cathodic protection and underwater survey for an floating
TRANSCRIPT
Cathodic Protection and
Underwater Survey for an
Floating Storage Offloading
(FSO) System
Michael Surkein*, Omarou Faricou & Joseph Kenmoe
ExxonMobil
*Mike is currently retired from ExxonMobil and Principal at Surkein Corrosion
Email: [email protected]
Web: WWW.Surkeincorrosion.com
Mobile: +1 281-989-4134
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Agenda
• Facilities
• FSO and Mooring Tower Jacket
• Cathodic Protection (CP) Design Basis
• Underwater Inspections
• Hull and Coatings
• Anodes
• Reference Cells
• Cathodic Protection Monitoring
• Conclusions
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FSO and Mooring Tower Jacket
• Converted FSO permanently
connected by the stern to a
Mooring Tower Jacket and a
submarine pipeline
connection to shore
• Moored in a depth of 35 m
• FSO is free to weathervane
around mooring
• FSO dimensions
• Length 350 m
• Breadth 60 m
• Depth 28 – 35 m
• Storage - 2.3 million barrels
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FSO and Mooring Tower Jacket
• In service late 2003
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Cathodic Protection Design
• Design life = 15 years
• Submerged surface area = 32,000 m2 (344,445 ft2)
• Hull coating multi layer with anti-foulant
• Design current density = 30 mA/m2 (2.79 mA/ft2)
• Vendor standard approach
• Anode capacity 1000 A
• Using DNV RP B401 (1993)
• Final current density = 90 mA/m2
• Coating breakdown factor = 0.245
• Calculated current requirement = 706 A
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• Used vendor standard approach
• Five - 200 A power sources for 1000 A capacity
• Six anodes
• Six alloy anodes - 3.65 m x 102 mm (12 ft x 4 in)
• Rated at 200 A each
• Epoxy dielectric shield - 3.8 m x 6.7 m (12.5 ft x 22 ft)
• Installed in cofferdam
• Two reference cells – high purity zinc
Cathodic Protection Design
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FSO and Tower Yoke
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Underwater Inspections
• Diver, video, pictures
• General visual inspection
• Splash zone, hull, riser, etc
• Hull survey
• Coatings*
• Metal loss
• Marine growth*
• Cathodic protection*
• Anode depletion*
• Cathodic protection levels*
• Coating*Cathodic protection meter
Ultrasonic thickness meter
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Anode Layout
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Anode Location
2000 m
m
(6.5
ft)
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Hull Fouling
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Hull Anode Inspection
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Hull Anode Inspection
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Anode Condition
Anode Prior to Cleaning
Anode Bolt Visible
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Zinc Reference Cell
• CP MEASUREMENT (-mV)
• ZINC TEST PRE DIVE -1046mV
• ZINC TEST POST DIVE -1048mV
• AROUND ANODE -786 / -784mV
• CP MEASUREMENT (-mV)
• ZINC TEST PRE DIVE -1046mV
• ZINC TEST POST DIVE -1048mV
• AROUND ANODE -786 / -784mV
Cathodic Protection
Measurement
Zinc
Pre Dive
-1046 mV
Zinc
Post Dive
-1048 mV
Around
Anode
-786 mV
-784 mV
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Location Potential,
mV vs.
Ag/AgCl
Location Potential,
mV vs.
Ag/AgCl
Zinc Test
Block
(Pre)
-1049 Zinc Test
Block
(Post)
-1051
C1 FWD -845 C1 AFT -846
C2 FWD -846 C2 AFT -849
C3 FWD -845 C3 AFT -846
C4 FWD -854 C4 AFT -853
C5 FWD -854 C5 AFT -854
C6 FWD -855 C6 AFT -855
C7 FWD -856 C7 AFT -858
C8 FWD -856 C8 AFT -858
CP Monitoring
CP system turned off during measurements
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CP Monitoring
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Dielectric Shield Coating
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Hull Coating Under Fouling
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• Anodes were half cleaned and inspected
• Anode assembly consists of alloy anodes mounted in a resin holder
• Anode assembly mounting area covered with an epoxy dielectric shield
• Marine growth was covering 80% of both anodes with a thickness around 50mm
• Anodes were still active and the hull was protected
• Different kinds of marine growths were adhered to and around the anodes
• In two locations, marine growth accumulation up to 500mm thick
• Marine growth on the anode average was between 5mm to 70mm
• After light / soft cleaning to avoid damage, anodes were found in good condition
• Resin holders were in good condition without any damage or visible cracks
• Anodes’ bolts were protected by polyurethane foam and well tightened
• Reference cells at port and starboard found in good working condition
• During inspection, CP current was off to allow divers to work in safe environment
FSO CP System Inspection
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Mooring Jacket CP Inspection
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Mooring Tower Jacket Fouling
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Anode Inspection
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CP Measurement on Riser
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• Mooring jacket inspected for type and thickness of marine growth
• Marine growth was cleaned jetting device on some locations
• Marine growth present on approx. 60% of surface and constituted by
hard and soft organisms
• Hard shells were principally barnacles, coral, oysters and tubeworms
• Soft marine growths were mostly sponges, white & brown algaes
• Coating not damaged during cleaning and only marine growth
removed
• Temperature measurements 22.2 C to 31 C
• All CP measurement in acceptable range
• Anode depletions estimated between 10% – 20 % (75 anodes
evaluated)
Mooring Tower Jacket Inspection
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Conclusions
• Underwater inspection successfully and safely conducted
• Cathodic protection system components in good condition
• Anodes & reference cells
• Significant fouling present on underwater FSO hull
• Fouling cleaned easily
• Anti-fouling coating working well
• FSO Hull coating in good condition
• FSO cathodic protection monitoring indicates system performing as intended
• FSO Dielectric anode coating showing slight degradation on one anode
• Mooring jacket CP system performing as intended
• Mooring jacket anode depletion within acceptable range