SPE 93795

Investigations Into the Suitability of Galvanic Cathodic Protection Systems for Long
Term Protection of Buried Pipelines in Desert Locations
J. Hawkyard, Eurabia Cathodic Protection, and D. McGlone, Bahrain Petroleum Co.

Copyright 2005, Society of Petroleum Engineers Inc.

This paper was prepared for presentation at the 14th SPE Middle East Oil & Gas Show and
Conference held in Bahrain International Exhibition Centre, Bahrain, 1215 March 2005.
This paper was selected for presentation by an SPE Program Committee following review of
information contained in a proposal submitted by the author(s). Contents of the paper, as
presented, have not been reviewed by the Society of Petroleum Engineers and are subject to
correction by the author(s). The material, as presented, does not necessarily reflect any
position of the Society of Petroleum Engineers, its officers, or members. Papers presented at
SPE meetings are subject to publication review by Editorial Committees of the Society of
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acknowledgment of where and by whom the paper was presented. Write Librarian, SPE, P.O.
Box 833836, Richardson, TX 75083-3836, U.S.A., fax 01-972-952-9435.

Proposal
The paper outlines the Khuff gas distribution system operated
and maintained by The Bahrain Petroleum Company
(BAPCO). It will detail the types of cathodic protection
installed and areas of apparent premature failure of galvanic
cathodic protection systems
In 1998 a number of new pipelines were installed and
magnesium sacrificial anode systems designed and installed.
At about the same time some remedial work was undertaken
on existing pipelines to replace depleted magnesium anodes.
During a recent routine survey of the cathodic protection
systems it was found that a number of these anodes had
apparently failed prematurely and were not achieving proper
protection levels.
The paper will outline investigations carried out into the failed
anodes, reasons for failure and recommendations for remedial
work.
This paper will focus on the use and suitability of sacrificial
anode systems versus impressed current systems for the longterm cathodic protection of buried pipelines in desert and
reclaimed land areas.
INTRODUCTION
The Bahrain Petroleum Company B. S. C. (BAPCO) supplies
natural gas through a network of above ground transmission
pipelines and buried distribution pipelines to customers in
Bahrain. The gas system operates at pressures up to
1000psig/69 Bar.

External corrosion protection of the pipelines is achieved

primarily via the external coating systems. As a further
corrosion protection measure, the buried pipelines are
cathodically protected, either by sacrificial (galvanic) cathodic
protection (CP) systems, which are based on the use of
magnesium or zinc anodes, or, in the case of three pipeline
sections, by impressed current cathodic protection (ICCP)
systems which utilise magnetite anodes powered by
conventional transformer-rectifier units.
Routine monitoring of the CP systems is carried out annually
and performance of the installed CP systems is assessed by
conventional measurement of pipe to soil potentials at
designated test locations installed on the pipeline routes. Pipe
to soil potential data collected during the routine surveys are
compared with relevant international standards to determine
conformance or otherwise with the criteria recommended.
Other data, such as open circuit anode potentials, anode output
current, etc., are also measured and recorded during the
routine surveys.
Upon review of the survey data collected during the 2003
routine annual survey it was noted that a number of
magnesium anodes appeared to have failed within only 4-5
years of installation. Of these failed anodes, in the case of one
recently installed pipeline, some of the anodes had never been
connected to the pipeline at the time the CP system was
commissioned and yet the survey data indicated failure of the
anodes.
A decision was made to investigate the apparent premature
failure of these anodes and to establish an appropriate strategy
for improving the longevity of the pipelines CP systems.
DESCRIPTION OF PIPELINES SYSTEM
The buried pipeline network consists of approx 70km of
pipelines of various diameters ranging from 6 (150mm) to
18 (450mm). The coating systems employed as the primary
corrosion protection system include coal tar epoxy, 3-layer
Polyethylene (PE) and fusion bonded epoxy (FBE) systems.
All pipes installed since the early 1990s are coated with FBE.
The pipeline network is summarised in Table 1.

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SPE 93795

PRINCIPLE OF CATHODIC PROTECTION

Cathodic protection (CP) is a technique which has been used
for many years to render metal structures, such as steel ships
and pipelines, immune from electrolytic corrosion by making
the structure the cathode in an electrochemical cell, either by
applying an electromotive force (e.m.f.) directly (in the case of
impressed current CP systems), or by putting it into contact
with a more electropositive metal (in the case of galvanic CP
systems). In pipeline applications, a small electric (d.c.)
current is applied to the surface of the pipeline to be protected
by means of an anode groundbed(s) connected to a
transformer-rectifier(s) or by means of galvanic anodes. The
structure adopts a more negative (cathodic) potential with
respect to its environment.
In the case of pipelines, CP is normally used in conjunction
with an external coating system applied to the pipeline and
which acts as both the primary defence against corrosion and
reduces the surface area of the pipeline which is exposed to
the surrounding electrolyte (soil, water) and thus reduces the
current required to cathodically protect the pipeline.
Three pipeline sections within the distribution network have
impressed current cathodic protection (ICCP) systems
installed. These utilise magnetite anode groundbeds and
conventional transformer-rectifier units as the external d.c.
power supply for the anode beds. The remaining pipelines are
protected via galvanic CP systems which utilise sacrificial
anodes of magnesium or zinc. The operation of a galvanic
anode system is based upon the natural potential difference
that exists between the steel (cathode) and the sacrificial
anode. The anode and cathode must be in a continuous
electrolyte (soil/water). As a result of the potential difference
electric current (d.c.) flows from the anode (which is
sacrificed) through the soil/water to the steel.
Specifications for galvanic anode cathodic protection systems
often call for a system design life of 20 years to be achieved
by the design. It may indeed be shown by theoretical design
calculations that a sufficient mass of anode can be provided to
realise any given design life requirement, based upon the
electrochemical characteristics of the anode material chosen,
current requirements, likely current output from the anodes,
etc. However experienced CP practitioners have long been
aware that in practice the performance of land-based galvanic
anode installations is much more difficult to predict
accurately. In many cases, land-based galvanic CP systems are
known to fail within 5-10 years from commissioning. Some
operators allow the use of galvanic anodes on pipelines to
provide temporary protection only, pending the installation
and commissioning of permanent ICCP systems.
BAPCO CP SYSTEMS MAINTENANCE
Galvanic Cathodic Protection Systems. As part of the
routine maintenance activities which are carried out on the
BAPCO pipelines, galvanic anodes which become

depleted/consumed are replaced on an as required basis. The

need for replacement is determined by analysis of the routine
survey results, in particular the anode open circuit potentials
and current outputs. As stated in the Introduction, on review of
the 2003 routine survey data it was noted that a number of
magnesium anodes which had been replaced as part of routine
maintenance had failed within 4-5 years of replacement. This
had occurred on a number of pipelines throughout the
distribution network. It was therefore decided that this should
be investigated further.
Hidd to ISPAT Pipeline. The pipeline which was chosen for
the initial investigation into the early anode failures, and
which is the subject of this paper, is the 10/250mm diameter
L465 pipeline from Hidd Metering Station (HMS) to ISPAT.
This pipeline was constructed but has not yet been
commissioned; it is not interconnected with any other piping
system or above ground structures and is thus effectively
isolated from all other structures.
During the period 1997 1999 the expansion of the
distribution network included the installation of the 10
pipeline from Hidd Metering Station to ISPAT. The line is
installed in an area of reclaimed land and is essentially above
sea level, although it is close to the sea shoreline. The fill
material used for reclamation purposes was dredged from the
sea bottom. The pipe material is API 5L Gr, B coated and the
pipeline has a factory applied fusion bonded epoxy (FBE)
coating, with heat shrink sleeves applied at field weld joints.
The coating was 100% holiday tested prior to backfilling.
Backfilling specification required a sand cushion of 150mm
surrounding the pipe.
Cathodic Protection System Design. The CP system design
was carried by a reputable consulting engineering company in
accordance with the recommendations (as stated in the Design
Document) of the following referenced standards:

BS 7361, Part 1: 1991 (1)

DNV RP-B401: 1993 (2)
NACE RP0169-92 (3)
Shell DEP 30.10.73.31-GEN (4)

Cathodic Protection System Design Data Summary. The

documented design present in BAPCO files gave the
following data:
Design Life:
Pipeline surface area:
Current Requirement:

30 years
1931m2
0.30172A
(equivalent to 0.1562mAm-2 for
FBE coated pipe)
Number of anodes required for protection:
14
Weight of anode material required for design life:
96.55kg
Number of anodes required for design life:
5
Average resistivity along pipeline route:
29.02
Ohm.m
Anode utilisation factor:
0.75

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SPE 93795

The CP System design calculations used were industry

standard calculations; e.g. modified Dwight formula for anode
resistance, standard current and anode weight requirement
calculations, etc. (It should be noted however that none of the
above referenced internationally accepted standards or
standard calculations make any reference to a factor for self
corrosion of the anode material.) On reviewing the
calculations we find that the number of anodes required for
protection is significantly less than 14 so we assume an
additional safety factor was applied.
The final CP system design adopted called for the installation
of 14 x 21.8 kg pre-packaged high potential (-1.7 Volt vs.
Copper/Copper Sulphate reference electrode (CSE))
Magnesium anodes, located at equal spacing along the
pipeline length.
Cathodic Protection System Installation. Installation of the
anodes was carried out as per the design and installation
specification. In summary the anodes were installed in a
vertical configuration, with the top of the anode below pipe
invert level. Anode lead wires and anode connection/pipe test
leads were routed to finished grade level and terminated in
surface test facilities in the normal manner.
On commissioning of the pipeline CP system it was found that
the pipeline achieved satisfactory levels of protection
following initial polarisation, with only 4 of the 14 installed
anodes connected to the pipeline. The remaining 10 anodes
were left disconnected.
Review of a post-commissioning Close Interval Potential
Survey (CIPS) report, which was carried out in October 2000
showed a potential profile along the pipeline route with On
potentials in the order of -1.15 Volts and Instant Off
potentials around -0.95 Volts. No mention is made of how the
Instant OFF potentials were achieved but it is assumed that
simultaneous interruption of the anode connection cables was
adopted.
Cathodic Protection System Survey Data. The survey data
in Table 2 shows that, from 2001 onwards, three out of the
four connected anodes appear to be acting as a current pick-up
point from another d.c. source, such as an adjacent CP system.
Thus the pipe Instant OFF potentials are more negative than
the ON potentials, the measured anode current is negative
(reversed) and the anode open circuit potential is insufficiently
negative, since the anodes are acting as cathodes.
It also means that the initial satisfactory potentials could be
entirely due to this third party current pick up, which would
explain why there was only a need to connect 4 out of 14
anodes at the time of commissioning. This cathodic effect
extended the anode life. However, by 2004 anodes had been
consumed so were no longer acting as current pick up points.
The survey data also shows that, as early as 2001, the
potentials observed at all test stations had begun to decay from

their post-commissioning 2000 levels. The current output from

the magnesium anodes was minimal, with only anode no. 12
passing any measurable current at 6.44 milliAmps. It should
also be noted that at anode nos. 3, 6 and 9, the anode current
values are negative, indicating a flow of current from the pipe
to the anode. The pipe to soil potentials at these locations also
show the pipeline becoming more negative as the anode is
disconnected, whereas the reverse would normally be the case.
By 2003 the pipeline potentials had deteriorated to the point
where
they
were
all
in
the
range
-600 to -630 mV with respect to CSE; i.e. effectively natural
potentials. It is particularly noteworthy that the open circuit
anode potentials, with one exception (Anode No. 14) had also
decayed to almost natural carbon steel values.
In summary therefore, the output from the installed
magnesium anodes had begun to deteriorate within 1-2 years
from commissioning date, and the anodes appeared to be
completely depleted within 4 years of commissioning. Thus a
decision was made to investigate this in greater detail during
the 2004 routine maintenance programme.
SITE INVESTIGATIONS
Following the routine survey in September 2004 three anode
locations were selected for excavation to allow visual
inspection of the installed anodes. It was decided to excavate
two anodes which had never been connected to the pipeline
since installation, (anode nos. 2 and 11), and one anode which
had been connected since commissioning (anode no. 3).
Pre-Excavation Tests. Soil resistivity measurements were
carried out at each anode location, using the Wenner 4-pin
method. The resistivity test results are tabulated below in
Table 3 and were found to be broadly in line with the predesign resistivity data.
Prior to excavation, potential and current measurements were
taken from each anode and found to be in line with the results
obtained during the routine survey as tabulated in Table 2
(2004 results). As it was not known whether the anodes had
actually been consumed, or had perhaps passivated, it was
decided to impress a temporary external current source
between the anode and pipe leads. A 12 Volt battery was
connected between the anode and pipe leads, with the positive
battery terminal connected to the anode lead and the negative
terminal connected to the pipeline lead. The energised pipe
potential showed an immediate increase to between -2.65 to 4.07 Volts with respect to CSE.
The battery was disconnected after 5 minutes and the pipe
potential was observed to decay rapidly back to its pre-test
level, with anode output current also reverting to zero. The test
was not conclusive but at least demonstrated that the
temporary connection of an external d.c. power source had had
no effect in terms of restoring anode operation, and therefore
the reduction in anode output was not due to the presence of a

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SPE 93795

coherent film of corrosion products. The anodes were then

excavated by hand, carefully tracing the anode and test leads
and exposing the anodes. The anodes were found to be
correctly installed in a vertical orientation below pipe invert
level. (Figure 1)

Figure 1 Anode No. 2 In-Situ Below Pipe

The hardened backfill material was then carefully broken

away from the anode in order to expose the anode itself, again
taking care not to disturb the anode cable connection and
encapsulation. The backfill material broke away easily and
cleanly, revealing that the only potion of the anode remaining
was the mild steel (MS) core of the anode. The anode lead
connection and encapsulation was found to be intact. (Figure
3)

Figure 3 Anode No. 2 Completely Consumed

The cotton sack containing the Gypsum, Bentonite and

Sodium Sulphate backfill material was found to be partially
intact and the backfill material remained in place around the
anodes when they were removed from the excavation. (Figure
2)

Figure 2 Anode No. 2 Removed From

Excavation

This process was repeated for all three anodes under

investigation, with identical results, the only difference being
the state of consumption of the mild steel anode core, which in
the case of anode no. 2 (Figure 3) was intact and only showing
slight rusting, whereas in the case of anode nos. 3 and 11 the
MS anode cores were more severely corroded. (Figure 4 & 5)

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SPE 93795

Figure 4 Anode No. 3 Completely Consumed

have been in an advanced state of depletion within 1-2 years

of installation, and had certainly been completely consumed
within 4 years of installation. Bearing in mind that there were
only 5 anodes required by the design to obtain a 30 year life
and 14 were installed then in theory a life expectancy of 84
years should have been obtained.
The open circuit anode potential recorded at anode no. 14
remains at some -1530 mV vs. CSE, which is anomalous to
the remainder of the results and suggests that this anode may
not have suffered the same degree of consumption as the
remaining anodes. However, even if the anode is 90+%
consumed, i.e. if a small amount of magnesium alloy remains,
the observed potential would still be that of magnesium. Thus
the only conclusion which can reliably be drawn from the
anode potential at anode no. 14 is that some anode material
remains, i.e. the degree of consumption of the anode is
between 0% and 99%. At the time of writing, it has not been
possible to excavate anode no. 14 to determine its condition,
although it is felt that this would be a useful exercise.

Figure 5 Anode No. 11 Completely Consumed

The most striking observation is that, even when the anodes

were not connected to the pipelines at any time during the
operational period, the anodes were nevertheless consumed
within in the same timescale as those which had been
connected. As a completely isolated entity placed in the
ground, not in contact with any other metallic structure, the
non-connected anodes should have in effect remained inert
this has obviously not been the case. This leads to the
conclusion that consumption of the anodes has occurred in
large part due to self-corrosion of the magnesium alloy.
The galvanic cathodic protection system has therefore failed
after achieving only 5-10% at most of its intended design life,
despite the design being carried out with all due diligence and
best practice in accordance with internationally accepted
recommendations and including a significant safety factor.
Whilst the average soil resistivity along the pipeline route may
be classified as corrosive(1), such resistivities are certainly
common throughout the eastern GCC region, especially in
coastal areas, and the system design allowed for this low
resistivity value in determining the mass of anode material
required to achieve the required design life.

DISCUSSION
The survey results, taken together with the site investigations
outlined above suggest that, of the 14 high potential
magnesium anodes which were installed on the HMS to
ISPAT pipeline, 13 anodes (93%) have been completely
consumed. The survey results suggest that the anodes may

Whilst the investigations outlined in this paper are limited to a

single pipeline installation, similar conclusions may be at least
tentatively drawn from the deterioration of anodes which has
been observed on other BAPCO pipelines with magnesium
anodes installed. The nature of the BAPCO pipeline network,
with many distributed pipelines of relatively short lengths,
makes the installation of galvanic anode systems an attractive
one, due to their inherent simplicity and low initial installation
cost. However, this option may be shown to be less attractive
in terms of life cycle cost if there is a repeated need to replace
anodes every 2-3 years. It is proposed that further
investigations on other BAPCO pipeline routes will be carried
out to determine if similar effects have occurred in these areas

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SPE 93795

also. The outcome of these investigations will then be used to

determine a more appropriate strategy for providing cathodic
protection to the pipeline network, for example by providing
an integrated impressed current cathodic protection scheme.

REFERENCES
1.
2.
3.

CONCLUSIONS

4.
In conclusion, these findings can be seen to have important
implications for the future design of cathodic protection
systems where galvanic systems are being considered for
long-term onshore pipeline protection.
The standards presently available for CP system design do not
provide any reference or factor to be applied to allow for selfcorrosion of the anode material. The results of the
investigations described in this paper indicate that accelerated
consumption of magnesium anode material has occurred due
to self-corrosion effects. This in turn has resulted in premature
failure of a complete galvanic cathodic protection system
within 3 years of its installation.
It is reasonable to suggest therefore that galvanic CP systems
should only be considered for short term protection of
pipelines (circa 2 years maximum); at least under the
conditions outlined in this investigation, until or unless a
reliable prediction of anode self-corrosion effects can be
incorporated into the design process.
It is noted that these investigations have only considered the
performance of magnesium anodes and that some operators,
including BAPCO, use Aluminium-Indium activated Zinc
anodes for onshore pipeline CP. It has been observed by the
author however that zinc anodes have been prone to
passivation effects in some circumstances. This is a
contrasting phenomenon to that of self-corrosion of the anode,
where the anode material suffers from a build up of adherent
corrosion product on the surface of the anode such that it
effectively switches off and stops passing current. The
development and use of activated alloys is intended to
ensure that passivation, i.e. switching off, does not occur. It is
therefore reasonable to assume that this self same process will
enhance self corrosion and lead to reduced life of the anodes.
However, this also requires further investigation and is outside
the scope of this discussion.
ACKNOWLEDGEMENTS
The authors gratefully acknowledge the permission and
assistance provided by the Bahrain Petroleum Company
B.S.C. (Closed) during the site investigations and preparation
of this technical paper.
The authors gratefully thank Dr Kevin Kendell, BSc, PhD, for
his contribution in carrying out the technical review of this
paper.

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BS 7361, Part 1: 1991; Cathodic Protection, Code of

Practice for Land and Marine Applications
DNV RP-B401: 1993; Recommended Practice Cathodic
Protection Design
NACE RP0169-92; Control of External Corrosion on
Underground or Submerged Metallic Piping Systems.
Shell DEP 30.10.73.31-GEN; Design of Cathodic
Protection Systems for Onshore Buried Pipelines.

SPE 93795

Table 1
BAPCO GAS DISTRIBUTION PIPELINE NETWORK
Line
No.
L 253
L255
L 257

From Node

To Node

Dia.

Length

(in.)

Ft/m

L 270

Al-Dar Valve Station

18 x2

18280/
5571

FBE

Impressed current

GPIC Valve Station

Al-Dar Valve Station

16 x 2

3720/
1133

FBE

Magnesium anodes

Alba Distribution Manifold

South Alba Distribution Point

8740/
2663

FBE

Magnesium anodes

Riffa Distribution Manifold

GPIC Valve Station

16 x 2

14860/
4529

FBE

Magnesium anodes

Sitra West Valve Station

Balexco Metering station

16 x 2

15220/
4639

FBE

Magnesium anodes

Sitra West Valve Station

New Metering Station

12

14670/
4471

Coal tar
Epoxy

Magnesium anodes

Sitra West Valve Station

New Metering Station

12

14320/
4364

Coal tar
Epoxy

Magnesium anodes

N 70

N 75

2230/
679

Coal tar
Epoxy

Zinc/Magnesium
anodes

N 75

Juffair Power Station

8x2

50/15

Coal tar
Epoxy

Impressed current

South Alba Distribution Point

OKB

4190/
1277

Wharf Valve Station

Hidd Metering Station

18 x 3

19300/
5882

3-layer PE

Magnesium anodes

GPIC Valve Station

Sitra West Valve Station

16 x 2

10170/
3099

FBE

Magnesium anodes

Hidd Metering Station

Hidd Power Station

18

9500/
2895

FBE

Magnesium anodes

Hidd Metering Station

Hidd Steel Plant (ISPAT)

10

5900/
1798

FBE

Magnesium anodes

Al-Dar Valve Station

Wharf Valve Station

18 x 3

12155/
3704

FBE

Magnesium anodes

L275
L 315
L316
L 365
L 375
L 380
L385
L 395
L396
L 397

Cathodic Protection
System

Alba Distribution Manifold

L258
L 267

Coating
System

Magnesium anodes

L 400
L401
L402
L 455
L456
L 460
L462
L 465
L 500
L501
L502

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SPE 93795

Table 2
10 HMS TO ISPAT CP SURVEY RESULTS, 2001-2004
2001
T.P./

Pipe Anode Open

Pipe On
Off cct Potential
Anode
(mV)
(mV)
(mV)
No.

2003
Anode
Current
(mA)

Pipe
Pipe On
Off
(mV)
(mV)

2004

Anode
Open cct
Potential
(mV)

Anode
Current
(mA)

Pipe
On
(mV)

Pipe
Off
(mV)

Anode
Open cct
Potential
(mV)

-975

-602

-662

-660

-683

-978

-603

-663

-674

-684

-985

-1003

-1005

-1006

-1009

-624

-691

-655

-686

-1009

-627

-683

-663

-682

-1012

10

-1027

-615

-252

-660

-788

11

-1029

-614

-630

-658

-739

12

-1078

13

-1024

-615

-651

-669

-802

14

-1061

-628

-1526

-675

-1531

-993

-944

-0.84

-604

-590

-625

-1030

-1021

-982

-978

-1647

-0.4

-1.29

6.44

-620

-618

-617

-1.2

-313

-620
-1009

-631

-617

-617

-690

-686

-618

-668

-666

-675
-622

-668

-1.6

-652

-660

-624

-635

-681
-646

-661

-658

-695

-725

-675

Table 3
SITE SOIL RESISTIVITY DATA AT ANODE LOCATIONS

Anode No.
2

Average at depth

Depth
1.0 m
1.5 m (Invert)
2.0 m
3.0 m
1.0 m
1.5 m (Invert)
2.0 m
3.0 m
1.0 m
1.5 m (Invert)
2.0 m
3.0 m
1.0 m
1.5 m (Invert)
2.0 m
3.0 m

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-353

-666
-1.5

Anode
Current
(mA)

Resistivity (Ohm m)
21.68
17.62
18.22
8.28
5.65
7.07
8.17
5.47
41.85
31.01
18.35
11.12
23.06
18.57
14.91
8.29