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1. Design parameter
Required current density for coated carbon steel in soil (ir)* ir 10 mA/m^2
System design life for permanent CP system (Yl) Yl 20 years
Average soil resistivity at groundbed active section (pG)* Pg 3393 Ohm.cm
Silicon iron anode practical consumption rate (Ca)** Ca 0.1 kg/A.y
Calcined petroleum (graphite) coke practical consumption rate (Cb)** Cb 1 kg/A.y
* The maximum recorded soil resistivity at depths equal to or below 20m depth as per
JST-IR-PI17-581 ‘Cathodic Protection system Investigation and Current Drainage Test
Report for Ca Mau Fertilizer Plant
2.2.2 Pipe and tank resistance (pipeline resistance to remote earth) Rp
Pipe work and tank resistance is calculated as follows:-
Note: Pipe work and tanks Potential Difference (∆E P) which is a scalar quantity with
respect to CSE.
∆EP = EPprotected pipe/tank - EPnative pipe/tank ∆EP 0.35 V
EPprotected pipe/tank 0.85 V
EPnative pipe/tank 0.5 V
Estimated specific Coating Resistance (C R)
CR = ∆EP / ir CR 0.035 V.m^2/mA
35 Ohm.m^2
Where, ir is the applied/required current density
Using 58mm diameter and 2134mm length tubular silicon iron anodes of weight 21kg
Weight of single anode (Wa) = 21 kg 21 kg
Number of Anodes Required (Na) = WRa / Wa
Therefore,
Na-req = WRa-req/Wa Na-req 2.5531746
Roundup 3 Anode
Na-maxGBED001-GBED005=WRa-maxGBED001-GBED005/Wa Na-maxGBED001-5 3.80952381
Roundup 4 Anode
Na-maxGBED006 = WRa-maxGBED006/Wa Na-maxGBED006 5.71428571
Roundup 6 Anode
Number of anodes to be supplied (Ns) shall be based on ITRU-max output current
conditions, such that:
Ns-maxGBED001-GBED005 4 Anode
Ns-maxGBED006 6 Anode
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5.3.3 Anode resistance calculation
The resistance of semi-deepwell groundbed is calculated from the modified H.B.
Dwight’s formula:
𝑅𝐴=𝑝𝑔/(2∗3.14∗𝐿𝑔)∗(ln(8𝐿𝑔/𝐷𝑔)−1)
Where,
pg = Soil Resistivity at Groundbed Location* pg 3,393 Ohm.cm
33.93 Ohm.m
La = Length (depth) of active groundbed = ‘X’ m
For groundbeds GB001 thru GB005 Lg1-5 30 m
For groundbed GB006 Lg6 50 m
Dg = Diameter of groundbed Dg 0.2 m
Therefore
RAGBED001-GBED005 1.09679568 Ohm
RAGBED006 0.71327586 Ohm
* The maximum recorded soil resistivity at depths equal to or below 20m depth as per
JST-IR-PI17-581 ‘Cathodic Protection system Investigation and Current Drainage Test
Report for Ca Mau Fertilizer Plant
5.3.4 Pipeline resistance Rp
Pipe work and tank resistance is calculated as follows:-
Note: Pipe work and tanks Potential Difference (∆E P) which is a scalar quantity with
respect to CSE.
∆EP = EPprotected pipe/tank - EPnative pipe/tank ∆EP 0.35 V
EPprotected pipe/tank 0.85 V
EPnative pipe/tank 0.5 V
Estimated specific Coating Resistance (C R)
CR = ∆EP / ir CR 0.035 V.m^2/mA
35 Ohm.m^2
Where, ir is the applied/required current density
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Header cable from TRU001 to NJB length (LcTRU-NJB) 50 m
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RTGbed 01- Gbed 05 = RAGbed 01- Gbed 05 + RP+ RCGbed 01- Gbed 05 1.20 Ohm
RTGbed 06 = RAGbed 06 + RP+ RCGbed 06 0.79 Ohm
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5.3.7 Transformer Rectifier Voltage Output Calculations
The voltage requirements of the system are those normally necessary to permit the
system to provide the required protective current and are dependent upon the voltage
available at the transformer rectifier unit (E T).
ET = (ITRU x RT) + Back EMF+ Potential swing at pipe
The required TRU output from design with the required total current equally divided
between the 6 TRU’s is calculated as follows:
ITRU-req = IT /6 ITRU-req 26.81 A
The maximum TRU output based on the unit output rating
ITRU-maxGBED001-GBED005 40 A
VTRU-maxGBED001-GBED005 50 V
ITRU-maxGBED006 60 A
VTRU-maxGBED006 50 V
Back EMF 1.5 V
Potential swing at pipe (due to pipe polarisation) 1 V
Therefore, under required output conditions:
ETGBED001-GBED005-req = ( ITRU-req x RT)+Back EMF+ Potential swing at pipe 34.6266141 V
<= rate of TRU Satisfy
ETGBED006-req = ( ITRU-req x RT)+Back EMF+ Potential swing at pipe 23.6885507 V
<= rate of TRU Satisfy
Under maximum rated output conditions:
ETGBED001-GBED005-max = ( ITRU- maxGBED001-GBED005x RT)+Back EMF+ Potential swing at pipe 50 V
<= rate of TRU Satisfy
ETGBED006-max = ( ITRU-maxGBED006 x RT)+Back EMF+ Potential swing at pipe 49.92 V
<= rate of TRU Satisfy
Under both conditions of ITRU-req and ITRU-max, for all TRU’s, ET is less than the rated output
voltage of the TRU’s and is therefore acceptable
5.3.8 Groundbed Consumption Calculation
The consumption of anode materials and hence the total weight of materials required at
a given system life for a single anode installation is calculated from:
Weight Required (WR) = Yl x Ca/b x ITRU
Where,
ITRU = TRU Output Current = IG = Groundbed Output Current
ITRU-req 26.81 A
ITRU-maxGBED001-GBED005 40 A
ITRU-maxGBED006 60 A
Yl = Required system life = 20 years 20 year
Ca = Anode consumption rate encased in backfill* kg/A.y
Cb = Backfill consumption rate* 1 kg/A.y
Considering, MAXIMUM RATED CURRENT OUTPUT
as a function of DESIGN LIFETIME
MMO anode 2.5cm diameter, 100cm length
Maximum output of each anode to achieve 20 years lifetime imax anode 11 A/anode
Number of Anodes Required (Na) = ITRU / i max anode
Therefore,
Nareq = ITRU-req/imax anode Na-req 2.44
Roundup 3 Anode
NamaxGBED001-GBED005=I TRU-maxGBED001-GBED005/imax anode NamaxGBED001-5 3.63636364
Roundup 4 Anode
NamaxGBED006 = I TRU-maxGBED006/imax anode NamaxGBED006 5.45454545
Roundup 6 Anode
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Number of anodes to be supplied (Ns) shall be based on ITRU-max output current
conditions, such that:
Ns-maxGBED001-GBED005 4 Anode
Ns-maxGBED006 6 Anode
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Anode spacing GBED001 to GBED005 (SactualGBED001-GBED005)= 30m/4anodes = 7.5m
Anode spacing GBED006 (Sactual-GBED006) = 50m/6anodes = 8.4m
Therefore, in all instances Sactual < Smax = Acceptable.
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p 1.724E-08 Ohm.m
D
L 1000 m
S 1.33E-05 mm^2
R 1.2962406 Ohm/km