OML 58 Upgrade Phase 1/OUR Gas Pipeline

Document number:

PERMANENT CATHODIC PROTECTION DESIGN

NG22-180-CAT-ZBJ-000017

Revision: 01
Status:
IFC
Approval Class: 2

Document Type :
REP
System / subsystem:
Discipline :CAT
Date :
25-Sept-2012

Page 1 of 9

PERMANENT CATHODIC PROTECTION DESIGN

Rev.
Status
Rev. Date
Revision Memo
Issued by
Checked by
Approved by
C0
IFR
01-Nov-2011
Issued for Review
K. Okanigbe
C. Harburn
G. Okeke

D0
IFA
02-Dec-2011
Issued for Approval
K. Okanigbe
C. Harburn
G. Okeke

00
IFC
30-Jan-2012
Issued for Construction
K. Okanigbe
C. Harburn
E. Okoronkwo

01
IFC
30-Sept-2012
Issued for Construction
M. Nnadi
D. Nnanna
E. Okoronkwo

This document has been generated by an Electronic Document System. When printed it is considered as for information only copy. The
controlled copy is the screen version and it is the holders responsibility that he/she holds the latest version.

This document is the property of TEPNG. It must not be reproduced or transmitted to others without written authorization from the company

NG22-180-CAT-ZBJ-000017

OML 58 Upgrade Phase 1/OUR Gas Pipeline

Document number:

PERMANENT CATHODIC PROTECTION DESIGN

NG22-180-CAT-ZBJ-000017

Revision: 01
Status:
IFC
Approval Class: 2

Document Type :
REP
System / subsystem:
Discipline :CAT
Date :
25-Sept-2012

Page 2 of 9

TABLE OF CONTENTS

1.0 INTRODUCTION

1.1

PROJECT OVERVIEW3

1.2

PURPOSE

2.0 REFERENCE DOCUMENTS4

2.1 TOTAL GENERAL SPECIFICATIONS

2.2

NLNG SPECIFICATIONS

2.3

INTERNATIONAL CODES AND STANDARDS.

3.0 ABBREVIATIONS & DEFINITIONS

4.0 CORROSION PROTECTION PHILOSOPHY OVERVIEW

5.0 CURRENT DENSITIES REQUIREMENTS7

6.0 CURRENT CALCULATIONS

7.0 CURRENT DEMAND 9

This document is the property of TEPNG. It must not be reproduced or transmitted to others without written authorization from the company

NG22-180-CAT-ZBJ-000017

OML 58 Upgrade Phase 1/OUR Gas Pipeline

Document number:

PERMANENT CATHODIC PROTECTION DESIGN

NG22-180-CAT-ZBJ-000017

Revision: 01
Status:
IFC
Approval Class: 2

Document Type :
REP
System / subsystem:
Discipline :CAT
Date :
25-Sept-2012

Page 3 of 9

INTRODUCTION
TEPNG intends to increase gas transportation capacity from OBITE TC to BONNY in line with the
development of the gas production facility to meet gas requirement for existing and planned future
NLNG trains. There is presently a project underway which shall increase the gas export capacity. This
project entails the construction of a 42 by 45 Km pipeline to transport this gas from Obite TC to Rumuji.
Project Overview
The OUR Gas Pipeline Project will export increased gas to NLNG. The second phase (RumujiBonny
pipeline segment) will be developed in accordance with future NLNG Plant extension program.
During this first phase, the new 42 Obite TCUbetaRumuji gas pipeline will be connected to the
NAOC GTS4 36 gas pipeline manifold at the Rumuji Node. At the Rumuji Node, a 20 SPDC pipeline
branch connection shall be provided on the 36 NLNG GTS1 pipeline manifold and blinded-off. This
connection shall enable SPDC connect to the GTS1 pipeline in future. At Ubeta a 24 x 28 hot tap tie-in
to GTS1 shall be provided, including another 42 connection for future tie-in to GTS6.

The new TEPNG 42 OUR gas pipeline shall be installed parallel to the existing gas pipelines from
Obite-Rumuji (GTS1) in a new ROW adjacent to the existing ROW.
The scope of work for the O.U.R. Gas Pipeline project includes but it is not limited to the provision of
Pig Launcher at Obite TC, Pig Receiver at Rumuji and related piping, valves and fitting connections to
GTS1 and GTS4 at the various Nodes. The work also includes associated instrumentation, electrical,
telecommunications, cathodic and corrosion protection facilities, associated civil/structural work, LSDS,
FOC
Purpose
The purpose of this document is to calculate the current demand required for the permanent cathodic
protection of the 42 OUR Pipeline.

This document is the property of TEPNG. It must not be reproduced or transmitted to others without written authorization from the company

NG22-180-CAT-ZBJ-000017

OML 58 Upgrade Phase 1/OUR Gas Pipeline

Document number:

PERMANENT CATHODIC PROTECTION DESIGN

NG22-180-CAT-ZBJ-000017

Revision: 01
Status:
IFC
Approval Class: 2

Document Type :
REP
System / subsystem:
Discipline :CAT
Date :
25-Sept-2012

Page 4 of 9

REFERENCE DOCUMENTS
The design of the Cathodic Protection System for the OML 58 O.U.R. pipeline shall complywith the
prevailing legislation application with the planning, design, construction, testing, commissioning and
operation of CP system in the Federal Republic of Nigeria.
In all cases the latest edition of the relevant Regulations, codes, Guidelines, Standards
and Specifications shall be used unless specifically indicated within this document. Refer to NLNG and
TOTAL Gap Analysis Report, NG-22-84-SOF-COR-REP-002001
TOTAL General Specifications
GS EP COR 111
External cathodic protection of onshore facilities

GS EP COR 110
External cathodic protection of buried pipelines
GS EP COR 210
Monolithic insulating joints
GS EP COR 220
Three layer polyethylene external coating for pipelines
GS EP COR 420
External field joint coatings of pipelines

2.2

NLNG Specifications

DEP 30.10.73.31
Design of cathodic protection systems for onshore buried pipelines
DEP 30.10.73.10
Manual Cathodic Protection

This document is the property of TEPNG. It must not be reproduced or transmitted to others without written authorization from the company

NG22-180-CAT-ZBJ-000017

OML 58 Upgrade Phase 1/OUR Gas Pipeline

Document number:

PERMANENT CATHODIC PROTECTION DESIGN

NG22-180-CAT-ZBJ-000017

Revision: 01
Status:
IFC
Approval Class: 2

Document Type :
REP
System / subsystem:
Discipline :CAT
Date :
25-Sept-2012

Page 5 of 9

2.3 International Codes and Standards.

ISO 15589 1
Petroleum and Natural Gas Industries - Cathodic Protection of
Pipeline Transportation Systems Part 1 On Land Pipelines

BS EN 12954
Cathodic Protection of Buried or Immersed Metallic Structures
General Principles and Applications for Pipelines

NACE RP 0169
Corrosion on Underground or Submerged Metallic Piping Systems

NACE RP 0286
Electrical Isolation of Cathodically Protected Pipelines

ASTM G 57-95
Standard Method for Field Measurements of Soil Resistivity using
the Wenner Four-Electrode Method

3.0

ABBREVIATIONS& DEFINITIONS

3LPE 3 Layer Polyethylene

A

Ampere

AC

Alternating Current

Ag / AgCl Silver / Silver Chloride

CP

Cathodic Protection

CPY

Total Exploration & Production Company Nigeria Limited (TEPNG)

CRA Corrosion Resistant Alloys

Cu/CuSO4

Copper / Copper Sulphate

DC

Direct Current

DEP

Design and Engineering Practices (Version 18, owned by Shell)

DFT

Dry Film Thickness

Eoa (V)

Design Protective Potential

FBE

Fusion Bonded Epoxy

fc

Coating Breakdown factor

GS

General Specifications (Version 2005)

HMWPE

High Molecular Weight Polyethylene

ICCP Impressed Current Cathodic Protection

ID

Internal Diameter

Km

Kilometer

mA

Milli-ampere

MLPP Multi-Layer Polypropylene

mV

Milli-volt(s)

NAOC Nigerian Agip Company

NLNG Nigerian Liquefied Natural Gas Company
This document is the property of TEPNG. It must not be reproduced or transmitted to others without written authorization from the company

NG22-180-CAT-ZBJ-000017

OML 58 Upgrade Phase 1/OUR Gas Pipeline

Document number:

PERMANENT CATHODIC PROTECTION DESIGN

NG22-180-CAT-ZBJ-000017

Revision: 01
Status:
IFC
Approval Class: 2

Document Type :
REP
System / subsystem:
Discipline :CAT
Date :
25-Sept-2012

Page 6 of 9

NNPC Nigerian National Petroleum Corporation

OML Oil Mining Lease
OUR ObiteUbetaRumuji
PVC

Poly Vinyl Chloride

Ref

Reference

ROW Right of Way

SACP Sacrificial Anode Cathodic Protection
SPDC Shell Petroleum Development Company
SRB

Sulphate Reducing Bacteria

SWA Steel Wire Armoured

ZBJ

ZB Joint Venture Limited

Volt(s)

Ohm(s)

(ohm.m) Soil Resistivity

XLPE Cross Linked Polyethylene
WORKS: Review and endorsement of the FEED documents, detailed engineering design and preparation
of all documents necessary for procurement, including as-built after installation.
PIPELINE: Refers to the OUR Pipeline.
OUR: Obite Ubeta Rumuji.

This document is the property of TEPNG. It must not be reproduced or transmitted to others without written authorization from the company

NG22-180-CAT-ZBJ-000017

OML 58 Upgrade Phase 1/OUR Gas Pipeline

Document number:

PERMANENT CATHODIC PROTECTION DESIGN

NG22-180-CAT-ZBJ-000017

Revision: 01
Status:
IFC
Approval Class: 2

Document Type :
REP
System / subsystem:
Discipline :CAT
Date :
25-Sept-2012

Page 7 of 9

CORROSION PROTECTION PHILOSOPHY OVERVIEW

As the primary (passive) protection against external corrosion, the buried steel pipe line in the O.U.R.
Gas pipeline project will be coated with a high quality coating before installation. The coating will be 3
layer polyethylene in accordance with Project specifications GS COR 200 and GS COR 420 and epoxy
on field joint coatings.
CURRENT DENSITIES REQUIREMENTS
The current densities listed in the table below are used for the calculations (as per GS EP COR 110).

Current density (mA/m)

Final (design life / year)

Coating system
Initial

10
20
30

years
years
years
Coal-tar, bitumen enamel, cold applied
0.2
0.4
0.6
0.8
tape

Fusion bonded epoxy

0.05
0.2
0.5
0.7

Three-layer PE or PP
0.02
0.05
0.1
0.3

The design life for permanent cathodic protection is 25 years for Permanent Cathodic Protection system.
The current densities used for calculations are:
0.2 mA/m for 3LPE coating;
0.6mA/m for epoxy coating.

This document is the property of TEPNG. It must not be reproduced or transmitted to others without written authorization from the company

NG22-180-CAT-ZBJ-000017

OML 58 Upgrade Phase 1/OUR Gas Pipeline

Document number:

PERMANENT CATHODIC PROTECTION DESIGN

NG22-180-CAT-ZBJ-000017

Revision: 01
Status:
IFC
Approval Class: 2

Document Type :
REP
System / subsystem:
Discipline :CAT
Date :
25-Sept-2012

Page 8 of 9

6.0
CURRENT CALCULATIONS
Current calculations are presented in the table below:

Input Data :

Diameter of Pipeline (m) :

1.067

Length of Pipeline (km) :

45.500
Design Life (year) :
25

Coating :
3LPE
Final Current Density (as per GS EP COR 110 - mA/m) :
0.2

Field Joint Coating :

EPOXY
Final Current Density (as per GS EP COR 110 - mA/m) :
0.6

Approximate length of pipe (m) :

12
Approximate number of welds (m) :
3792
Approximate length of Field Joint Coating (m) :
0.80
TR Location (KP) / UBETA
12.500
TR Location (KP) / RUMUJI
45.500
Safety Margin for TR Sizing (%) :
25

Calculations :

Total Pipeline Surface (m) :

152520
Pipeline Surface with 3LPE coating :

142352
Pipeline Surface with EPOXY coating (Field Joint Coating) :
10168
Protection Current Demand (A) :
34,57
Protection Current Demand for Section 1 (KP 0,000 to KP 29) / (A) :
22,03
Protection Current Demand for Section 1 (KP 29 to KP 45,5) / (A) :
12,54
TR Sizing with safety margin / UBETA / (A) :
27.54
TR Sizing with safety margin / RUMUJI / (A) :
15.67

This document is the property of TEPNG. It must not be reproduced or transmitted to others without written authorization from the company

NG22-180-CAT-ZBJ-000017

OML 58 Upgrade Phase 1/OUR Gas Pipeline

Document number:

PERMANENT CATHODIC PROTECTION DESIGN

NG22-180-CAT-ZBJ-000017

Revision: 01
Status:
IFC
Approval Class: 2

Document Type :
REP
System / subsystem:
Discipline :CAT
Date :
25-Sept-2012

Page 9 of 9

The surface of the pipeline is calculated using the formula below:

S=PxdxL
Where:
d = diameter of the pipeline (m);
L = length of the pipeline (m) - length with 3LPE or epoxy coating.
The total current (I) requirement is calculated using the formula below:
I = I3LPE + IEPOXY
Where:

I3LPE = current density (for 3LPE) x surface (coated with 3LPE);

IEPOXY = current density (for EPOXY) x surface (coated with EPOXY).
Note: a safety margin of 25 % is used for the sizing of the TR.
7.0

CURRENT DEMAND

The total current demand to protect the 42 OUR Pipeline against corrosion is 34.57 amperes.
The first Transformer Rectifier (located at UBETA Node) has to be designed to provide 22.03 amperes.
The Transformer Rectifier rating is : 50 V / 30 A.
The second Transformer Rectifier (located at RUMUJI Node) has to be designed to provide 12.54
amperes. The Transformer Rectifier rating is : 50 V / 20 A.

End of Document

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NG22-180-CAT-ZBJ-000017