeline Polarization
The risers polarized to (-) 1.050 V vs. Ag/AgC1 several days after first oil (Figure 9). Prior to
first oil, the potentials were more negative than (-) 1.100 V. The pipeline potentials close to the
production platform are more negative than the well caisson side of the pipeline. These results are
likely due to temperature effects. The higher temperature on the well side increases current density
requirements. The potentials from both the risers and the 1st joint in the mud show the line to be fully
polarized. The design potential for these locations is (-) 1.00 V.
A survey was performed on 24-June-1999 to verify the entire length of the pipeline had
properly polarized. The potential of the pipeline was measured using a diver held, dual Ag/AgCI
contact probe. The survey data along with the design model are shown in Figure 10. To verify the
accuracy of the attenuation design model approach, the model was recalculated using the actual end
point survey potentials. The original design model was calculated with end point potentials of (-) 1.00
V vs. Ag/AgC1 and 5% bare steel. The actual end potentials used for the recalculation were (-) 1.025
and (-). 1050 V vs. Ag/AgC1. In comparison with the survey data, the original design assumptions
have proven to be conservative.

Anode Current Output

Before startup, the current output of the well caisson mounted anode sled was =0.3 amps.
Immediately after startup (mid-May) current output increased to 1.8 amps then decreased steadily to
below 0.8 amps (Figure 11). The production platform sled output followed a similar pattern. This
phenomenon is likely due to the increase in temperature from ambient to 290 F. To date the current
output of the sleds has been far below the design current of 6 amps from each sled. The current output
by the anode bracelet in the enclosure near the well caisson decreased from 0.035 amps to 0.015 amps
over this period (Figure 12). In comparison, the design current of 0.178 amps has shown to be
conservative.

Current Density
The current densities of the monitors on the risers and the departing product temperature are
shown in Figure 13. During startup in mid-May, the uncoated steel surface briefly reached 10.7 mA/ft. 2
(115.0 m A i m 2 ). From May through mid August the current density steadily decreased to between 4
and 3.7 m A ] f t 2 (43.0 and 39.8 mA/m2). This decrease in required current density is due to polarization.
Polarization of the steel results in production of hydroxyl ions. This raises the pH at the boundary, and
if calcium carbonate concentration in the electrolyte is near the solubility limit, it will precipitate out
on the cathode, restricting oxygen diffusion to the cathode, and current density decreases.

The TSA surface recorded negative current densities from startup until mid-July. This result
indicates that the TSA surface was acting as an anode during this period. The FBE/CMPP coated
surfaces drew current densities of between 0.05 and 0.15 mA/ft 2 (0.54 and 1.6 mA/m2). Using data
from 1-July to 11 -Aug, the percentages of uncoated steel on the FBE/CMPP and TSA on the riser were
2.75 and 4.84 mA/ft 2 (29.6 and 52.1 mA/m2), respectively.
The current density data for the pipeline inside the L-shaped expansion box is shown in Figure
14. The current densities on the coated surfaces were higher than on the riser. Current density on the
TSA was 2-4 mA/ft 2 ( 21.5 - 43.0 mA/m2), which equates 51.45 % bare steel from 1-July to 11-Aug.
The current density on the FBE/CMPP surface was ranged from 0.4 to 0.8 mA/ft 2 (4.3 to 8.6 mA/m2).
The percent bare steel on the FBE/CMPP surface was 12.66%. It is likely that temperature effects on
the riser surface are not as pronounced as in the box as these surfaces are exposed to the bulk seawater.

Expansion Boxes
The boxes both polarized immediately to protected potentials. Both expansion boxes polarized
to values more negative than (-) 1.030 V vs. Ag/AgCI and (+) 0.020 V vs. Zinc.
CONCLUSIONS
1. The cathodic protection system is performing well. The pipeline has achieved full polarization and
is well protected. The data reviewed to date shows the current required to reach protected levels to be
lower than originally calculated. This is new technology however, and should be monitored into the
future to assure long-term performance.
2. The CP system is working well inside the boxes. The current output is less than the design
parameters. However, data from this area should continue to be analyzed, as current densities are high
on the monitored surfaces.
3. The boxes have polarized to design potentials and are well protected.
4. The low current density on the FBE/CMPP coated surfaces indicates that this coating system is
performing optimally. TSA coated surfaces in some cases recorded negative current densities
indicating anodic properties even when used with cathodic protection.

REFERENCES
1. Det Norske Veritas, Recommended Practice B401 "Cathodic Protection Design",
1993.
2. Schreiber, C.F. and R.W. Murray, "Effect of Hostile Marine Environments on the A1Zn-In-Si Sacrificial Anode", paper no. 32 Presented at CORROSION/97, March 1988, St.
Louis, Missouri.

Remote well
caisson

}~.,~~

~~

, ~ Expansiondogleg boxes

-7

plaflorm

FIGURE 1 Simplified diagram of the high temperature flowline.

-

FIGURE 2 - Effect of temperature on the current capacity of A1-Zn-In anodes in

seawater.
1000
=r

<_

ii

II Data

700

~ R e g r e s , ~ o n Line i

5O0
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10

20

30

40

50

60

70

Temperature (Celclus)

80

90

100

110

~-'r-].................. ~ ...................

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I

:ii

:i

i ~'

lii
i i

ural

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Anode (typ.)

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i

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FIGURE

3 - P i p e l i n e a n o d e sled.

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F I G U R E 5 - Schematic of the current density monitor.

F I G U R E 6 - Diver/ROV accessible current measuring boxes.

.'

F I G U R E 7 - Self Contained Diver/ROV cathodic protection probe.

F I G U R E 8 - Remote monitoring data acquisition system.

-800 -

300
Departing Temperature

250

-850

I
,.----,---i

-9O0

'x

Boarding Temperature

2OO
@
t,C

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Well Caisson Riser Potential

-1000

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-1050

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Host Platform Riser P o t e n -

10-May 20-May 30-May

9-Jun 19-Jun 29-Jun

9-Jul

-50
19-Jul 29-Jul 8- Aug 18-Aug

Time

FIGURE 9 Riser potentials and temperature during spring-summer 1999.

-

1,100
4, CPSURVEY ~, DesignmModeledResets

1.050

~ 1.000~

.//

~ o.aoo

0.750
0

--

2000

4000

6000

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8000

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10000

Distance (Feet)

FIGURE 10 - Potential attenuation models. The graph shows the original design, data
from the field survey, and the model based on the actual end point (Riser) potentials.

F I G U R E 11 - Well caisson-mounted anode sled current output, spring-summer 1999.

2
1.8
1.6 ~ - - ,

-=,~Anode Sled Current

Output

1.41.2

|,
0.8~--

a6

0.4
0.20

10-May 20-May 30-May 9-Jun 19-Jun 29-Jun 9-Jul

19-Jul 29-Jul B-Aug 1B-Aug

Time

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~ = ' A n o d e Bracelet Current Output

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0.06
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F I G U R E 12 - Anode bracelet current output, spring-summer 1999.

121 i

Temperature

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F I G U R E 13 - Current densities on various surfaces on the well caisson riser.

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9-Jul

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F I G U R E 14 - Current densities on the pipeline inside the expansion box.