FFS-SU-5221

ALUMINUM ALLOY ANODES FOR OFFSHORE

PLATFORM CATHODIC PROTECTION

APPLICATION: FLOATING & FIXED PLATFORMS

This document is the confidential property of Chevron USA Inc. Neither

the whole nor any part of this document may be disclosed to any third
party without the prior written consent of Chevron USA Inc. Neither the
whole nor any part of this document may be reproduced, stored in any
retrieval system or transmitted in any form or by any means (electronic,
mechanical, reprographic, recording or otherwise) without the prior
written consent of Chevron USA Inc.

Rev

Date

Description

Author

Sponsor

10/2006

Initial release

RYOS

DCOC

12/2008

Document number change only.

Formerly CPM-SU-2.03

September 2006

2006 Chevron USA Inc. All rights reserved.

CWAN

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Aluminum Alloy Anodes for Offshore

Platform Cathodic Protection

FFS-SU-5221

CONTENTS

1.0

Scope ..........................................................................................................................3

2.0

References ..................................................................................................................3
2.1 ......Purchaser Documents ......................................................................................3
2.2 ......Industry Codes and Standards .........................................................................3

3.0

Specification Review .................................................................................................3

4.0

Physical Specifications .............................................................................................3

4.1 ......Anode Cores ....................................................................................................4
4.2 ......Casting .............................................................................................................4
4.3 ......Anode Weight Tolerance ..................................................................................4
4.4 ......Dimensional Tolerance .....................................................................................5
4.5 ......Casting Defects ................................................................................................5
4.6 ......Marking .............................................................................................................5

5.0

Chemical Composition ..............................................................................................6

5.1 ......Composition .....................................................................................................6
5.2 ......Testing ..............................................................................................................6

6.0

Electrochemical Specifications ................................................................................7

6.1 ......Electrochemical Requirements .........................................................................7
6.2 ......Closed-Circuit Potential Testing .......................................................................7
6.3 ......Alloy Energy Capacity Testing .........................................................................9

7.0

Inspection and Reporting ..........................................................................................9

7.1 ......General .............................................................................................................9
7.2 ......Reports ...........................................................................................................10

8.0

Shipping and Handling ............................................................................................10

8.1 ......Packaging .......................................................................................................10
8.2 ......Shipping .........................................................................................................10

9.0

Identification and Marking .......................................................................................10

10.0

Workmanship ...........................................................................................................11

11.0

Safety ........................................................................................................................11

Appendix A Aluminum Anode Detail (Approximate) for Example Purposes ..........12

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Aluminum Alloy Anodes for Offshore

Platform Cathodic Protection
1.0

FFS-SU-5221

SCOPE
1. This specification sets forth the minimum requirements for the manufacture of cast galvanic
aluminum standoff anodes for offshore applications.
2. Any exceptions to this specification requested by the manufacturer shall be stated at the time
of bid.

2.0

REFERENCES

2.1

Purchaser Documents
FFS-DS-5221

2.2

Data Sheet for Aluminum Alloy Anodes for Offshore Platform Cathodic
Protection

Industry Codes and Standards

American Petroleum Institute (API)
SPEC 5L

Specification for Line Pipe

American Society for Testing and Materials (ASTM)

A 106

Standard Specification for Seamless Carbon Steel Pipe for

High-Temperature Service

A 53

Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-coated,

Welded and Seamless

D 1141

Standard Practice for the Preparation of Substitute Ocean Water

Det Norske Veritas (DNV)

RP-B401

Cathodic Protection Design

National Association of Corrosion Engineers International (NACE)

RP0387

Metallurgical and Inspection Requirements for Cast Sacrificial Anodes for

Offshore Applications

TM0190

Impressed Current Laboratory Testing of Aluminum Alloy Anodes

No. 2 (SSPC-SP 10) Near-White Metal Blast Cleaning

(Joint Surface Preparation Standard)
Society for Protective Coatings (SSPC)
SP 10 (NACE No. 2) Near-White Metal Blast Cleaning
(Joint Surface Preparation Standard)
3.0

SPECIFICATION REVIEW
1. Prior to award of the contract for anode manufacture, Purchaser reserves the right to have all
bidders attend a meeting to review the specifications.
2. At this review meeting any exceptions to this specification will be discussed, and production
schedules finalized.

4.0

PHYSICAL SPECIFICATIONS
Except as modified below, the manufacture of anodes shall be in accordance with the most
up-to-date version of NACE RP 0387.

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Aluminum Alloy Anodes for Offshore

Platform Cathodic Protection
4.1

FFS-SU-5221

Anode Cores
1. The core shall be carbon steel seamless or ERW pipe which is in compliance with the latest
revision of any of the following specifications: ASTM A 106 Grade B, ASTM A 53 Grade B,
or API 5L Grade B PSL1 or PSL2.
2. Cores shall be of the nominal diameter shown on the bid drawings and shall be a single piece
of weldable pipe Schedule 80 or heavier. Core lengths which contain a butt weld shall not be
allowed.
3. Unless otherwise specified, straight pipe cores shall protrude from the end faces of the anode
as shown in Appendix A.
4. The core diameter should not exceed 50 percent of the anode vertical or horizontal centerline
cross section dimension. Additionally, the minimum alloy cover on the anode core shall be
two inches to help minimize casting defects from shrinkage during the manufacturing process.
5. Core pipe shall be new and of prime quality.
a. Each anode core shall be marked with the anodes unique heat and sequence numbers, and
with the manufacturers initials, such that the marking is visible after casting of the anode.
b. For heat-treated anodes, a heat-treatment batch number shall also be marked.
c. These markings shall agree with the mill certificates which will also be provided.
6. Purchaser reserves the right to inspect the pipe core material.
a. Pipe that has been remarked, pipe without markings or pipe with illegible markings will be
rejected.
b. Pipe that is cut prior to inspection by Purchaser or its representatives will be rejected.
7. The anode cores shall be free from oil, grease, rust, foreign matter, sharp corners or anything
likely to compromise the bonding of the aluminum to the core. At the time of casting, the core
pipe condition shall have been blasted and maintained to meet the requirements of
NACE 2/SSPC-SP 10.
8. The core shall be positioned within the anode mold 0.25 inch of the centerline of the casting
cross section. In the finished anode, the core shall be 0.5 inch of the specified location. The
core shall extend through the ends of the anode.

4.2

Casting
1. Each anode shall have been cast in one pour.
2. Intermediate solidifications shall not be acceptable.

4.3

Anode Weight Tolerance

1. Each anode shall be individually weighed.
a. The gross weight and net aluminum weight shall be recorded.
b. The net aluminum weight shall be calculated as the gross weight minus the core weight.
c. If each individual core is not weighted, then the core weight shall be determined as the
average weight of 10 percent of the cores as determined before casting.
2. Individual anodes of each type and of nominal weights greater than 110 pounds shall be within
3 percent of the nominal weight or 5 pounds, whichever is greater.

September 2006

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Aluminum Alloy Anodes for Offshore

Platform Cathodic Protection
4.4

FFS-SU-5221

Dimensional Tolerance
The anodes shall be cast within the tolerances shown in Table 1.
Table 1:

Casting Tolerances

Anode length:

1/2 inch

Core length:

1/2 inch

Anode width and height:

1/4 inch

Finished core centrality:

1/2 inch of centerline

Straightness shall not deviate from the longitudinal axis by more than 1 percent of
nominal anode length.
4.5

Casting Defects
The following casting defects shall result in rejection of the anode:
1. Anode weights or dimensions outside of tolerance.
2. Cold laps not metallurgically bonded to the anode.
3. Shrinkage cavities shall be limited to one face of the anode only and shall not exceed 1/2 inch
in depth for anodes up to 400 pounds net weight or 3/4 inch in depth for anodes exceeding
400 pounds net weight.
4. Cavities, excluding shrinkage cavities on the top cast surface of the anode, which exceed
1/2 inch length or diameter and 1/4 inch deep.
5. Slag or non-metallic inclusions covering more than 1 percent of the anode surface.
6. Any mechanical treatment to the anode such as peening, grinding or filling which may be
construed as an attempt to mask casting defects.
7. Longitudinal cracks exceeding 1/8 inches wide and 6 inches length.
8. Transverse cracks greater than 3/16 inch wide at the surface of the anode.
9. Transverse cracks which extend around more than two complete adjacent surfaces of the
anode.
10. Cracks that intersect or can be projected to intersect in such a manner that loss of anode could
result.

4.6

Marking
1. The following information shall be metal stamped in letters 1/8 inch high or greater onto the
aluminum anode end:
a. heat number
b. anode number (pouring sequence)
c. manufacturers initials
2. Order number or other identification (such as color code), if specified, to distinguish anode
sizes or alloys supplied by manufacturer shall also be marked onto each anode core in such a
way as to remain visible through to the installation stage.

September 2006

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Aluminum Alloy Anodes for Offshore

Platform Cathodic Protection
5.0

CHEMICAL COMPOSITION

5.1

Composition

FFS-SU-5221

The alloy used in the manufacture of the anodes shall be in accordance with the requirements of
this specification and shall comply with the Purchaser approved anode chemistry described in
Table 2.
Table 2:

Purchaser Approved Aluminum Alloy Composition

Al-Zn-In Alloy

ELEMENT

Minimum
(% by wt)

Maximum
(% by wt)

Zinc (Zn)

4.75

5.75

Indium (In)

0.016

0.025

0.08

0.12

Iron (Fe)

0.06

Copper (Cu)

0.003

Cadmium (Cd)

0.002

0.02 each

Tin (Sn)
Silicon (Si)

Other

elements1

Total other elements

Aluminum (Al)2
1.
2.

5.2

0.05
Balance

Balance

No additions other than indium, zinc, or silicon are allowed.

Raw aluminum stock shall be not less than 99.80% pure. No scrap
aluminum or recycled anodes may be used.

Testing
It is the anode manufacturers responsibility to conduct all testing and inspections as specified
herein. Purchaser, or a representative of its choice, may witness all and any phases of testing and
inspection.
5.2.1

Methods
The following methods of chemical assay are acceptable:
1. atomic absorption
2. optical emission spectrometer
3. inductively coupled plasma

5.2.2

Equipment Calibration
1. The method and calibration standards used to calibrate the chemical assay equipment
must be available for review by Purchaser, or a representative of its choice.
2. Purchaser reserves the right to provide calibration standards for the chemical assay
equipment and have the equipment calibrated to those standards without cost to
Purchaser.

September 2006

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Aluminum Alloy Anodes for Offshore

Platform Cathodic Protection
5.2.3

FFS-SU-5221

Sampling Frequency
1. Samples for chemical assay analysis shall be collected at three intervals for each heat,
or each batch of heats representing 5 tons of produced alloy.
2. Samples shall be taken from the start, middle, and end of pour.
3. The chemical composition of all three samples shall be tested and recorded.
4. Test samples and test data are to be retained by the manufacturer for 5 years from the
date of anode delivery.

5.2.4

Acceptance Criteria
1. All samples must show chemical composition within the limits of the specification.
2. If any sample falls outside the specification, two additional samples cut from the
anodes produced in that heat may be retested.
3. If both these cut samples are within the specification, all anodes in the heat shall be
accepted, if either of these cut samples are out of specification, all anodes in the heat
shall be rejected.

6.0

ELECTROCHEMICAL SPECIFICATIONS

6.1

Electrochemical Requirements
1. This section covers the minimum electrochemical performance requirements for the alloy and
the methods for testing.
2. The manufacturer shall submit their own published specifications, at the time of bid
presentation, for the following:
a. closed circuit potential (vs. SCE)
b. alloy energy capacity (amp-hrs/lb)
3. If the manufacturers specifications claim superior performance (i.e., more negative open
circuit potential or greater current capacity), then the manufacturers values shall apply.
4. Manufacturers values are subject to approval by Purchaser.

6.2

Closed-Circuit Potential Testing

6.2.1

Accepting Values
The closed-circuit potential of the alloy shall meet the minimum criteria shown in Table 3.

Table 3:

Minimum Criteria

Alloy

Al-Zn-In

September 2006

Current Capacity

Closed Circuit Potential

(mV vs. SCE)

(A-hr/lb)

(A-hr/kg)

Minimum

Average

Minimum

Minimum

-1.030

-1.080

1136

2500

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Aluminum Alloy Anodes for Offshore

Platform Cathodic Protection
6.2.2

FFS-SU-5221

Test Procedures
1. One sample shall be tested from each heat, or each batch of melts representing 5 tons
of produced alloy. The sample shall be representative of the finished anode material
and shall be drawn from the middle of the pour.
2. For each heat, a middle of pour sample shall be collected then stamped with the heat
number and manufacturer identity. These samples shall be provided to Purchaser at
the time of anode delivery along with all required documentation prior to payment
(see Section 5.2 of this specification).
3. The hydrogen evolution method shall not be used to qualify anodes unless otherwise
specified.
4. Tests shall be performed with a constant current density of 4 mA/in2 impressed onto
the sample from a constant current power supply.
5. Tests may be performed on either cut or as-cast surfaces. All test surfaces shall
receive a pretreatment per NACE TM 0190.
6. Tests shall be performed in a quiescent room temperature air-exposed test solution
conforming to ASTM D 1141. Test solution pH and temperature shall be recorded
daily and the solution shall be changed if the pH falls outside the range 49.
7. Potential values shall be recorded using a laboratory grade saturated calomel reference
electrode fitted with a Luggin probe, in conjunction with a high input impedance
digital voltmeter. Several readings, distributed over the sample surface, shall be
observed with the Luggin probe 1 millimeter from the anode surface, and the
minimum and average values shall be recorded.
8. A single test shall be run using a single sample for 14 days.
9. Anode potentials shall be measured at the beginning and end of an 8 hour working
day, after the initial 24 hour period and until the 14th day of monitoring.
10. The minimum and average of the readings for each sample must meet those specified
in Table 3.
11. No anodes will be shipped until the conclusion of the current capacity test, unless
otherwise approved in writing by Purchaser.

6.2.3

Test Accuracy
1. One SCE reference electrode shall be designated the primary reference, and shall not
be used for routine potential measurements.
2. Before each set of anode potential measurements, the secondary reference electrode
used for routine measurements shall be checked against the primary reference and the
potential difference recorded.
3. If the secondary reference shows a discrepancy of more than 5 mV to the primary
reference, it shall be discarded.
4. If more than one secondary reference fails this test, it may be necessary to replace the
primary reference with a new, unused SCE reference electrode.

September 2006

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Aluminum Alloy Anodes for Offshore

Platform Cathodic Protection
6.3

FFS-SU-5221

Alloy Energy Capacity Testing

6.3.1

Acceptance Criteria
1. Energy capacity, determined by mass loss, shall meet a minimum of 1136 A-hrs/lb.
2. If the manufacturers standard specifications are indicative of higher values, then
those values will apply.
3. The minimum value stated applies to each independent heat.

6.3.2

Mass Loss Testing

1. Fourteen day mass loss test data shall be collected from the samples in the 14 day
potential test, performed using NACE TM0190.
2. Energy capacity shall be calculated from the following formula:
C = I T 453.6 / (Wi-Wf)

where:
C = alloy capacity (A-hrs/lb)
I = current passed (amperes)
T = test duration (hours)
Wi = initial sample weight (grams)
Wf = final sample weight (grams)
3. Current Time (Coulombs) shall be determined by placing a copper coulometer in the
circuit.
a. Coulometer weights shall be reported with the sample weights.
b. Data from a digital coulometer will be accepted provided it is reported in the test
results.
6.3.3

Changes to NACE TM0190

1. Cut or as-cast surfaces may be used for testing.
2. Both cut and as-cast surfaces shall be pretreated per NACE TM0190.
3. Rinse and wash step shall be performed with reagent grade water and brush only.
4. Samples to be oven dried for weight loss.

7.0

INSPECTION AND REPORTING

7.1

General
1. The anode manufacturer is responsible for conducting all testing and inspections as specified
herein.
2. Purchaser, or a representative of its choice, may witness all and any phases of the testing and
inspection.

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Aluminum Alloy Anodes for Offshore

Platform Cathodic Protection
7.2

FFS-SU-5221

Reports
1. All inspection and testing documentation shall be submitted to Purchaser and/or its designated
representative. Submission of satisfactory test documentation is a condition for shipment
release.
2. Documentation (to be retained by the manufacturer for five years) required for each heat and
for inspection and testing in accordance with this specification shall include, but not be limited
to, the following:
a. purchase order number
b. manufacturers name
c. pipe core mill certification
d. heat number, sequence number, and number of anodes per heat
e. alloy name
f.

chemical analysis reports

g. closed circuit potential test results

h. current capacity test results
i.

dates of casting and testing

j.

heat-treatment temperature charts (for heat-treated anodes only)

k. net and gross weights of each anode

l.
8.0

heat and sequence numbers of each rejected anode and reason for rejection

SHIPPING AND HANDLING

FFS-DS-5221 or an alternate approved at the time of bidding shall be used for reporting.

8.1

Packaging
1. Anodes shall be packed in bundles after inspection.
2. Anodes shall be adequately fastened to withstand all reasonable shipping and handling without
damage.

8.2

Shipping
1. Qualified anodes shall be shipped to the designated job site specified on the purchase order.
2. Care shall be taken to prevent the possibility of interchange with non-qualified anodes.
3. The bill of lading must clearly show the number of anodes shipped and their respective heat
and sequence identification numbers.

9.0

IDENTIFICATION AND MARKING

1. Each anode core shall be steel-die stamped with the anodes unique heat and sequence number
and with the manufacturers initials, such that the marking is visible after casting the anode.
2. For heat-treated anodes, a heat treatment batch number shall also be marked.

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Aluminum Alloy Anodes for Offshore

Platform Cathodic Protection
10.0

FFS-SU-5221

WORKMANSHIP
Workmanship shall be in accordance with the Technical Requirements and with the requirement
that specialized tasks such as welding structural steel shall be accomplished only by suitably
qualified and certified personnel.

11.0

SAFETY
Safety shall be in accordance with the requirement that the Contractor shall select equipment and
employ installation methods that will ensure safe installation and operation of the Cathodic
Protection system.

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Aluminum Alloy Anodes for Offshore

Platform Cathodic Protection

FFS-SU-5221

APPENDIX A ALUMINUM ANODE DETAIL (APPROXIMATE)

FOR EXAMPLE PURPOSES

45q CORE

STRAIGHT THROUGH CORE

ANODE CROSS SECTION

Approximate
Anode Gross
Weight
45o
Straight
(lb)
(lb)
450
430

A
(in)
96

B
(in)
95

C
(in)
6

725

930

860

96

95

93/4

93/4

108

1115

1350

1285

120

119

95/8

111/2

Alloy
Net
Weight
(lb)
385

830

1060

1000

G
1

120

119

Approximate Dimensions
D
E
F
H
(in)
(in)
(in)
(in)
1
3
7 /2
6 /4
108 140

9 /4

9 /16

(min)
(in)
12

Core2
(in)
2

156

12

132

182

12

132

182

12

These dimensions are approximate. The anode pour depth (and therefore top width) may be adjusted slightly to meet the critical Alloy
Net Weight specification.
2

Nominal core size, Schedule 80 pipe

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