1/17/23, 8:53 AM Coating Breakdown Factor - an overview | ScienceDirect Topics

Coating Breakdown Factor

Coating breakdown factor (fraction of the external pipe surface that is
exposed to coating defects and bare areas)
From: Corrosion Control for Offshore Structures, 2014

Related terms:

Cathodic Protection, Polarisation, Anode, Anode Resistance, Anode Utilization

Factor, Cathodic Protection System, Current Drain, Design Current Density

Subsea Corrosion and Scale

Yong Bai, Qiang Bai, in Subsea Engineering Handbook (Second Edition), 2019

17.3.3.3 Coating Breakdown Factor

The coating breakdown factor describes the extent of current density reduction due
to the application of a coating. The value fc = 0 means the coating is 100%
electrically insulating, whereas a value of fc = 1 implies that the coating cannot
provide any protection.
The coating breakdown factor is a function of coating properties, operational
parameters and time. The coating breakdown factor fc can be described as follows:

𝑓𝑐 = 𝑘 1 + 𝑘 2 ⋅ 𝑡 (17.11)

where t is the coating lifetime, and k1 and k2 are constants that are dependent on
the coating properties.
Four paint coating categories have been defined for practical use based on the
coating properties in DNV [9]:
Category I: one layer of primer coat, about 50-μm nominal dry film thickness (DFT);
Category II: one layer of primer coat, plus minimum one layer of intermediate top
coat, 150- to 250-μm nominal DFT;
Category III: one layer of primer coat, plus minimum two layers of intermediate/top
coats, minimum 300-μm nominal DFT;
Category IV: one layer of primer coat, plus minimum three layers of intermediate
top coats, minimum 450-μm nominal DFT.
The constants k1 and k2 used for calculating the coating breakdown factors are
given in Table 17.3.

Table 17.3. Constants (k1 and k2) for Calculation of Paint Coating Breakdown
Factors [10]

Depth (m) Coating Category

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Subsea Tree Design

Yong Bai, Qiang Bai, in Subsea Engineering Handbook (Second Edition), 2019

25.6.1 Design Basic Data

To account for the effect of a coating system on coating breakdown factors, in
accordance with DNV RP B401, three coating categories have been defined.
• Category I: One layer of epoxy paint coating, minimum 20 μm of nominal DFT
(dry film thickness).
• Category II: One or more layers of marine paint coating (epoxy, polyurethane,
or vinyl based), minimum 250 μm of total nominal DFT.
• Category III: Two or more layers of marine paint coating (epoxy, polyurethane,
or vinyl based), minimum 350 μm of total nominal DFT.
Coating plan for piping assembly exterior, structure frame, and foundation are as
follows:
• Painting scheme, as shown in Table 25-14.

Table 25-14. Painting Scheme

Paint/Thinner Code and Name DFT (μm)

Paint 670HS epoxy paint (primer paint) 400

670HS epoxy paint (finish paint) 100

Thinner GTA 220

• Since DFT ≥ 350 μm, the coating belongs to Category III.

• Surface preparation includes blast cleaning to minimum SA 3.0 (blast
cleaning to pure metal: white metal 100% clean) in accordance with
ISO 8501.

25.6.1.1 Piping Assembly Interior

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Corrosion Prevention and Advanced CP Design

Qiang Bai, Yong Bai, in Subsea Pipeline Design, Analysis, and Installation, 2014

Coating Breakdown Factor

The coating breakdown factor describes the extent of current density reduction due
to the application of coating. The value fc = 0 means the coating is 100% electrically
insulating. fc = 1 implies that the coating provides no protection.
The coating breakdown factor is a function of the coating properties, operational
parameters, and time. The coating breakdown factor, fc, can be described as

𝑓c = 𝑘 1 + 𝑘 2 · 𝑡 [19.6]

where t is the coating life time and k1 and k2 are constants dependent on the
coating properties.
In seawater, to account for the effect of a coating system on coating breakdown
factor, four paint coating categories have been defined for practical use, based on

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the coating properties in DNV RP B401 [3]:
• Category I: One layer of primer coat, about 50 μm nominal DFT (dry film
thickness).
• Category II: One layer of primer coat, plus a minimum of one layer of
intermediate top coat, 150–250 μm nominal DFT.
• Category III: One layer of primer coat, plus a minimum of two layers of
intermediate/top coats, minimum 300 μm nominal DFT.
• Category IV: One layer of primer coat, plus a minimum of three layers of
intermediate top coats, minimum 450 μm nominal DFT.
The constants k1 and k2 used for calculating the coating breakdown factors are
given in Table 19.2.

Table 19.2. Constants (k1 and k2) for Calculation of Paint Coating Breakdown
Factors

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Cathodic Protection of Offshore Pipeline Risers and

Associated Equipment
Ramesh Singh, in Corrosion Control for Offshore Structures, 2014

Results Summary

Voltage Check CheckVoltage = “PASS”

Life Expectancy Check CheckLifeExpect = “PASS”

Mass Check CheckMass = “PASS”

Coating Breakdown Factor CBF = “ISO” fcf = 0.45%

Distance to Low Point Potential (ft) DLPP = 12,687 ft

Low Point Potential (-Volts AgCl) VLPP = 0.867 V

Potential at x = 0 (-Volts AgCl) VS1 = 0.91 V

Potential at x = L (-Volts AgCl) VS2 = 0.91 V

Current Required of Source 1 (x = 0) CS1 = 2.046 A

Current Required of Source 2 CS2 = 2.046 A

(x = Length)

Total Current TC = 4.093 A

Envelope IR Drop at x = L (Volts) Vdrop = 0.14 V

Mass Required at Source 1 Mass 1 = 549.236 lb

Mass Required at Source 2 Mass 2 = 549.236 lb

Total Mass Required Mass T = 1098.472 lb

Number and Resistance of Anodes at N1 = 2 RA1 = 0.068 Ω

Source 1

Number and Resistance of Anodes at N2 = 2 RA2 = 0.068 Ω

Source 2

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Design Life td = 25 years

Life Expectancy (Years) LifeExpect = 27.013

Minimum required Anode Mass (lbs) MinAnodeMass = 1203.1

Anode Mass Provided (lbs) Anode_MassT = 1300

Minimum required Anode Mass at Each Anode_Loc = 601.553

Location (lbs)

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Corrosion Prevention
Yong Bai, Qiang Bai, in Subsea Pipelines and Risers, 2005

15.5.2 CP Design Practice

Offshore pipeline CP design includes the determination of the current demand Ic,
required anode mass M and number and current output per anode Ia. The current
demand is a function of cathode surface area, Ac, a coating breakdown factor, fc,
and current density, ic, and can be expressed as (DNV, 1993):

𝐼 𝑐 = 𝐴 𝑐 ⋅ 𝑓 𝑐 ⋅ 𝑖𝑐 (15.9)

where ic depends upon water depth, temperature, sea water versus mud exposure,
and whether or not the mean or final life of the CP system is being evaluated.
Current density ic is normally in the range 60–170 mA/m2 (DNV, 1993). As the
initial polarization period proceeding steady-state conditions is normally quite
short compared to the design life, the mean (time-averaged) design current density
im becomes very close to the steady state current density. Therefore, it is used to
calculate the minimum mass of anode material necessary to maintain cathodic
protection throughout the design life. Correspondingly, M can be calculated as:
8, 760 ⋅ 𝑖𝑚 ⋅ 𝑇 (15.10)
𝑀= 𝑢⋅𝐶

where u is a utilization factor, C is anode current capacity and T is design life. The
cathode potential is assumed to be spatially constant. Therefore, the current output
per anode can be calculated by:
𝜙𝑐 − 𝜙𝑎 (15.11)
𝐼𝑎 = 𝑅𝑎

where ϕc and ϕa are the closed circuit potential of the pipe and anode, respectively,
and Ra is the anode resistance.

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Subsea Corrosion and Scale

Yong Bai, Qiang Bai, in Subsea Engineering Handbook, 2010

17.3.4.2 CP Design Practice

Offshore pipeline CP design includes the determination of the current demand Ic,
required anode mass M, and number and current output per anode Ia. The current
demand is a function of cathode surface area Ac, a coating breakdown factor fc, and
current density 𝑖𝑐 , and can be expressed as follows [9]:

𝐼 𝑐 = 𝐴 𝑐 · 𝑓 𝑐 · 𝑖𝑐 (17-14)

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where 𝑖𝑐 depends on water depth, temperature, seawater versus mud exposure,
and whether or not the mean or final life of the CP system is being evaluated.
Current density 𝑖𝑐 is normally in the range of 60 to 170 mA/m2 [9]. Because the
initial polarization period preceding steady-state conditions is normally quite short
compared to the design life, the mean (time-averaged) design current density 𝑖
comes very close to the steady-state current density. Therefore, it is used to
calculate the minimum mass of anode material necessary to maintain cathodic
protection throughout the design life. Correspondingly, M can be calculated as:
8760 · 𝑖 ·𝑚 𝑇 (17-15)
𝑀= 𝑢·𝐶

where u is a utilization factor, C is anode current capacity, and T is design life. The
cathode potential is assumed to be spatially constant. Therefore, the current output
per anode can be calculated by:
𝜙𝑐 − 𝜙𝑎 (17-16)
𝐼𝑎 = 𝑅𝑎

where 𝜙𝑐 and 𝜙𝑎 are the closed-circuit potential of the pipe and anode,
respectively, and 𝑅𝑎 is the anode resistance.

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Design and Construction of Offshore Pipelines

André C. Nogueira, David S. Mckeehan, in Handbook of Offshore Engineering,
2005

11.10.1 Current Demand Calculations

The current demand Ic to achieve polarisation during the initial and final lives of
the cathodic protection system, and the average current demand to maintain
cathodic protection throughout the design life should be calculated separately.
The surface area Ac to be cathodically protected should be multiplied with the
relevant design current density ic and the coating breakdown factor fc:

𝐼 𝑐 = 𝐴 𝑐 ⋅ 𝑓 𝑐 ⋅ 𝑖𝑐 (11.34)

where Ic = current demand for a specific surface area, ic = design current density,
selected from tables 11.14 and 11.15, which follow guidance provided by DNV RP
B401 (1993) Section 11.3, fc = coating breakdown factors. See DNV RP B401 (1993)
table 11.4.1 and Sections 6.5.3 and 6.5.4 for guidance on offshore pipelines.

Table 11.14. Initial and final design current densities for various climatic regions
and depths – adapted from table 6.3.1 of DNV RP B401 (1993)

Water
depth (ft) Design current densities (initial/final) in A/ft2

Tropical Subtropical (12– Temperate (7–

(>20°C) 20°C) 12°C) Arctic (<7°C)

Initial Final Initial Final Initial Final Initial Final

0–100 0.0139 0.0084 0.0158 0.0102 0.1860 0.0121 0.0232 0.0158

100 0.0121 0.0074 0.0139 0.0084 0.0167 0.0102 0.0204 0.0121

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Corrosion protection
Mohamed Abdallah El-Reedy Ph.D., in Offshore Structures (Second Edition), 2020

Current drain design parameters

All items which are expected to become electrically connected to a CP system shall
be considered in current drain calculations.
Complex offshore structures often include temporary or permanent components
which are not considered to require CP but will drain current from the CP system
as the mooring systems for floating installations or secondary structural
components such as piles and skirts which can readily tolerate some corrosive wear
or casings installed in the sea bed and do not need corrosion protection for
structural purposes due to high wall thickness relative to expected corrosion rates.
Calculations of current drain shall use the design current densities and coating
breakdown factors for items requiring CP. Calculations of surface areas and current
demands shall be carried out.
The design current densities and coating breakdown factors, respectively, are
applicable for the calculation of current drains to components that are not
considered to need CP, but will be or are expected to be electrically connected to
the protection object by the CP system being designed.
For buried surfaces of mud mats, skirts, and piles, a current drain value of
0.020 A/m2 shall be accounted for, based on the outer external surface area which
is exposed to sediment. In some cases and based on the owner specification for
parts of steel skirts and piles to be buried in sediments, a current density
(initial/final and average) of 0.025 A/m2 shall be used. The current drain to open
pipes shall cover an internal surface area equivalent to 10 times π times their
respective diameter.
For open pile ends, the top internal surface shall be included for a distance of five
times the diameter and shall be regarded as seawater exposed. Internal surfaces of
piles filled with sediments do not have to be included.
Unless otherwise specified or accepted by the owner, a current drain of 5 A/well
casing shall be included in current drain calculations.
Casings for subsea wells are typically cemented, which reduces the current drain
d t l tf ll hi h ll t t d H b
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Advancements in Cathodic Protection of offshore

structures
Jim Britton, Matthew L. Taylor, in Trends in Oil and Gas Corrosion Research and
Technologies, 2017

25.2.2 New design guidelines

25.2.2.1 Improved coatings
As the offshore industry moves into ever deeper waters, pipeline design is
changing to accommodate the new pipe-lay techniques as well as we are seeing
significant changes in pipe coating technology. Now the single and double coat
FBS-coating systems are being replaced with three- and five-layer systems to give
better thermal and mechanical properties. In many cases, very thick (up to
100 mm) thermally insulated coatings are being applied for flow assurance reasons.
These coatings provide a very high level of efficiency such that the only areas where

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CP is really required is at the field joints and on the end termination structures.
This has caused a revision in the design guidelines for coating breakdown factors
and the way in which CP is designed and applied. When an operator invests in a
coating system that can cost close to $1000/m, it is not smart to start poking holes
in the coating to provide attachment for anode bracelets.
25.2.2.2 Anode sleds and attenuation modeling
Because the coatings are now so efficient 99.95% or better, the amount of backup
CP required is minimal. Also the wall thickness of the pipes used in deep water is
heavier. These two factors mean that CP can be “thrown” much further along the
pipeline than on a conventional pipeline. So the new design codes allow for the
anodes to be located off the pipeline and “attenuation” calculations can be used to
estimate the distance that can be protected from an anode sled, or alone on an end
termination sled. So now we see new pipelines being installed with anode sleds
connected with clamps (Fig. 25.3) and sleds can be spaced tens of kilometers apart
and the pipeline is well protected. These attenuation formulae can conveniently be
computed by modern multiphysics finite element analysis software to give a
graphic output. The CP designs on these pipelines are really only looking at the
field joints.

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Attenuation Modeling for Offshore Pipelines

Ramesh Singh, in Corrosion Control for Offshore Structures, 2014

Appendix to Section 5

Symbols and their meanings

Aa Anode surface area

Ac Structure (cathode) surface area

Ac(1) Pipe surface area protected by a single anode

C Anode current capacity

d Distance from an offset anode to a position on a pipeline

D Diameter of a circle about which an array of equally spaced anodes are

placed

Ea Magnitude of cathodic polarization at z = 0

Eb Magnitude of cathodic polarization at z = L

Ec(z) Magnitude of cathodic polarization at z

fc Coating breakdown factor (fraction of the external pipe surface that is

exposed to coating defects and bare areas)

io Initial cathodic protection design current density

im Mean cathodic protection design current density

if Final cathodic protection design current density

ic Structure (cathode) current density demand

ic(z) Cathodic current density at z along a pipeline

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Recommended publications

Corrosion Control for Offshore Structures

Book • 2015

Offshore Structures (Second Edition)

Book • 2020

Subsea Pipelines and Risers

Book • 2005

Subsea Pipeline Design, Analysis, and Installation

Book • 2014

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