CALCULATION PT.

WIJAYA KARYA (Persero) Tbk

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PROTECTION Page Number
PRPP-10-CS-CP-0001 SYSTEM FOR 1 dari 10
PIPELINE

PROJECT END USER : PT. PERTAMINA (PERSERO)

PROJECT OWNER : PT. KERETA CEPAT INDONESIA CHINA

COMPANY : HIGH SPEED RAILWAY CONTRACTOR

CONSORTIUM PT. WIJAYA KARYA (Persero) Tbk –
DEPARTEMEN SIPIL UMUM 1

CONTRACTOR : PT. WIJAYA KARYA (Persero) Tbk –

DEPARTEMEN INDUSTRIAL PLANT

PROJECT : RELOCATION FUEL OIL PIPELINE PERTAMINA

DK 117-128 & DK 135-138

LOCATION : TOL PURBALEUNYI, BANDUNG, JAWA BARAT

CONTRACT NUMBER : TP.02.01/HSRCC.WIKA.P/96/X/2018

1/HSRCC.WIKA.P/96/X/2018

0 09/09/201
2019 IFA BGS RA GPS
Made By Reviewed By Approved By
REV. DATE DESC
PT WIJAYA KARYA
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REVISION HISTORICAL SHEET

Rev No Date Detail Description

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Table of Contents

1. INTRODUCTION ................................................................
......................................................................................4
2. STANDARD ..............................................................................................
................................ ..............................4
3. SCOPE OF WORKS ................................................................
...................................................4
4. SUMMARY ...............................................................................................
................................ ...............................4
5. DESIGN AND CALCULATION
CALCULATI FOR THE SACP SYSTEM ..............................5
5.1 SURFACE AREA CALCULATION ................................................................
................................... 6
5.2 CURRENT DEMAND ................................................................
......................................................... 7
5.3 ANODE QUANTITY BASED ON TOTAL WEIGHT REQUIREMENT.......... 7
5.4 ANODE QUANTITY BASED ON CURRENT REQUIREMENT ..................... 7
5.5 ANODE QUANTITY CHOSEN ................................................................
.......................................... 9
6 BILL OF MATERIAL FOR THE SACP SYSTEM ............................................
................................ 9
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1. INTRODUCTION
PT. Gesit Nazelo Protection (GESIT) has been awarded by PT. Wijaya Karya (Persero) Tbk. to
provide Cathodic Protection
rotection System for the underground pipeline located in Bandung area, West
Java, Relocation of Fuel oil Pipeline Pertamina DK 117 38 projects which is owned by
117-128 and DK 135-138
PT. Pertamina (Persero).

This document covers The Design Engineering of the Cathodic Protection System by using
Sacrificial Anode Cathodic Protection (SACP) system method. This system is used to protect the
underground pipeline
ne from the corrosion attack.

2. STANDARD
This proposal is made by referring the following standard:
BS 7361: Part 1 Code of Practice for Land and Marine Applications
NACE RP-0169-07 Control of External Corrosion on Underground or Submerged Metallic
Piping System
NACE RP-0502-08 Pipeline External Corrosion Direct Assessment Methodology
ISO 155891:2015 Petroleum, Petrochemical and Natural Gas Industries –
Cathodic Protection of Pipelines System

3. SCOPE OF WORKS
The scope of work of this project is as follows:

Site Survey

Design Engineering

Materials Supply

Installation

Testing and Commissioning

4. SUMMARY
There are 12”” OD pipelines
pipeline in separated location (DK 117-128, Section A and DK 135
135-138, Section B),
made of carbon steel and to be buried into soil therefore will suffer corrosion. The buried pipeline
will use 3LPE (3 Layer Poly Ethylene) coating as a barrier from its environment. Cathodic
Protection system is used to protect the carbon steel pipeline from corrosion especially on the
defect of the coating/barrier.
ating/barrier.

The prepackaged high potential magnesium anode is used for the SACP system. The net weight of
prepackaged anode: 14.5
14 kg and gross weight: 29.0 kg. Each ground bed consists of one anode
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and will be connected to the pipe directly. Total 33 (thirty three) pieces of prepackaged magnesium
anode needed for this system.

Test box is utilized for easy monitoring of this SACP system. Test box will be located at ground
level and installed at average space.
space

The entire aboveground and underground pipe should be isolated electrically at the flanges by
insulation gasket (supplied and installed by PT. Wijaya Karya (Persero) Tbk
Tbk. All cable connection to
the pipe willl use exothermic welding method and covered by Th
Thermocap.

5. DESIGN AND CALCULATION FOR THE SACP SYSTEM

The underground piping that will be protected by SACP refers to Requisition for Cathodic Protection
System:
Total
OD Pipe
No. Pipe Location Length Remark
(inch)
(meter)
1. DK 117-128
117 , Section A 12.75 11,4461 3 LPE Coated
2. DK 135-138
135 , Section B 12.75 2,272
72 3 LPE Coated

Design Parameter used as follows:

No. Parameter Value

1. Soil Resistivity in Toll Padaleunyi Area 30000 Ohm.cm
2. Design Lifetime 20 Years
3. Design Current Density (coated line) 0.125 mA/m2
4. Safety Factor 5 %
5. Utilization Factor 0.8
0.80

The propose anode for this SACP System is as follows:

− Anode materials : HIGH Potential Magnesium Anode
− Anode dimension : D-Shape, 140 W X 127 H X 521 L mm
− Anode cable tail : 2 m length, 1c X 6 mm2 XLPE/PVC
cable, stranded copper conductor.
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− Anode Net Weight : ~ 14.5 kg.

− Prepacked Dimension : 210mm dia. X 720mm mm length.
− Prepacked Weight : ~ 29.0 kg.
− Backfill Composition : 75% Gypsum,
20% Bentonite,
5% Sodium Sulphate.
Prepacked in Cotton bag.
− Closed Potential : ~ -1.50 volt vs. Cu/CuSO4 Ref. Cell.
− Anode Design Capacity : 1100 A.Hr/kg
− Anode Chemical Composition:

Elements (%)
Aluminium 0.01 max
Manganese 0.50 – 1.30
Silicon 0.05 Max
Cuprum 0.02 Max
Nickel 0.001 Max
Ferro 0.03 Max
Magnesium Remainder

5.1 SURFACE AREA CALCULATION

Surface area for the pipeline is calculated with the following formula:

S/A = π x OD x L (Formula 1)
where:
OD = Outside Diameter of Pipe, m
L = Length of Pipe, m
S/A = Surface Area, m²
π = 3.14

For the 12” OD underground pipeline DK117-DK128, Section A:

S/A = π x 0.324 x 11461
= 11,660.488 m2

Therefore the total surface area with 5% safety factor is becomes 12,243.50 m2.
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5.2 CURRENT DEMAND

The currents required to protect the pipess are calculated with formula below:

I = S/A x DCD (Formula 2)

where:
I = Current demand, A
S/A = Surface area, m²
DCD = Design Current Density on coated line, mA/m²

For the 12” OD underground pipeline Section A:

I = 12,243.500 x 0.125/1000
= 1.53 A

5.3 ANODE QUANTITY BASED ON TOTAL WEIGHT REQUIREMENT

Total weight rerquirement for design lifetime is calculated with the following formula:
8760 xIxt
WL = (Formula 3)
ACxU
Where:
WL = Total weight in lifetime.
I = Current requirement ((1.53 A).
t = Lifetime ((20 years)
AC = Anode capacity (1 (1100 Amp.Hr/kg)
U = Utility factor (0.
(0.80)

Total Weight of Mg Anode needed for the 12” OD underground pipeline Section A is 304.70 kg.
Therefore the quantity needed is 22 ea.

5.4 ANODE QUANTITY BASED ON CURRENT REQUIREMENT

This SACP
P system will use horizontal ground bed is given by formula:

ρ  4 L2 + 4 L S 2 + L2 S S 2 + L2 
RH = ln + − − 1 (Formula 4)
2πL  dS L L 

Where:
RH = Resistance,
Resistance single horizontal anode
ρ esistivity, soil, (3000 Ω.cm)
= Resistivity
L = Length,
Length ground bed (0.720 m)
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d = Diameter,
Diameter ground bed (0.210 m)
S = Twice depth (2x 2 m)

pipeline 11.33 Ω.
The resistance of single horizontal anode for the 12” OD underground pipeline:

The interference factor between group of anodes which is installed parallel horizontally in a
ground bed is calculated with the following formula:

 2L 
 ln (0.656 N ) 
f =1+  S 
(Formula 5)
  8L  
  ln − 1 
  D  
Where:
f = Interference factor
L = Length,
Length anode (0.720 m)
d = Diameter,
Diameter anode (0.210 m)
S = Space between anode (1.0 m)
N = Number of anode in ground bed (2 ea)

One ground bed is consist of 1 (one) anode, therefore the interference factor: 1.00
1.
The ground bed resistance is calculated with the following formula:

R H xf (Formula 6)
Rg =
N
Where:
Rg = Resistance, ground bed
f = Interference factor
N = Number of anode in ground bed
RH = Resistance of single anode

11 Ω.
The resistance of ground bed for the 12” OD underground pipeline: 11.33
Each prepackaged anode (ground bed) driving potential is: -0.850 - (-1.50)
( = 0.65 Volt. Ground
bed current output for the underground pipeline between = 0.65/11.33
33 = 0.06 ampere.
The quantity of anode needed:
I
N= (Formula 7)
Ia
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where:
N = Quantity
I = Current Demand, A
Ia = Ground bed Current Output, A

The quantity of ground bed for the underground pipeline is calculated by formula 7 (round up):
27 ground bed.. Total quantity of anode = 1 x 27 = 27 ea.

5.5 ANODE QUANTITY CHOSEN

The anode quantity chosen is that can cover both quantity in item 5.3
.3 and 5.4.
Therefore the quantity for Underground Pipeline (12” OD) Section A is 27 ea.

6 BILL OF MATERIAL FOR THE SACP SYSTEM

The Bill of Material for this SACP System is as follows:

Section A

ITEM DESCRPITION QUANTITY

1 Prepackaged Magnesium Anode, High Potential alloy, GESITMAG, 27 Ea

Net Weight: 14.5 Kg, Type "D", Estimated Total Gross Weight w/
backfill: 29 Kg, Dimension Prepackaged: 210mm Dia. x 720mm L, c/w
anode's cable tail XLPE/PVC, uk.: 1C x 10MM2, MM2, 2M long, colour:
Red/Black,, Brand: GESIT. GESIT P/N: PM-32-HP
2 Test Point, Cast Concrete Head, Size: 2", 3 terminals. GESIT P/N: 27 Ea
TB1-CCH-3T T
3 Gesit CP Cable, Cu/XLPE
Cu/XLPE/AWA/PVC,/PVC, 0.6/1kV, size: 1c x 10MM² for 270 Meter
installation of test point cable, color: Black, manufactured by: Voksel
or Equivalent
4 Thermit welder charges/powder for 10MM² cable, 15 gram, @20Ea 3 Box
per box
5 ThermOcaps pre-primed
pre @20Ea per box 3 Box
6 Cable lug, Cable ties, Cable marker and Densoline Mastic (Permagum 1 Lot
Sealer), Rubber Tape, etc.etc
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Section B

ITEM DESCRPITION QUANTITY

1 Prepackaged Magnesium Anode, High Potential alloy, GESITMAG, 6 Ea

Net Weight: 14.5 Kg, Type "D", Estimated Total Gross Weight w/
backfill: 29 Kg, Dimension Prepackaged: 210mm Dia. x 720mm L, c/w
anode's cable tail XLPE/PVC, uk.: 1C x 10MM2, MM2, 2M long, colour:
Red/Black,, Brand: GESIT. GESIT P/N: PM-32-HP
2 Test Point, Cast Concrete Head, Size: 2", 3 terminals. GESIT P/N: 6 Ea
TB1-CCH-3T T
3 Gesit CP Cable, Cu/XLPE
Cu/XLPE/AWA/PVC,/PVC, 0.6/1kV, size: 1c x 10MM² for 60 Meter
installation of test point cable, color: Black, manufactured by: Voksel
or Equivalent
4 Thermit welder charges/powder for 10MM² cable, 15 gram, @20Ea 1 Box
per box
5 ThermOcaps pre-primed
pre @20Ea per box 1 Box
6 Cable lug, Cable ties, Cable marker and Densoline Mastic (Permagum 1 Lot
Sealer), Rubber Tape, etc.etc
 Doc. No.: GNP-WIKA-KCIC-CDS-01 Rev.1 1 of 2
Date: 9-Sep-19 (incl.contige BR2 BR2 - A
Area: TOL PADALENYI, WEST JAVA Ttl Length 11.5 KM
Type of Anode: Prepackaged Magnesium Anodes, High Potential, "GESITMAG HP"
Name of Client: PT. WIJAYA KARYA (PERSERO) Tbk. FOR PT. PERTAMINA (PERSERO) PT. GESIT NAZELO PROTECTION
Name of Project: PEKERJAAN RELOKASI PIPA PERTAMINA DI DK117 – 128 DAN DK 135 – 138 Solution For Corrosion
1
2 Structural Data Basic Design Data
3 Permanent SACP for Section A
(1 (1 (1 (1
4 Pipe Size OD (m) Length (m) Corrosivity Operating/Design Temperature 40 °C
(1
5 12.75 '' 0.324 11,461 Severe Soil Resistivity 3,000 Ohms-Cm
6 Design Life 20 Years
7 Cathodic Protection Type Sacrificial Anode
8 Structural Condition Buried in Soil in 2 Meter Depth Anode Material Prepackaged Magnesium Alloy, High Potential
9 Type of Coating 3 Layer PE Design Current Densities for Operating Temperature
(1
0.125 mA/M2
10 Coating Thickness 3.0 MM Protective Potential 0.85 Volts
2
11 Total Area to be Protected 11,660.48 M Closed Potential 1.50 Volts
12 Safety Factor (assumed) 5.0 % Utilization Factor 0.80
2
13 Total Area to be Protected including Safety Factor 12,243.50 M
14
15 Anode Requirement Data
16
17 Type of Anode High Potential Magnesium Anode Anode Density 1760 Kg/M3
18 Anode Material GESITMAG HP Alloy Anode Capacity at Operating Temp. 1100 Ah/Kg
19 Anode Model Prepackaged Magnesium Anodes, High Potential
20 Type of Attachment Direct to pipe by Thermit Weld or via Test Point
21 GESIT P/N PM-32-HP Position Anode Installation (Vertical or Horizontal) Horizontal
22 Net Weight of Anode (Magnesium Alloy) 14.5 Kg Depth of Anode to be installed (assumed) 2.00 Meter
23 Gross Weight of Anode with Backfill 29.0 Kg
24 Length of Prepackaged Magnesium Anode w/ backfill 0.720 Meter
25 Diameter of Prepackaged Magnesium Anode w/ backfill 0.210 Meter
26
27 Anode Calculations
28
29 Quantity of Anode By Weight Quantity of Anode By Current
30 Current Demand 1.53 Ampere Current Demand 1.53 Ampere
31 Net Weight of Anode 304.70 Kg Resistance of Single Anode 11.33 Ohm
32 Total Quantity Anode Required by Weight 22 Pcs Maximum Quantity of Anode in Groundbed 1 Pcs
33 Total Quantity Anode Required by Current 27 Pcs Spacing of Anode in Groundbed 1.00 Meter
34 Interference Factor 1.00
35 Minimum Quantity of Anode Required 27 Pcs Resistance of Groundbed 11.33 Ohm
36 Current Output of each Groundbed 0.06 Ampere
37 Material to be used / supplied: Minimum Qty of Anode's Groundbed by current 27 Unit
38 - Test Point, 3 Terminals 27 Units Qty of Anode to be used by current 27 Pcs
39 - Magnesium Anode 27 Pcs Spacing between Groundbed 425 Meter
40 - XLPE/PVC Cable 1C x 10MM2 for Anode & Test Point 270 Meter
41 - Thermite Charge 15 Gram 3 boxes
42 - ThermOcaps pre-primed 3 boxes
43 - C-Bolt Connector - Pcs
44 - Cable lug, cable ties, insulation rubber, etc 1 Lot
45
46
47
48 Calculation Design Check
49
50 Total Anode Required x Current Output ≥ Current Demand
51 1.549 ≥ 1.530 OK
52 Total Net Weight x Anode Capacity x Utilization Factor ≥ 8760 x Life Time x Mean Current Demand
53 344,520.000 ≥ 268,132.650 OK
54
55 Reference
56 1. Data dari PT. Wijaya Karya (Persero) Tbk.
57 2. Standard ISO 15589-1, 2003, Petroleum and Natural Gas Industries – Cathodic Protection of Pipeline Transportation System – Part 1: On-Land Pipelines.
58
59
60
61
62
63
64
65
66
67
 Doc. No.: GNP-WIKA-KCIC-CDS-01 Rev.1 2 of 2
Date: 9-Sep-19 (incl.contige BR2 BR2 - A
Area: TOL PADALENYI, WEST JAVA Ttl Length 2.3 KM
Type of Anode: Prepackaged Magnesium Anodes, High Potential, "GESITMAG HP"
Name of Client: PT. WIJAYA KARYA (PERSERO) Tbk. FOR PT. PERTAMINA (PERSERO) PT. GESIT NAZELO PROTECTION
Name of Project: PEKERJAAN RELOKASI PIPA PERTAMINA DI DK117 – 128 DAN DK 135 – 138 Solution For Corrosion
1
2 Structural Data Basic Design Data
3 Permanent SACP for Section B
(1 (1 (1 (1
4 Pipe Size OD (m) Length (m) Corrosivity Operating/Design Temperature 40 °C
(1
5 Soil Resistivity 3,000 Ohms-Cm
6 12.75 '' 0.324 2,272 Severe Design Life 20 Years
7 Cathodic Protection Type Sacrificial Anode
8 Structural Condition Buried in Soil in 2 Meter Depth Anode Material Prepackaged Magnesium Alloy, High Potential
9 Type of Coating 3 Layer PE Design Current Densities for Operating Temperature
(1
0.125 mA/M2
10 Coating Thickness 3.0 MM Protective Potential 0.85 Volts
2
11 Total Area to be Protected 2,311.54 M Closed Potential 1.50 Volts
12 Safety Factor (assumed) 5.0 % Utilization Factor 0.80
2
13 Total Area to be Protected including Safety Factor 2,427.12 M
14
15 Anode Requirement Data
16
17 Type of Anode High Potential Magnesium Anode Anode Density 1760 Kg/M3
18 Anode Material GESITMAG HP Alloy Anode Capacity at Operating Temp. 1100 Ah/Kg
19 Anode Model Prepackaged Magnesium Anodes, High Potential
20 Type of Attachment Direct to pipe by Thermit Weld or via Test Point
21 GESIT P/N PM-32-HP Position Anode Installation (Vertical or Horizontal) Horizontal
22 Net Weight of Anode (Magnesium Alloy) 14.5 Kg Depth of Anode to be installed (assumed) 2.00 Meter
23 Gross Weight of Anode with Backfill 29.0 Kg
24 Length of Prepackaged Magnesium Anode w/ backfill 0.720 Meter
25 Diameter of Prepackaged Magnesium Anode w/ backfill 0.210 Meter
26
27 Anode Calculations
28
29 Quantity of Anode By Weight Quantity of Anode By Current
30 Current Demand 0.30 Ampere Current Demand 0.30 Ampere
31 Net Weight of Anode 60.40 Kg Resistance of Single Anode 11.33 Ohm
32 Total Quantity Anode Required by Weight 6 Pcs Maximum Quantity of Anode in Groundbed 1 Pcs
33 Total Quantity Anode Required by Current 6 Pcs Spacing of Anode in Groundbed 1.00 Meter
34 Interference Factor 1.00
35 Minimum Quantity of Anode Required 6 Pcs Resistance of Groundbed 11.33 Ohm
36 Current Output of each Groundbed 0.06 Ampere
37 Material to be used / supplied: Minimum Qty of Anode's Groundbed by current 6 Unit
38 - Test Point, 3 Terminals 6 Units Qty of Anode to be used by current 6 Pcs
39 - Magnesium Anode 6 Pcs Spacing between Groundbed 379 Meter
40 - XLPE/PVC Cable 1C x 10MM2 for Anode & Test Point 60 Meter
41 - Thermite Charge 15 Gram 1 boxes
42 - ThermOcaps pre-primed 1 boxes
43 - C-Bolt Connector - Pcs
44 - Cable lug, cable ties, insulation rubber, etc 1 Lot
45
46
47
48 Calculation Design Check
49
50 Total Anode Required x Current Output ≥ Current Demand
51 0.344 ≥ 0.303 OK
52 Total Net Weight x Anode Capacity x Utilization Factor ≥ 8760 x Life Time x Mean Current Demand
53 76,560.000 ≥ 53,153.947 OK
54
55 Reference
56 1. Data dari PT. Wijaya Karya (Persero) Tbk.
57 2. Standard ISO 15589-1, 2003, Petroleum and Natural Gas Industries – Cathodic Protection of Pipeline Transportation System – Part 1: On-Land Pipelines.
58
59
60
61
62
63
64
65
66
67