Engineering Standard

SAES-X-500 18 October 2018

Cathodic Protection of Vessel and Tank Internals
Document Responsibility: Cathodic Protection Standards Committee

Contents
1 Scope ................................................................ 2
2 Conflicts and Deviations ................................... 2
3 References........................................................ 3
3.1 Saudi Aramco References ....................... 3
3.2 Industry Codes and Standards ................ 4
4 Definitions and Abbreviations............................ 5
5 Design Review and Approval .......................... 10
6 General Design Requirements ........................ 14
6.1 Contractor/Designer Qualifications ........ 14
6.2 General / Philosophy / Limitations ......... 14
6.3 Design Life............................................. 17
6.4 Current Density Criteria ......................... 19
6.5 Protection Criteria .................................. 20
6.6 Anodes .................................................. 20
6.7 Circuit Resistance .................................. 21
6.8 DC Power Source .................................. 22
6.9 Cables ................................................... 22
6.10 Junction Boxes ...................................... 23
7 Installation, Records, Commissioning,
and Inspection................................................. 23
Revision Summary................................................. 23

Previous Issue: 18 April 2018 Next Planned Update: 18 April 2021

Revised paragraphs are indicated in the right margin Page 1 of 23
Contact: Shahzad, Usman (shahzaux) on phone +966-(0)13-8808808

©Saudi Aramco 2018. All rights reserved.

Document Responsibility: Cathodic Protection Standards Committee SAES-X-500
Issue Date: 18 October 2018
Next Planned Update: 18 April 2021 Cathodic Protection of Vessel and Tank Internals

1 Scope

1.1 This standard prescribes the minimum mandatory requirements governing the
design and installation of cathodic protection systems for the internal surfaces of
new metallic vessels and tanks. For existing tanks and vessels this standard may
be used as guideline considering the CP requirements mentioned in section 1.2
below.

1.2 This standard is applicable to but not limited to the vessels and tanks categorized
in Table 1:

Table 1 – Cathodic Protection Requirements and Categories of Vessels and Tanks

B) List of Vessels and Tanks for
A) List of Vessels and Tanks which shall be which CP Consideration
internally protected by CP
depends on other factors¹
Water Storage Tanks, i.e., Potable Water, Fire RO Surge Tanks
Water, and Sea Water, etc.
Hot Water Storage Tanks
Sand Traps
Cooling Water Surge Tanks
Condenser Water Boxes
Fresh or Lean DGA Storage Tanks
Salt Water Strainers
Methanol Storage Tanks
Sewage Treatment Plant
Glycol Storage Tanks
Slop Oil Tanks
Lube Oil Storage Tanks
Wet Crude Separation Vessels, i.e., Desalters,
Gas Chiller Separators
Dehydrators, Oil and Water Separation Plants
(WOSEP), Low Pressure Production Traps (LPPT), Regen Gas LP KO Drums
High Pressure Production Traps (HPPT)
Refrigerant Cooling Water Surge Drums
Effluents Tanks, Product Tanks, Sump Tanks, and
all types of Chemical and Hydrocarbon Tanks that Compressed Air Receivers
may accumulate a layer of water, condensate, or LP Hot-water Expansion Tanks
sediment in the bottom.
MP Hot-water Expansion Tanks
Seawater Filters and Deaerators
Jet Fuel Tanks (Kerosene)
Note ¹: For tanks and vessels listed in category B) CP requirement shall be considered as per
recommendation from Corrosion Engineering Group (CEG) - CSD and/or Proponent and shall be
based on many factors but not limited to electrolytic resistivity, corrosion inhibitor dosage,
electrolyte’s corrosiveness, possibility of water condensate, pH of electrolyte, Chloride, H 2S, and
oxygen concentration in the electrolyte.

2 Conflicts and Deviations

Any conflicts between this document and other applicable Mandatory Saudi Aramco
Engineering Requirements (MSAERs) shall be addressed to the EK&RD Coordinator.

Saudi Aramco: Company General Use

Page 2 of 23
Document Responsibility: Cathodic Protection Standards Committee SAES-X-500
Issue Date: 18 October 2018
Next Planned Update: 18 April 2021 Cathodic Protection of Vessel and Tank Internals

Any deviation from the requirements herein shall follow internal company procedure
SAEP-302.

3 References

Referenced standards and specifications shall be the latest edition/revision unless stated
otherwise.

The Saudi Aramco Engineering Standards intranet website

(https://standards.aramco.com.sa/) contains the latest revisions of all standards and
standard drawings.

3.1 Saudi Aramco References

Saudi Aramco Engineering Procedures

SAEP-302 Waiver of a Mandatory Saudi Aramco Engineering
Requirement
SAEP-303 Engineering Reviews of Project Proposal and
Detail Design Documentation
SAEP-332 Cathodic Protection Commissioning
SAEP-333 Cathodic Protection Monitoring

Saudi Aramco Engineering Standards

SAES-L-133 Corrosion Protection Requirements for Pipelines,
Piping and Process Equipment
SAES-P-104 Wiring Methods and Materials

Saudi Aramco Materials System Specifications

17-SAMSS-004 Tap Adjustable Rectifiers for Cathodic Protection
17-SAMSS-005 Cathodic Protection Phase Controlled Rectifiers
17-SAMSS-006 Galvanic Anodes for Cathodic Protection
17-SAMSS-007 Impressed Current Anodes for Cathodic Protection
17-SAMSS-008 Junction Boxes for Cathodic Protection
17-SAMSS-012 Photovoltaic Power Supply for Cathodic Protection
17-SAMSS-017 Impressed Current Cathodic Protection Cables
17-SAMSS-018 Remote Monitoring System (RMS) for Cathodic
Protection Applications

Saudi Aramco: Company General Use

Page 3 of 23
Document Responsibility: Cathodic Protection Standards Committee SAES-X-500
Issue Date: 18 October 2018
Next Planned Update: 18 April 2021 Cathodic Protection of Vessel and Tank Internals

Saudi Aramco Standard Drawings

The following standard drawings outline specific methods of designing and

installing cathodic protection systems:
AA-036353 Water Storage Tanks Impressed Current C.P.
AA-036354 Water Storage Tanks Galvanic Anode C.P.
AB-036378 Cathodic Protection Onshore Rectifier Installation
Details
AA-036388 Internal Galvanic Anodes Installation Details for
Vessels
AA-036389 Galvanic Anode Details
AA-036762 Crude and Product Tank Bottom, Internal,
Magnesium Anode Installation
AD-036785 Symbols for Cathodic Protection

Saudi Aramco Best Practices

SABP-X-001 CP Design Package Preparation
SABP-X-003 Cathodic Protection Installation Requirements

Saudi Aramco General Instructions

GI-0002.710 Mechanical Completion and Performance
Acceptance of Facilities
GI-0428.001 Cathodic Protection Responsibilities

3.2 Industry Codes and Standards

National Fire Protection Association

NFPA 70 National Electrical Code (NEC)

National Electrical Manufacturers Association

National Association of Corrosion Engineers

NACE SP0388 – 2014 Impressed Current Cathodic Protection of
Internal Submerged Surfaces of Carbon Steel
Water Storage Tanks
NACE SP0196 – 2015 Galvanic Anode Cathodic Protection of Internal
Submerged Surfaces of Steel Water Storage
Tanks

Saudi Aramco: Company General Use

Page 4 of 23
Document Responsibility: Cathodic Protection Standards Committee SAES-X-500
Issue Date: 18 October 2018
Next Planned Update: 18 April 2021 Cathodic Protection of Vessel and Tank Internals

NACE SP0575 – 2007 Internal Cathodic Protection (CP) Systems in Oil-

Treating Vessels

4 Definitions and Abbreviations

The following general list of definitions and abbreviations has been developed
specifically for application with Saudi Aramco cathodic protection standards and
specifications:

AA: The ANSI cooling class for a dry-type self-cooled transformer or reactor that is
cooled by the natural circulation of air. Syn.: AN (IEC), See definition 3.1 in
IEEE C57.12.

Anode: An impressed current or a galvanic anode for cathodic protection applications.

Anode Cable: A cable directly connected to an impressed current or galvanic anode.

ANSI: American National Standards Institute

ANV: The ANSI cooling class for a dry-type non-ventilated self-cooled transformer,
which is so constructed as to provide no intentional circulation of external air through
the transformer, and that operates at zero gauge pressure. Syn.: ANAN (IEC),
See definition 3.15 in IEEE C57.12.

Armored Cable: Armored cable for cathodic protection is a single core insulated cable
manufactured with a double layer spiral wound insulated galvanized steel sheath to
provide mechanical protection, and typically used for subsea applications.

ASME: American Society of Mechanical Engineers (USA)

ASTM: American Society for Testing and Materials

AWS: American Welding Society

Bond Cable: A cable installed between two metallic structures to provide electrical
continuity between the structures for the purpose of cathodic protection.

Buyer: Saudi Aramco Purchasing Department Representative

Buyer's Representative: The person or persons designated by the Purchasing

Department to monitor/enforce the contract. Normally, this is the on-site inspector.

Calcined Petroleum Coke Breeze: A carbonaceous backfill used as a conductive

backfill media for impressed current anodes in soil.

Coated Casing: The term “coated casing” as used in this engineering standard
describes a well casing with an external non-conductive coating (typically Fusion Bond
Saudi Aramco: Company General Use
Page 5 of 23
Document Responsibility: Cathodic Protection Standards Committee SAES-X-500
Issue Date: 18 October 2018
Next Planned Update: 18 April 2021 Cathodic Protection of Vessel and Tank Internals

Epoxy or FBE). The coating must be applied to all sections of the casing in contact
with soil or formation, from surface to the bottom of the casing or to a depth determined
to facilitate external corrosion mitigation with cathodic protection through the relevant
down hole corrosive aquifers. Casings that have been coated over the upper two or
three joints of casing only are not “coated casings”. Coating applied to well casings is
not applied as a corrosion barrier. It is applied to reduce the total amount of CP
required or to extend the influence of the applied CP.

CP: Cathodic Protection

CP Assessment Probe: A CP assessment probe is a multi-electrode probe designed to

enable measurement of the soil resistivity in addition to representative polarized and
depolarized potentials for the pipeline or other buried or immersed metallic structure at
the probe location.

CP Coupon: A CP coupon is a single electrode coupon that has been designed to

enable measurement of representative potentials, current densities, or corrosion rates on
a pipeline or other buried or immersed metallic structure at the coupon location.

CP System Operating Circuit Resistance: The total resistance seen at the output of a
CP power supply or the total working resistance in a galvanic anode system.

CP System Rated Circuit Resistance: The rated output voltage of a cathodic

protection power supply divided by the rated output current. For photovoltaic power
supplies, the rated output current is the design commissioning current.

Cross-Country Pipeline: A pipeline between; two plant areas, another cross-country

pipeline and a plant area, or between two cross-country pipelines.

CSD: The Saudi Aramco Consulting Services Department.

Deep Anode Bed: Anode or anodes connected to a common CP power supply and
installed in a vertical hole with a depth exceeding 15 m (50 ft).

Design Agency: The organization responsible for the design of the pipeline and
associated CP system. The Design Agency may be the Design Contractor, the Lump
Sum Turn Key Contractor or an in house design organization of Saudi Aramco.

Drain Point: The location on the cathodically protected structure where the negative
cable from the T/R or negative junction box is fastened to the structure.

Flowline: A pipeline connected to a well. A surface pipeline carrying oil, gas, or water
that connects the wellhead to a manifold or to production facilities

Flare Line or Blow Down Line: A line for pumping out of unwanted gas or
hydrocarbon
Saudi Aramco: Company General Use
Page 6 of 23
Document Responsibility: Cathodic Protection Standards Committee SAES-X-500
Issue Date: 18 October 2018
Next Planned Update: 18 April 2021 Cathodic Protection of Vessel and Tank Internals

Foundry (for anodes): An anode foundry is a facility that produces metal castings
from either ferrous or non-ferrous metals or alloys.

Galvanic Anodes: Anodes fabricated from materials such as aluminum, magnesium or

zinc that are connected directly to the buried structure to provide cathodic protection
current without the requirement for an external cathodic protection power supply.
Galvanic anodes are also referred to as sacrificial anodes.

GOSP: Gas and Oil Separation Plant

Hazardous Areas: Those areas where fire or explosion hazards may exist due to
flammable gases or vapors, flammable liquids, combustible dust, or ignitable fibers or
filings (see NEC Article 500).

HDD: Horizontal Directional Drilled

ICCP: Impressed Current Cathodic Protection

Impressed Current Anodes: Anodes typically fabricated from High Silicon Cast Iron
(HSCI) or Mixed Metal Oxide (MMO) that are connected through a DC power supply
to the buried or immersed structure to provide cathodic protection current.

Lead Wire (for anodes): A cable directly connected to an anode.

Manufacturer: The Company that assembles the components for the finished product
and provides the finished product either through a Vendor or directly to Saudi Aramco.

Mill (for anodes): An anode mill is a facility that produces anodes such as MMO or
Platinized Niobium (without lead wires) for cathodic protection applications (or any
other anode type that does not involve casting).

MSAERs: Mandatory Saudi Aramco Engineering Requirements

Multiple Well (Multi-well) Casing CP System: Two or more well casings protected
by one common CP rectifier system.

NEC: National Electric Code

NEMA: National Electrical Manufacturers Association (USA)

Negative Cable: A cable that is electrically connected (directly or indirectly) to the

negative output terminal of a cathodic protection power supply or to a galvanic anode.
This includes bond cables to a cathodically protected structure.

Non-incendive Equipment: Equipment having electrical/electronic circuitry that is

incapable, under normal operating conditions, of causing ignition of a specified

Saudi Aramco: Company General Use

Page 7 of 23
Document Responsibility: Cathodic Protection Standards Committee SAES-X-500
Issue Date: 18 October 2018
Next Planned Update: 18 April 2021 Cathodic Protection of Vessel and Tank Internals

flammable gas-air, vapor-air, or dust-air mixture due to arcing or thermal means.

(See NEC Article 100).

Non-metallic Flowline: A flowline that is made out of non-metallic materials.

Off-Plot: Off-plot refers to any area outside of the plot limits.

ONAN: The ANSI cooling class for a transformer or reactor having its core and coils
immersed in mineral oil or synthetic insulating liquid with a fire point less than or equal
to 300C, the cooling being effected by the natural circulation of air over the cooling
surface. (ONAN was previously termed OA). See definition 3.303 in IEEE C57.12.

On-plot: On-plot refers to any area inside the plot limit.

Perimeter Fence: The fence which completely surrounds an area designated by Saudi
Aramco for a distinct function.

Photovoltaic Module: A number of solar cells wired and sealed into an environmentally
protected assembly.

Pipeline: The term “pipeline” is used generically in this standard and can be used to
refer to any type of pipeline.

Plant Area: A plant area is the area within the plot limits of a process or storage facility.

Plot Limit: The plot limit is the boundary around a plant or process facility. The plot
limit may be physical such as a fence, a wall, the edge of a road or pipe rack, chains and
posts or a boundary indicated on an approved plot plan.

Positive Cable: A cable that is electrically connected (directly or indirectly) to the positive
output terminal of an impressed current cathodic protection power supply, including
impressed current anode cables.

PMT: Project Management Team used as a truncated version of Saudi Aramco Project
Management Team or SAPMT.

Process Pipeline: A pipeline typically associated with a plant process and typically
above ground within a plant facility.

Production Pipeline: A pipeline transporting oil, gas or water to or from a well.

These include flow-lines, test-lines, water injection lines and trunk-lines.

Pyramid Anode: An offshore anode assembly custom manufactured for Saudi Aramco
that is fabricated with mixed metal oxide anode components and placed on the sea bed.
The pyramid anode derives its name from the pyramid shaped concrete base.

Saudi Aramco: Company General Use

Page 8 of 23
Document Responsibility: Cathodic Protection Standards Committee SAES-X-500
Issue Date: 18 October 2018
Next Planned Update: 18 April 2021 Cathodic Protection of Vessel and Tank Internals

Reference Electrode: An industry standardized electrode used as a common reference

potential for cathodic protection measurements. A copper/copper sulfate (Cu/CuSO4)
reference electrode is typically used for soil applications. A silver/silver chloride
(Ag/AgCl/0.6M Cl) reference electrode is typically used for aqueous applications.

Resistivity Meter (such as Megger Tester or equivalent): A meter designed to

measure ground resistivity, or can be connected to measure resistance in a format that
excludes the resistance of the test wires.

RSA: Responsible Standardization Agent - for CP material, this would usually be the
Supervisor of the CSD Cathodic Protection Team or the Saudi Aramco CSD Cathodic
Protection Subject Matter Expert.

SAES: Saudi Aramco Engineering Standard

SAMSS: Saudi Aramco Materials System Specification

Shared Well Casing CP System: Two or more well casings protected by two or more
CP rectifier systems that are negatively bonded thru a Dedicated Bonding Facility
arrangement. Shared well casings are not allowed except for solar systems.

Single Well Casing CP System: One well casing CP system protected by one CP
rectifier system.

Soil Transition Point: The on grade location where a pipeline enters or exits the soil,
i.e., above grade to below grade transition, or below grade to above grade transition.

Subject Matter Expert (SME): For the purposes of this standard, the SME shall be
the assigned Consulting Services Department cathodic protection specialist.

Surface Anode Bed: Anode or anodes connected to a common CP power supply,

installed either vertically or horizontally at a depth of less than 15 m (50 ft.).

Tension Spring Anode: An offshore anode assembly custom manufactured for Saudi
Aramco that is fabricated with mixed metal oxide anode components and suspended on
a wire rope/tension spring assembly beneath an offshore platform.

Test-line: A pipeline that is used for testing an individual well or group of wells.

Thermite Weld: An exothermic process for use in making electrical connections

between two pieces of copper or between copper and steel.

T/R: Transformer/Rectifier - A cathodic protection power supply that transforms and

rectifies AC power into an adjustable output DC power for cathodic protection
applications. Typically abbreviated or truncated as “T/R” or “Rectifier”.

Saudi Aramco: Company General Use

Page 9 of 23
Document Responsibility: Cathodic Protection Standards Committee SAES-X-500
Issue Date: 18 October 2018
Next Planned Update: 18 April 2021 Cathodic Protection of Vessel and Tank Internals

Transmission Pipeline: A cross country pipeline transporting product between GOSPs

WIPs or other process facilities.

Trunk-line: A pipeline designed to distribute or gather product from two or more

wells, typically connecting flow-lines or injection lines to the associated GOSP or WIP.

Uncoated Casing: The term “uncoated casing” when used in this engineering standard
describes a well casing that is either bare (no external coating), or may have an external
coating applied to the shallow sections of casing to minimize corrosion in the landing
base or surface soils.

Unconventional Deep Anode Bed: Anode bed drilled to typical depth of 120 meters
thru dry drilling using air or foam with a geotextile liner to 120 meters and PVC water
reservoirs on the top 60 meters.

Utility-line: A pipeline designed to deliver a service product (typically water, gas or air).

Utilization Factor: Utilization factor is a constant value, depending upon the shape of
anode and how it is attached, relates to reduction in anode size due to consumption to the
minimum size before it ceases to provide the required current output.

Vendor: A company that receives a purchase order to supply the finished product,
material or equipment. The Vendor may also be the Manufacturer.

Venturi Spool: A gas metering spool recording apparatus at gas well sites.

VpCI: Vapor Phase Corrosion Inhibitor

Well Casing: Large-diameter pipe lowered into an open hole and cemented in place.

Well Head: The system of spools, valves, and assorted adapters that provide pressure
control of a production well.

WIP: Water Injection Plant

5 Design Review and Approval

5.1 The proposed construction drawings and the related cathodic protection design
information for every design package in accordance with SAEP-303 shall be
submitted to the CP Proponent organization (as defined by GI-0428.001) and to
Saudi Aramco’s Consulting Services Department (CSD) for review and
approval.
Commentary Notes:

1) As noted in GI-0428.001, PMT should request assistance from CSD for the
verification of the qualifications of the Design Contractor’s engineer responsible

Saudi Aramco: Company General Use

Page 10 of 23
Document Responsibility: Cathodic Protection Standards Committee SAES-X-500
Issue Date: 18 October 2018
Next Planned Update: 18 April 2021 Cathodic Protection of Vessel and Tank Internals

for designing the CP systems.

2) It is recommended that the CP Design Agency hold a pre-design meeting with

CSD and the Proponent CP Group to outline the design approach for the Project
Proposal and Detailed Design.

5.2 The Design Agency shall not issue drawings for construction until the drawings
have been reviewed and approved in writing by CSD and the CP Proponent
organization or where applicable by the CSD approved local design office
Engineers and the CP Proponent organization.

5.3 Product hardware and software specifications and relevant design information
for all remote monitoring equipment proposed for cathodic protection systems
shall be submitted to the Supervisor of IT/COD/SCSD (Information
Technology/Communication Operations Dept/Satellite & Communication
Support Div.) for review and approval during the Project Proposal and Detail
Design phases of the Project.

5.4 The Project Proposal package shall provide all general design considerations
that can be developed without requiring measurement of field data. The process
data including but not limited to type of service, operating temperature,
operating pressure, coating details, pH and TDS of electrolyte, H2S, oxygen, and
Cl content along with existing CP system details (if any) shall be provided as an
input by the PMT team after collecting the same from Proponent.

5.5 DBSP and project proposal does not require conducting a site visit unless that is
mandatory to complete the package. The proposed construction drawings and
the related cathodic protection design information for every design package shall
at minimum be submitted to the CP Proponent organization (as defined by
GI-0428.001) and to Saudi Aramco’s Consulting Services Department (CSD) or
where applicable to the CSD approved local design office Engineers for review
and approval. The most up to date list of approved design offices is posted on
ShareK.

5.6 Unless specifically requested by PMT, DBSP does not need to be reviewed or
approved by CSD per SAEP-303. The DBSP shall specifically state if cathodic
protection is required, or is not required, as dictated by SAES-X-500. No other
design considerations for cathodic protection are required for the DBSP.
DBSP may be reviewed by CSD approved local design offices.

5.7 Unless specifically requested by PMT, project proposal does not need to be
reviewed or approved by CSD. Project Proposal packages submitted to CSD for
review shall provide all design considerations that can be developed without
requiring the measurement of field data or a site visit.

Saudi Aramco: Company General Use

Page 11 of 23
Document Responsibility: Cathodic Protection Standards Committee SAES-X-500
Issue Date: 18 October 2018
Next Planned Update: 18 April 2021 Cathodic Protection of Vessel and Tank Internals

The Project Proposal and 90% Design package should include:

a. The detailed CP Design Philosophy, scope of work / basis of the CP design
with reference to project specifications and applicable standards.
b. List all Critical CP Design’s assumptions, limitations and exclusions clearly.
c. Calculations of surface area of the structure to be protected.
Commentary Notes:

1) Surface area calculations shall be verified by PMT and/or proponent, review

and approval of any design packages by CSD is based on verified surface
area values provided in the design package.

2) Any change in surface area after CSD approval of CP design package shall be
reconsidered by CP Designer / CP Contractor in revised CP Design package
and require review and re approval from CSD.

d. All design calculations and applicable field data required to verify design
compliance with Saudi Aramco Cathodic Protection Engineering Standards.
e. Professionally drafted full size Index “X” CP drawings that:
● Detail each CP item by description and stock number if applicable.
● Detail the proposed location for each piece of CP equipment including
but not limited to T/Rs, anodes, junction boxes and test stations.
● Detail and specifically identify all cathodic protection cables including
all anode, structure, bond, and T/R cables.
● Clearly identify the specific and individual cable routing and termination
points within the respective junction boxes, bond boxes, and T/Rs.
● Detail all cathodic protection equipment using the cathodic protection
symbols shown on Standard Drawing AD-036785 “Symbols for
Cathodic Protection”.
f. All details for the Remote Monitoring System including details on the
hardware, software, and connectivity.
g. Detail all existing CP installations that could have an effect on the new CP
system, and also provide information on spare current capacity of existing
CP systems that will be utilized by the project.
h. All calculations and applicable field data are required to verify design
compliance with the Saudi Aramco Cathodic Protection Engineering
Standards. CSD's approval of the design calculations, using average fluid
resistivity values, does not relieve the designer from his responsibility of
meeting the required potential criteria stated by this standard.

Saudi Aramco: Company General Use

Page 12 of 23
Document Responsibility: Cathodic Protection Standards Committee SAES-X-500
Issue Date: 18 October 2018
Next Planned Update: 18 April 2021 Cathodic Protection of Vessel and Tank Internals

Commentary Notes:

1) Cathodic protection design considerations begin at the Design Basis Scoping

paper (DBSP) stage and should be reasonably developed by the Project
Proposal stage. The Project Proposal Design Package should include all
design considerations that can be developed without acquiring actual field
measurement data, including spare system capacity within the plant, proposed
anode type(s) and sizing of the cathodic protection power source(s).

2) The Detailed Design Package submitted to CSD for review, should present a
complete and comprehensive cathodic protection system design including all
required field measurement data, calculations, a detailed description of the
proposed cathodic protection equipment, and a set of detailed drawings that
illustrate the proposed placement of all cathodic protection equipment and the
associated protected structures.

5.8 The Project Proposal and 90% Detailed Design Package shall include a specific
statement in the scope of work that clearly identifies any requirement to provide
CP based on the data provided.

5.9 The Project Proposal and 90% Detailed Design Package shall provide clear
direction on the general design approach with respect to the following:

The CP power source shall be:

 Galvanic, or
 AC powered
 air cooled, or
 oil cooled
 single phase, or
 three phase

5.10 The Project Proposal and 90% Detailed Design Package shall clearly state if
remote monitoring equipment will be included per 17-SAMSS-018 with the CP
power supplies and if so it shall provide the following general design information:
a. Will the CP power supply be provided with:
 signal transmitters, or
 a Remote Monitoring Unit (RMU)
b. What operating parameters are going to be monitored (must meet minimum
requirements)
c. What communication system will be used for the remote monitoring system?
d. What software will be supplied for the CP Proponent? If the data is not
transmitted to the area Saudi Aramco PI data base, then the software shall

Saudi Aramco: Company General Use

Page 13 of 23
Document Responsibility: Cathodic Protection Standards Committee SAES-X-500
Issue Date: 18 October 2018
Next Planned Update: 18 April 2021 Cathodic Protection of Vessel and Tank Internals

be provided through the Project.

6 General Design Requirements

6.1 Contractor/Designer Qualifications

6.1.1 Cathodic protection designs shall be completed by CSD approved local

design offices with a minimum of five years verifiable cathodic
protection design experience and a minimum industry qualification of
NACE CP Level 4 and BS degree. Indicate the NACE CP level,
certification number, name of designer and/or his signature/initial in the
design package.

6.1.2 Field measurements required for the design, survey, installation, walk-
through, pre-commissioning, commissioning, inspection, monitoring,
restoration, replacement, troubleshooting, field-investigation, assessment
etc. shall be performed by an Engineer or Technician with a minimum
industry certification level of NACE CP Level 2. Indicate the NACE CP
level, certification number, name of designer and/or his signature/initial
in the design package.
Commentary Note:

As noted in GI-0428.001, PMT may request assistance from CSD for the
verification of the qualifications of the Design Contractor’s engineer
responsible for designing the CP systems and to approve new designers.

6.2 General / Philosophy / Limitations

When cathodic protection is required, based on recommendations from

Corrosion Engineering Group (CEG) - CSD considering important factors
including but not only limited to mentioned in Note 1 of section 1.2, as
appropriate corrosion mitigation measures, following CP design parameters
shall be considered.

6.2.1 Cathodic protection is required for the internal surfaces of metallic tanks
and vessels based on the following:
a) Cathodic protection shall be designed based on actual resistivity if
the resistivity of the electrolyte is less than 2,000 ohm-cm
b) Cathodic protection shall be designed based on design input of
2,000 ohm-cm if the actual resistivity of the electrolyte is between
2,000 – 5,000 ohm-cm. In such cases, potential criteria is not
applicable for commissioning or commissioning shall be carried out
during hydrostatic test (where possible).

Saudi Aramco: Company General Use

Page 14 of 23
Document Responsibility: Cathodic Protection Standards Committee SAES-X-500
Issue Date: 18 October 2018
Next Planned Update: 18 April 2021 Cathodic Protection of Vessel and Tank Internals

c) If the actual resistivity of electrolyte is greater than 5,000 ohm-cm,

cathodic protection is only required if deemed necessary by the
Cathodic Protection Proponent Organization and concurred by Saudi
Aramco's Consulting Services Department.

6.2.2 Determination of Need for CP in oil treating vessels is further explained

in section 3.2.1 of NACE SP0575.

6.2.3 Impressed Current Cathodic Protection (ICCP) is not recommended for

hydrocarbon and chemical tanks due to safety reasons and galvanic CP
shall be considered for such environments. For safety precautions while
designing CP systems in oil-treating vessels refer to Section 9 “Safety”
of NACE SP0575 – 2007.

6.2.4 Cathodic protection cannot reverse the corrosion damage that has already
occurred. Moreover, cathodic protection cannot protect surfaces that are
not in contact with electrolyte (non-submerged) during operation.

6.2.5 The CP system for vessels shall be based on internal configuration of the
vessel. Compartmented vessels should have at least one anode installed
in each compartment exposed to the corrosive field. Anodes should be
placed such that CP current can reach to all surfaces exposed to
electrolyte.

6.2.6 Number, weight and shape of anodes required for CP of vessels depends
on surface area to be protected, current density required, anticipated
anode output, vessel configuration and design life. For typical vessels
requirements of CP system including number, type and weight of anodes
etc. are governed by Standard Drawing AA-036388.

6.2.7 Only zinc alloy anodes typically known as “high temperature zinc
(HTZ)” specified by the manufacturer and approved by CSD/Cathodic
Protection as suitable for service at elevated temperatures from 50 -
70°C, aluminum alloy anodes shall be used above 70°C in all
applications. Refer to Standard Drawing AA-036389.

6.2.8 Anode monitoring system (AMS) is mandatory requirement for CP

system of all vessels regardless of application. Refer to Standard
Drawing AA-036389.

6.2.9 Cathodic protection shall be provided by galvanic or impressed current

systems for water storage tanks according to Standard Drawings
AA-036353 and AA-036354. Design drawings shall use standardized
symbols for cathodic protection equipment in accordance with Standard
Drawing AD-036785.

Saudi Aramco: Company General Use

Page 15 of 23
Document Responsibility: Cathodic Protection Standards Committee SAES-X-500
Issue Date: 18 October 2018
Next Planned Update: 18 April 2021 Cathodic Protection of Vessel and Tank Internals

6.2.10 Cathodic protection of sumps and bottoms of crude tanks and product
storage tanks shall be cathodically protected by galvanic anodes
according to Standard Drawing AA-036762.
Commentary Note:

CP requirements for final product tanks shall be decided in consultation

with Corrosion Engineering Group (CEG)-CSD.

6.2.11 For galvanic anode system for tank internals, CP designers should be
aware of limitations of CP and tank design effects on CP. Please see
sections A.5 and A.6 of NACE SP-0196.

6.2.12 An impressed current system utilizing inert anodes shall be used where
undesirable contamination of the contained liquid would occur due to the
corrosion products of other anode materials.

6.2.13 CP designs as per standard drawings AA-036389 and AA-036762 with

no change / modification prepared by CSD approved CP designers can
go to construction without CSD approval; however, such designs shall
still be reviewed by Area Technical Support and/or Proponent.
Commentary Notes:

1. CP designs that use standard drawings but considers several modifications

due to either changes to dimension of the tank/vessel or process
parameters etc. shall be submitted to CSD for review and approval.

2. Anode quantity mentioned in the standard drawings shall be taken as the

minimum requirements only.

6.2.14 For Tank Internal CP system, all internal metallic structures, i.e., pipework
and appurtenances shall be coated (where applicable) and included in CP
surface area calculations where they are immersed. For galvanic CP
system in oil treating vessels, coating shall be considered for all internal
mixed metal structures. Where coating is not possible or not applicable,
i.e., stainless steel coalescence packing, it shall be designed to remain
electrically isolated from the structure throughout the design life.
Commentary Note:

Isolation failure may result in accelerated anode consumption and

ineffective CP which means the exposed surfaces are prone to corrosion.

6.2.15 For applications with sea water electrolyte where ICCP system is selected
with MMO anodes, required MMO coatings thickness of anodes shall be
calculated based on manufacturer’s data sheet and required current
demand for each project considering handling damages and consumption

Saudi Aramco: Company General Use

Page 16 of 23
Document Responsibility: Cathodic Protection Standards Committee SAES-X-500
Issue Date: 18 October 2018
Next Planned Update: 18 April 2021 Cathodic Protection of Vessel and Tank Internals

rates during design life to avoid titanium substrate exposure to sea water
which may result in failure if reached to its breakdown voltage.

6.3 Design Life

6.3.1 The minimum design life for galvanic anode systems shall be either
8 years, or the testing and inspection (T&I) period plus one year,
whichever is greater.

6.3.2 The minimum design life for impressed current cathodic protection
(ICCP) systems shall be either:
 25 years, or
 Equal to design life of the structure (tank / vessel) or
 Three times the testing and inspection (T&I) period plus one year
{3 x (T&I period +1)}, whichever is greater.
Commentary Note:

T & I period mentioned above is usually 7 years, addition of one year

is required due to possible extension / necessary arrangements, etc.

6.3.3 The consumption rates detailed below in Table 2 shall be used for the
calculation of the design life of galvanic anodes. Each anode must serve
the required life taking into account its current output, the equation
detailed below:

𝐴𝑛𝑜𝑑𝑒 𝑊𝑒𝑖𝑔ℎ𝑡 (𝑘𝑔𝑠) × 𝑈𝑡𝑖𝑙𝑖𝑧𝑎𝑡𝑖𝑜𝑛 𝐹𝑎𝑐𝑡𝑜𝑟

[ ] ≥ 𝐷𝑒𝑠𝑖𝑔𝑛 𝐿𝑖𝑓𝑒 (𝑌𝑒𝑎𝑟𝑠)
𝐴𝑛𝑜𝑑𝑒 𝑂𝑝𝑒𝑛 𝐶𝑖𝑟𝑐𝑢𝑡 𝑃𝑜𝑡𝑒𝑛𝑡𝑖𝑎𝑙 − 𝑃𝑟𝑜𝑡𝑒𝑐𝑡𝑒𝑑 𝑃𝑜𝑡𝑒𝑛𝑡𝑖𝑎𝑙
{𝐶𝑜𝑛𝑠𝑢𝑚𝑝𝑡𝑖𝑜𝑛 𝑅𝑎𝑡𝑒 × ( ) }
𝐴𝑛𝑜𝑑𝑒 𝑅𝑒𝑠𝑖𝑠𝑡𝑎𝑛𝑐𝑒

Commentary Note:

For the life calculation of a galvanic anode system, use the lowest
water (electrolyte) measured resistivity value for the planned.

Table 2 – Consumption Rates for Galvanic Anodes (kg/A-Y)

ANODE TYPE
Zn
Structure Al Mg Zn
(High Temp) (¹)
Water Storage Tanks 3.8 10.95 11.8 11.8

Process Vessels (²) 6.9 N/A 11.8 11.8

Process Vessels (³) 23.3 N/A N/A 16.1

Saudi Aramco: Company General Use

Page 17 of 23
Document Responsibility: Cathodic Protection Standards Committee SAES-X-500
Issue Date: 18 October 2018
Next Planned Update: 18 April 2021 Cathodic Protection of Vessel and Tank Internals

Notes:
(1)
Zinc anodes shall be certified by the manufacturer for maximum consumption
rates at 70°C of equal to or better than the consumption rates listed in Table 1.
(2)
Process vessels for this application are those vessels that contain no dissolved
H2S and normally operate at temperatures below 50°C.
(3)
Process vessels for this application are those vessels that contain dissolved
H2S and normally operate at temperatures above 50°C.
(4)
N/A indicates not applicable, or not suitable for this application

Commentary Note:

The consumption rates detailed in Table 2 are corrected for efficiency,

however, a utilization factor of 0.85 shall be included in the calculations.

6.3.4 Following equations shall also hold true for the proposed CP design:
𝐶𝑢𝑟𝑟𝑒𝑛𝑡 𝐷𝑒𝑚𝑎𝑛𝑑(𝐴𝑚𝑝) × 𝐷𝑒𝑠𝑖𝑔𝑛 𝐿𝑖𝑓𝑒 (𝑦𝑒𝑎𝑟𝑠)𝑥 8760
[ ] ≤ 𝑇𝑜𝑡𝑎𝑙 𝑤𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑎𝑙𝑙 𝑎𝑛𝑜𝑑𝑒𝑠
𝑈𝑡𝑖𝑙𝑖𝑠𝑎𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝐴𝑛𝑜𝑑𝑒 𝑥 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 𝑜𝑓 𝐴𝑛𝑜𝑑𝑒

𝐼𝑛𝑑𝑖𝑣𝑖𝑑𝑢𝑎𝑙 𝑎𝑛𝑜𝑑𝑒 𝑐𝑢𝑟𝑟𝑒𝑛𝑡 𝑜𝑢𝑡𝑝𝑢𝑡 × 𝑇𝑜𝑡𝑎𝑙 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝐴𝑛𝑜𝑑𝑒𝑠 𝑃𝑟𝑜𝑝𝑜𝑠𝑒𝑑 ≥ 𝐶𝑢𝑟𝑟𝑒𝑛𝑡 𝐷𝑒𝑚𝑎𝑛𝑑

Commentary Notes:

1) Current demand shall be calculated by multiplying surface area to be

protected with required current density.

2) Individual anode current output shall be calculated based on the

resistance of selected anode (calculated using dimensions of anode) and
electrolyte resistivity.

6.3.5 The consumption rates detailed in Table 3 shall be used for the
calculation of the design life of impressed current anodes using the
equation detailed below:
𝑇𝑜𝑡𝑎𝑙 𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝐴𝑙𝑙 𝐴𝑛𝑜𝑑𝑒𝑠(𝑘𝑔𝑠)
[ ] ≥ 𝐷𝑒𝑠𝑖𝑔𝑛 𝐿𝑖𝑓𝑒 (𝑌𝑒𝑎𝑟𝑠)
{𝐶𝑜𝑛𝑠𝑢𝑚𝑝𝑡𝑖𝑜𝑛 𝑅𝑎𝑡𝑒 × 𝐶𝑃 𝑃𝑜𝑤𝑒𝑟 𝑆𝑜𝑢𝑟𝑐𝑒 𝐷𝑒𝑠𝑖𝑔𝑛 𝐶𝑢𝑟𝑟𝑒𝑛𝑡 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 }

Table 3 – Design Parameters for Impressed Current Anode Materials

Current Density
Anode Material Consumption (kg/A-Y)
Maximum (mA/cm2)
HSCI 0.5 0.7
MMO1 Not applicable
(see manufacturer’s Require CSD approval
specification for 25 year life)
Any other Require CSD approval Require CSD approval
Note: (1) Inert anodes (i.e., MMO) shall not be used in vessels that have hydrocarbon
products (asphaltine).

Saudi Aramco: Company General Use

Page 18 of 23
Document Responsibility: Cathodic Protection Standards Committee SAES-X-500
Issue Date: 18 October 2018
Next Planned Update: 18 April 2021 Cathodic Protection of Vessel and Tank Internals

6.3.6 The maximum allowable current density and voltage characteristics

detailed in Table 4 shall be used for the design of impressed current
anode systems.

Table 4 – Current Density and Voltage Maximums

for Impressed Current Anodes
A N O D E T Y P E (1)
HSCI Mixed Metal Oxide
60.0 (Salt Water)
Current (mA/ cm²) 0.7
11.0 (Fresh Water)
Voltage (volts) 100 Per Manufacturer Rating

Notes:
(1) Do not exceed manufacturer's rated current output of anodes in the applicable
electrolyte.
(2) Inert anodes (i.e., MMO) shall not be used in vessels that have hydrocarbon
products (asphaltine).

6.3.7 Temporary CP is not required for tanks and vessels designed to be

protected by galvanic anode CP system. For ICCP designed CP systems,
CP system should be energized as soon as possible (within 90 days) after
the tank is filled with electrolyte.

6.4 Current Density Criteria

The system design shall provide the minimum current density values for coated
and uncoated surfaces shown in Table 5.

Table 5 – Minimum Current Density Requirements (mA/m²)

Current Density
Surface
Process / Water (1) Process / Water (2) Sea Water
Coated Tanks 0.5 3 13.0
Coated Vessels 3.0 11.0 13.0
Uncoated Tanks & Vessels 30.0 108 65.0

Notes:
(1) Tanks and vessels for this application are those vessels that contain no dissolved H 2S
and normally operate at temperatures below 50°C.
(2) Tanks and vessels for this application are those vessels that contain dissolved H2S and
normally operate at temperatures above 50°C.
(3) N/A indicates not applicable, or not suitable for this application.

Saudi Aramco: Company General Use

Page 19 of 23
Document Responsibility: Cathodic Protection Standards Committee SAES-X-500
Issue Date: 18 October 2018
Next Planned Update: 18 April 2021 Cathodic Protection of Vessel and Tank Internals

Commentary Note:

Suitable temperature correction factor shall be applied to values mentioned

above for tanks and vessels that contain no dissolved H2S and operating more
than 50°C.

6.5 Protection Criteria

The cathodic protection potential shall comply with the following potential
criteria:

6.5.1 The minimum steel-to-electrolyte potential shall be equal or more

negative than negative 0.9 V (on) with reference to a silver/silver
chloride electrode, or equal or less positive than 0.15 V (on) with
reference to a zinc electrode.

6.5.2 A minimum of 100 mV of cathodic polarization (potential decay)

between steel-to-electrolyte. The “potential decay” is the decrease in
potential between the “instant off” and the steady state off potential.
Refer to NACE SP0388 for further details.
Commentary Note:

This criteria shall not be used when mixed-metal components or

dissimilar metals are in contact for example steel pipeline in contact with
copper or stainless steel (pipe or tubing).

6.5.3 The maximum steel-to-electrolyte potential for impressed current

systems shall be equal or less negative than negative 1.5 V (on) with
reference to a silver/silver chloride electrode, or equal or less negative
than negative 0.45 V (on) with reference to a zinc electrode.
Exception:

The maximum limit of the criteria can be exceeded subject to

demonstration that polarized potential has not exceeded negative 1.15 V
with respect to a silver/silver chloride electrode and negative 0.1 V with
reference to a zinc electrode.

6.6 Anodes

6.6.1 Anode materials (manufactured in accordance with 17-SAMSS-006 or

17-SAMSS-007) shall be selected from Table 2 in Section 6.3.3 or Table 3
in Section 6.3.4.

6.6.2 The number and location of anodes shall depend upon the accessibility
of components, the current requirement, and the configuration of the tank
or vessel. Shielding by structural members or compartments shall be
recognized and accounted for in the design.
Saudi Aramco: Company General Use
Page 20 of 23
Document Responsibility: Cathodic Protection Standards Committee SAES-X-500
Issue Date: 18 October 2018
Next Planned Update: 18 April 2021 Cathodic Protection of Vessel and Tank Internals

6.6.3 Magnesium anodes shall not be used if the electrolyte resistivity at

normal operating temperature is less than 500 ohm-cm.

6.6.4 Zinc anodes shall not be used in environments where temperature

exceeds 50°C, except for high temperature zinc anodes which meets the
requirements in Table 2 of Section 6.3.3.

6.6.5 Mercury activated aluminum anodes and zinc anodes shall not be used in
water systems where humans and/or animals may consume the water.
All Saudi Aramco approved aluminum and zinc anodes do not contain
mercury.

6.7 Circuit Resistance

6.7.1 For a T/R, the CP system rated circuit resistance shall be defined as the
T/R rated voltage, divided by the T/R rated current. Rated voltages and
currents are as detailed on the manufacturer's data sheet/plate.

Example, 1 ohm is the rated resistance for a 50V/50A rectifier.

6.7.2 The CP system operating circuit resistance for an ICCP system shall be
defined as the total effective resistance seen by the output terminals of the
respective ICCP power supply, and for calculation purposes shall include:
a. Anode resistance to water.
b. Positive cable resistance from CP power source to anodes.
c. Negative (cable)s resistance from CP power source to structure.
d. Effective resistance caused by +0.95 volts anode back emf
(for MMO in water plus the structure back emf -0.9 volts
(example: -0.9 volts tank back emf + 0.95 volts anode bed back emf
= 1.85 volts total between the anodes and structure).

6.7.3 ICCP system designs shall take into consideration the calculated
operating resistance and shall size the positive and negative cables and
voltage rating of the T/R such that the “calculated” operating output of
the T/R complies with all of the following:
a. At the design stage only, the target commissioning current shall be
achieved at a voltage between 40% and 60% of the T/R rated voltage
output. The target commissioning current shall be achieved at a
voltage between 30% and 70% of the T/R rated voltage output.
b. The normal operating output current shall be achieved with the
voltage adjustment set at more than 10% of the available (rated) T/R
voltage output.
Saudi Aramco: Company General Use
Page 21 of 23
Document Responsibility: Cathodic Protection Standards Committee SAES-X-500
Issue Date: 18 October 2018
Next Planned Update: 18 April 2021 Cathodic Protection of Vessel and Tank Internals

Commentary Note:

The above section is a mandatory design requirement but is not a

mandatory requirement for commissioning acceptance.

6.7.4 The CP system “operating” circuit resistance measured during

commissioning of a new CP system shall not be greater than 90% of the
CP power supply “rated” circuit resistance.

6.8 DC Power Source

6.8.1 Cathodic protection rectifiers shall be manufactured in accordance with

17-SAMSS-004.

6.8.2 Install the CP power supplies in accordance with Saudi Aramco Standard
Drawing AB-036378 sheets 1 and 2.

6.8.3 Selection of type of T/R shall be as per Table 1 of 17-SAMSS-004.

Use oil immersed T/Rs (type ONAN) inside hydrocarbon plant areas, for
all outdoor marine environment applications, and for Class I Division 2
(Zone 2) applications.

6.8.4 DC power supplies shall have a maximum rated output voltage of no

greater than 100 volts. The sizing of the T/R shall be optimized based on
the circuit resistance in accordance with Section 6.7 of this standard.

6.8.5 For hazardous areas (maximum Class I, Zone 2), the design agency shall
select a cathodic protection DC power supply (and other CP system
equipment) that complies with the requirements of NEC Articles 500 to
504 for hazardous (Class I, Zone 2) areas. CP equipment shall not be
placed in Class 1 Zone 1 areas.

6.8.6 Transformer/Rectifiers and junction boxes shall be permanently and

systematically labeled in line with the plant electrical devices and
equipment labeling system. Use T/R for transformer/rectifier and J/B for
junction box. Transformer/rectifier example is ANDR-GOSP-1-T/R-07.
Junction box example is ANDR-GOSP-1-T/R-07-J/B-12.

6.9 Cables

All cathodic protection cables including the primary positive and negative cables
shall be sized to comply with the most recent edition of NFPA 70, National
Electric Code (NEC).
Commentary Note:

For typical applications, use the 90°C column in Table 310.15(16) and refer to
310.15(B)(2) to consider an ambient temperature of 40°C to calculate the
Saudi Aramco: Company General Use
Page 22 of 23
Document Responsibility: Cathodic Protection Standards Committee SAES-X-500
Issue Date: 18 October 2018
Next Planned Update: 18 April 2021 Cathodic Protection of Vessel and Tank Internals

ampacity for HMWPE cables.

6.10 Junction Boxes

Cathodic protection junction boxes shall be manufactured in accordance with

17-SAMSS-008.

7 Installation, Records, Commissioning, and Inspection

Refer to Saudi Aramco Best Practice SABP-X-003. SABP-X-003 shall be deemed a

mandatory document for this standard.

As built drawings and documents as well as Commissioning Reports shall be submitted

to Proponent for review and approval.

Commissioning Reports shall be submitted to CSD for information and feedback.

Refer to Saudi Aramco Engineering Procedures SAEP-332 for commissioning and

SAEP-333 for monitoring procedures.

Revision Summary
22 April 2013 Revised the “Next Planned Update.” Reaffirmed the content of the document, and reissued
with several editorial changes and mandated the need for NACE CP qualifications.
24 July 2013 Editorial revision.
18 April 2018 Major revision incorporating all ideas and comments accepted during value engineering
workshop.
18 October 2018 Editorial revision.

Saudi Aramco: Company General Use

Page 23 of 23