Case Study: Design and Installation Aspects of Cathodic Protection of Above Ground Storage Tanks in a large Tank Farm Project in Africa

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A large-scale refinery is being set up in Africa. The refinery includes the construction of tank farms consisting of 150+ above ground storage tanks with diameter varying from 4.1m to 92m for the storge of crude oil, intermediate and products. Tanks are constructed on various types of tank foundations such as Ring beam foundation, sand pad foundation with fire bricks and without fire bricks.

Product Number: 51323-19040-SG

Author: Shailesh Javia

Publication Date: 2023

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This case study addresses the design and installation of cathodic protection systems for new construction above ground storage tanks (150+ ASTs) with non-conductive polyethylene liner in tank foundation in a large tank farm project in Africa. Design and installation reliability were identified as key factors by the project owner and will be the focus of this paper. The project is in final stage of completion and expected to be commissioned in early 2023.

In this paper we will discuss the design process and the installation challenges associated with a large EPC project being designed in Asia, installed in Africa with components being supplied from the United States and India. Knowing the challenges presented at the site, the design was tasked to minimize on-site fabrication and to facilitate ease of installation and testing of cathodic protection system. The design used custom manufactured, factory tested, pre-assembled mixed metal wire based linear anode segments with lead cables for an exceptionally simple installation while assuring the highest system reliability.

Transformer Rectifier Units with remote monitoring facility and programmable current interruption facility for synchronized ON/OFF interruption are used on this project. A customized central monitoring system was developed to manage the numerous tanks located in several areas around the site.

This paper will discuss the lessons learned during the execution of this large project and focus on the design process, manufacturing of anodes, rectifiers, central monitoring system and the installation works.