CORROSION MATTERS

DESIGN , ENGINEERING AND INSTALLATION MANUAL FOR PERMANENT CATHODIC PROTECTION SYSTEM FOR UNDERGROUND PIPELINE.

CORROSION MATTERS - ,
ND

FLOOR , SWATHI PLAZA

RAJBHAVAN ROAD, SOMAJIGAUDA, HYDERABAD

PHONE NO TELEFA

EMAIL kbswaroop@corrmatt.com WEBSITE www.corrmatt.com

Page 1 of 48

CORROSION MATTERS

COMPANY OVERVIEW

Corrosion Matters , this company has been founded by Corrosion and Electrochemical En ineers in to cater to pro ects, related to corrosion prevention systems For prevention of corrosion , our team of en ineers , are havin hands on experience in handlin time bound and critical pro ects of importance. The company is actively en a ed in Cathodic Protection related comprehensive desi n and pro ect mana ement services for pro ects that are typically , cross country pipelines, complex plant Under round pipin , Onshore and Offshore facilities , City Gas and Water mains, above round stora e tanks , concrete steel structures etc. The company has been chosen to foresee and supervise construction pro ects and key assets of National and International Importance in Oil and Gas sectors. The Ob ective of the company is to provide services to the industry to the minute detail and innovate user friendly methods of Cathodic Protection Applications which shall help the industries world over in a lon way.

REGARDS,

CORROSION MATTERS

Page 2 of 48

CORROSION MATTERS

CATHODIC PROTECTION SYSTEM FOR U G PIPING ( CROSS-COUNTRY)

. SCOPE OF WORK

The scope of work covers the Desi n, En ineerin , Supply of Materials, Installation, Testin & Commissionin of Permanent cathodic protection system for external surface of under round pipeline includin post commissionin surveys such as Coatin Conductance Measurements ,CIPL survey, Pearson detection followed by DCVG [for defect classification] at defect locations evinced. Also ettin specific approval for ma or activities like Soil Resistivity survey & site data eneration/collection. CP Desi n & Detailed En ineerin Field Testin & Commissionin Procedures for interference testin & miti ation All ma or installation Procedures Coatin conductance, CPIL & PEARSON Survey. Post Commissionin , Monitorin methodolo y & frequency formats

Page 3 of 48

CORROSION MATTERS

SOIL RESISTIVITY SURVEY

Soil resistivity survey should be carried out at at minimum two plots for each proposed CP station as option for selectin best location for construction. Soil resistivity will be carried out at different depth and at all anode bed locations. The locations of anode round bed plot will be selected based on the land availability to avoid problems durin construction & keepin maintenance in view. However from the resistance

calculations it can be decided type of anode bed. Land selection for anode round bed has been taken base on followin broad uidelines, however final decision to be taken at site based on land availability. . site for shallow round bed should have minimum the pipeline. . Location shall be remote (anode remoteness requirement to be calculated based on desi n current ratin with local resistivity & criteria) . Accessibility of location and route for layin of anode header cable shall be checked and marked on plot plan drawin . . . Anode bed shall not be situated below HT line and near electrical earthin . Lowest resistivity location shall be considered over options available, for better anode round bed resistance option. mtr perpendicular distance from

Page 4 of 48

CORROSION MATTERS

DESIGN BASIS & CRITERIA

The intent of this section is to propose desi n data and criteria for the Permanent Cathodic Protection System.

. .

Cathodic Protection Design Life & Current Density

In accordance with the pro ect specification, the Cathodic Protection system will be desi ned to have a desired desi n life in years. For Example : The Pipeline external surface is coated with considered for the desi n is as follows: i) ii) For Polyethylene coated Pipeline (Normal Soil) For Polyethylene coated Pipeline (Salt pan Area) . i.e. : A m A m Layer Polyethylene ( LPE) coatin and the current density

A safety mar in of

has been provided for the current calculations over and above the

specified protective current density.

. .

Philosophy of Cathodic Protection System for Permanent CP

The Cathodic protection systems shall be a MMO Lida anodes systems and shall be desi ned for Deepwell and Horizontal type anode bed.

. .

Codes & Standards

Latest revision of followin standards shall be considered S -Cathodic Protection-Part Cathodic Protection code of Practice for Land and Marine Applications S: CP: NACE RP Protection of Iron & Steel Structures From Corrosion. Miti ation of alternatin current and Li htnin Effects on Metallic structures and corrosion control systems NACE RP NACE RP Electrical Isolation of Cathodically protected pipelines Control of external corrosion on under round or submer ed metallic pipin system.

CP_MANUAL.doc

Page 5 of 48

CORROSION MATTERS
NACE TM Measurement techniques related to criteria for cathodic protection of under round-submer ed metallic pipin system.

NACE Publication No NACE RPO.

Cathodic protection monitorin for buried pipelines. For Deep well CP

. .

Cathodic Protection Design Criteria for Perma nent CP

Cathodic Protection system shall be desi ned to meet the followin criteria: . The pipe to Soil Potential measurements shall be in between (-) . V Off and (-) . . V Off

as measured between the pipe surface and a copper copper sulphate reference electrode. . In rare circumstances a minimum polarization shift of (-) mV shall indicate adequate levels of

cathodic protection for the pipeline with the written permission from owner. . A positive potential swin of mV shall be considered as the criteria for presence of an

interaction situation requirin investi ation and incorporation of miti ation measures.

CP_MANUAL.doc

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CORROSION MATTERS

Cathodic Protection Stations

In line with the pro ect specifications and desi n calculations, location and No. of CP Station shall be proposed as under:-

S.N.

CP Stn. Location

CP Station No.

Chainage (Km)

Type

Rating

(SV (SV (SV (SV

) ) ) )

CP CP CP CP

DESIGN CALCULATION

The followin Calculation shall be used for desi n the permanent cathodic protection system

. .
i.

Total Cathodic Protection Current Requirement

Surface Area

Sa =

x Dx L

Where : Sa D L ii. = Surface area of Pipeline m = Diameter of pipeline m = len th of pipeline m Current Requirement It = Sa x Cd x . Amps.

Where It Sa Id . = C.P. current requirement (Amp) = Surface area of Pipeline m = C.P. protective current density mA/m = Safety Mar in

CP_MANUAL.doc

Page 7 of 48

CORROSION MATTERS
The current requirement calculations shall be tabulated as under:

CP station

Area

Classification

Chainage (Km)

Dia. (mm)

Protection span (Km)

Total Km

Surface Protective Current Area (m ) Current Required Density (A) (Amp.)

From

TO

CP

(SV ) (SV )

CP

CP

(SV )

CP

(SV )

CP_MANUAL.doc

Page 8 of 48

CORROSION MATTERS

. .
Current N A = I t Ia . Where

Anode Requirement

NA = It Ia Weight W = = =

Total Anode Wei ht (K .) C.P. current requirement Out put current of Anode ( Amps)

I t x C t x L Uf

Where W Ct It Uf = = = = Total Anode wei ht (K ) Consumption Rate of anode ( m /Amp-year) C.P. current requirement Anode utilization factor

Total current requirement as per Location design (Amps)

Out put current of individual anode (Amps)

Type of Anode

Anode required as per current (Nos)

Anode required as per Weight (Nos.)

Number of Anode proposed (Nos)

CP CP CP CP

(SV (SV (SV (SV

) ) ) )

CP_MANUAL.doc

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CORROSION MATTERS

. .
i)

Ground bed Resistance calculation

Horizontal Grounded Resistance Calculation

The resistance of horizontal anode to electrolyte is calculated by the followin formula :

Rs = .

Ps [ Ln ( L Where

L(S

L ) DS

S (S L

L)

)] L

Rs = Ps = L =

Resistance to earth in ohms of the horizontal anode () Soil Resistivity in - m Len th of Active Anode in Mtr Diameter of Active Anode in Mtr Twice the depth of Anode (M)

D = S =

ii)

DEEP ANODE BED RESISTANCE CALCULATION

The resistance of deep anode to electrolyte is calculated by the followin formula : Rdb = . L Where Rdb Ps L D = = = = Resistance to earth in ohms of the Deep anode () Soil Resistivity in m Len th of Active Anode in Mtr Diameter of Active Anode in Mtr Ps [ Ln ( L d)- ]

iii)

INDIVIDUAL ANODE TO BACKFILL RESISTANCE

Rbs = . L

P [ Ln (

L d)- ]

where
Rbs = Ps = Individual Anode to backfill resistance in ack fill Resistivity for calcined petroleum coke breeze ( -cm )

L = Len th of Anode in mtr. d = Diameter of Anode in mtr.

CP_MANUAL.doc

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CORROSION MATTERS
TOTAL ANODE TO BACKFILL RESISTANCE

Rtbs = Rbs N where Rtbs = Rbs = N iv) = Total Anode to ackfill Resistance in Individual Anode to backfill resistance in Number of Anodes

TOTAL GROUND BED RESISTANCE OF THE BED Rtbs

Rgb = Rs

= =

Total Ground bed resistance Resistance of vertical /Horizontal Anode to earth in ()

Rs Rtbs =

Total Anode to ackfill Resistance in

v)

TOTAL CABLE RESISTANCE

ANODE TAIL CABLE RESISTANCE OF SHALLOW GROUNDBED Sin le core copper conductor Armoured cable of specification. sq.mm is selected as Anode Tail Cable as per tender

Ri = L i x R Where Ri Li R = = = Individual Anode lead Cable resistance in ( i = Len th of Anode cable in meters Resistance of sq.mm cable = . / km to )

Rta =

R ........ R n)

CP_MANUAL.doc

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CORROSION MATTERS

HEADER CABLE RESISTANCE FOR CP SYSTEM Sin le core copper conductor cable of sq.mm is selected as Anode and Cathode Header cable .

Rac = R ( Lac L cc )
Where Rac = Lac = Lcc = R = Resistance of Header Cable Len th of Anode Header Cable Len th of Cathode Cable Resistance of sq.mm cable = . / km

TOTAL RESISTANCE OFFERED BY ALL CABLES Rtc = Rta Rac Rtc Rta Rac = = = Total cable resistance Total anode tail cable resistance Total Header Cable Resistance

vi)

TOTAL CIRCUIT RESISTANCE Rtcr = R Rtcr Rtotal = R

b b

Rtotal = Total circuit resistance in

Total cable resistance in = Total Ground bed resistance in

vii) It

OUTPUT OF SYSTEM = = current required for CP Station in amps Total Circuit resistance in : Volts = = It x Rtcr V

Rtcr

ack Volta e

Additional Volta e to drive the required current (V) Total Output Volta e (Vt)

CP_MANUAL.doc

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CORROSION MATTERS
viii) REMOTE EARTH CALCULATIONS Followin Formulae is used to calculate the distance to remote earth VE = xA/ xxd

Where A D VE = = = = Resistivity in Ohm- mtr Current in Amps Distance between pipeline & Anodebed in mtr Volta e at Pipeline V

Remote earth volta e shall be less than the Natural PSP i.e. - .

CP_MANUAL.doc

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CORROSION MATTERS

Summary of Design Calculation

CP Stn. Locati on ( )

Average Soil Resistivity ( mtr Considered ( )

Proposed No. of Anodes

Installed Anode

Type of Anode Bed ( ) Depth (mtr) ( )

Size of Anode bed.

Total Ground Total cable Rtance (Rtc) ( )

Total circuit Rtance (Rtcr) ( )

Total out put required Amps (It) ( ) Volts (Vt) ( )

Remote earth Voltage (Volts) ( )

Distance between Anode bed to Pipeline proposed (mtr) ( . )

Type ( )

No ( )

current Ratin (Amps) ( ) (Amps) ( )

Active Len th (mtr) ( )

Dia / Width (mm) ( )

Distance between Anode ( )

bed Rtance -

Rab ()
( )

SVSVSVSV-

Note If column (

) is less than pipeline Natural PSP , the distance of remoteness is sufficient.

CP_MANUAL.doc

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CORROSION MATTERS

.
i) Ap

Length Of Pipeline Protected From Drain Point

CROSS SECTION AREA OF PIPELINE = x t x ( D-t ) where A D T = = = Cross section area of Pipe Diameter of Pipe Thickness of pipe in m

ii) Rs

LINEAR RESISTANCE OF PIPE = s x l A where s A l = = = Resistivity of steel pipe Cross section area of pipe Unit len th of pipe ( . x
-

in km

) ohm meter

iii)

COATING LEAKAGE RESISTANCE PER KM FOR LPE COATING

Rl

Rp Sakin per km

where Rp = Coatin resistance in Surface area of pipe per Km

Sak =

iv)

ATTENUATION CONSTANT - = ( Rs Rl )
.

Where Rs Rl = = Linear Resistance of pipe Coatin leaka e resistance

v)

MINIMUM POTENTIAL SHIFT AT END POINT

Page 15 of 48

CP DESIGN / PERM / CORRMATT

CORROSION MATTERS

Edp = where P/s min P/s nat

P s min - P s nat in Volts

= Least ne ative PSP at end point = Natural PSP of pipeline

vi)

LENGTH OF PIPELINE PROTECTED FROM DRAIN POINT

Lp =

) x Cosh- (Edp Ed)

Summary of current Attenuation calculation Dia (mtr) Thickness (mm) Surface Area of Km Pipe (m ) Resistivity of steel pipe (ohm-m) Coatin Resistance of Pipe (ohm/ m ) Linear Resistance of pipeline (ohm/km) Coatin Leaka e resistance of Pipe (ohm/km) Attenuation constant Least ne ative PSP at end point Natural PSP of pipeline Minimum potential shift at end point Max. PSP at drain point Len th of pipeline protected from drain point

CP DESIGN / PERM / CORRMATT

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CORROSION MATTERS

Sample Design Calculation for CP Station for Span Length from

Equation

to

Km
Value m . m m . Amps m . . . . mA/mt grams Amps m/A-Y Years . . . . m/m ) Nos rams rams unit

Description Sa Surface area

. . Sa = P x d x l

d l

Dia Len th Total Current requirement

. . It = Sa x Id x . /

It

Sa Surface area Id Current density

. .

W Total Anode Weight It W = I t x Ct x L / U f Ct L Uf Total Current Consumption Rate Life Anode Utilization factor

. . Nw = W/ Wa

Nw No of Anode required by weight W Total Anode Wei ht Wa Wei ht of Anode (Thickness of MMO Coatin

CP DESIGN / PERM / CORRMATT

Page 18 of 48

CORROSION MATTERS
. .

Nt No of Anode required by current Nt = It/ Ia It

Total current

. .

Nos Amps Amps

Ia Anode output current

GROUND BED RESISTANCE CALCULATION FOR SHALLOW HORIZONTAL ANODE BED . .

RS Individual anode to backfill resistance PS Soil Resistivity

Rs = . Ps/L Ln( L L (S L )
.

Ohms ohmmtr Nos mtr . mtr mtr . Ohms ohm. mtr mtr

)/DS) ( S/L) (S L ) . /L )

N No of Anodes L
Active len th of anode

D Active diameter of Pre-packed anode bed S

. . Twice the depth of Anode

Rbs Individual anode to backfill resistance Pb L d

ackfill Resistivity for Calcined Coke Len th of anode Diameter of anode . .

Rbs = .

Pb/L

Ln (

L / d)-

mtr Ohms . ohms Nos

. .

Rtbs Total Anode to Backfill Resistance Rtbs = Rbs/N Rbs Individual anode to backfill resistance N Number of Anodes

CP DESIGN / PERM / CORRMATT

Page 19 of 48

CORROSION MATTERS

. .

R b = Rs Rtbs

Rgb Total Ground bed Resistance Rs Resistance of vertical Anode to earth Rtbs Total Anode to ackfill Resistance

. . . .

Ohms Ohms Ohms Ohms mtr

Rta = /( /R ) ( /R ) R i = Li x R R &R . . R &R = R &R = R &R = . . x . x . x . . . . = . = . = . ohms ohms ohms = x . . = . ohms

..

/R

Rta Resistance of Anode Tail Cable

Li Len th of Anode cable

Resistance of

mm cable

. . .

Ohm/Mtr Ohms Ohm/mtr mtr mtr . . . . . . Ohms Ohms Ohms Ohms Ohms Ohms

Rac Resistance of Header cable R Rac = R ( Lac L cc ) Lac Len th of Cathode cable lcc Len th of Anode cable
Resistance of mm cable

. .

Rtc Total Reisistance offered by All cables Rtc = Rta Rac Rac Resistance of Header cable Rta Resistance of Anode tail cable

. .

Rtotal Total Circuit Resistance Rtotal = R

b

Rtc

Rgb Total Ground bed Resistance Rtc Total Reisistance offered by All cables

CP DESIGN / PERM / CORRMATT

Page 20 of 48

CORROSION MATTERS
. .

Vt Total Output Voltage Rtotal Total Circuit Resistance Vt = (Rtotal x It) Volts It
Total Current ack Volta e .

Volts Ohms

Amps Volts

. .

Vx Vx = I / L

Voltage rise in earth with earth

respect to remote . Volts Ohms Mtr Amps is

Soil Resistivity L I
Distance between P/L and Anode bed Maximum current output

From above electrically remoteness calculations for Anode bed, it can observed that Volta e raise in earth with respect to remote earth at a distance less than to pipeline Volta e to earth (ie . V) & Remoteness of anode round bed can be achieved . .

Ap Cross section area of Pipe

D Diameter of Pipe (m) Thickness of pipe

. . .

Mtr Mtr Mtr

Ap = P x t x ( D-t )
t P . . ohm K m

Rs Linear Resistance of pipeline s Rs = s x l / Ap

I Resistivity of steel pipe unit len th of pipe

. .

ohm-mtr mtr

Ap Cross section area of Pipe

CP DESIGN / PERM / CORRMATT Page 21 of 48

mtr

CORROSION MATTERS
. . . ohm K m ohmmtr .

Rl Coating Leakage Resistance for LPE Rl = Rp/Sa Rp Coatin Resistance Sa Surface area per Km
. . .

mtr . . . . - . ohm/Km ohm/Km V

attenuation Constant =( Rs/Rl )

.

Rs Linear Resistance of pipeline Rl Coatin Leaka e Resistance for LPE

. .

Edp Maximum potential shift at drain point P/s

Edp =P/s max - P/s nat

max

Least ne ative PSP at drain point

- . V

P/s
nat

Natural PSP of pipeline

- .

. .

Ed Maximum potential shift at end point P/s

- . V

Ed =P/s min - P/s nat

min

Least ne ative PSP at end point

- .

P/s
nat

Natural PSP of pipeline

- . . - .

V Km V

. .

Lp Length of P L protected from drain point Lp=( /) x Cosh- (Edp/ Ed)

Edp Maximum potential shift at drain point Ed Maximum potential shift at end point

- . V .

attenuation Constant

CP DESIGN / PERM / CORRMATT

Page 22 of 48

CORROSION MATTERS

. INSTALLATION PROCEDURES . . TEST STATION JUNCTION BO

Purpose :

INSTALLATION

Test stations/ Junction box shall be provided along the pipeline ROW for monitoring the performance of the Cathodic Protection system
Materials Required : Shuttering Plates, Reinforcement, Concrete Mix, CableLugs , Ferrules

Detailed Procedure: The location of the test stations/junction box shall be marked on row as per approved design with their connection scheme and other related information on alignment sheet. The test stations/junction box shall be installed with the front of the test station facing the pipeline. The overall dimensions of foundations shall be 600 mm(W) x 700 mm (H) X 500 mm (D). Excavate 1m x 1 m x 1 m where the foundation is to cast. Place reinforcement properly and take TLP bend and place it properly in the reinforcement. Take MS shuttering and place it in right position. Fill annular space with RCC Mix. The mixture shall be constantly rammed for proper compaction. Remove the shuttering after 24 hrs. The foundation shall be cured properly or it shall be coated with curing compound. Place the TLP boxes/Junction boxes on the studs of the bend cast in concrete foundation and tighten the bolts. The bolts shall then be distorted by hitting with a heavy hammer to make the installation vandal/theft proof

CP DESIGN / PERM / CORRMATT

Page 23 of 48

CORROSION MATTERS
Precautions: All the connections should be checked for proper tightening. Cable core ferrules are to be provided at end before final termination Door of the TLP/Junction box should face Pipeline Cable should be neatly dressed inside the trench and to be terminated inside test station. In case of location, where sacrificial anode is to be installed, the same should be taken parallel and the anode cable to be terminated at test station.

Documentation: Inspection Reports shall be furnished as per the report formats attached below:

CP DESIGN / PERM / CORRMATT

Page 24 of 48

CORROSION MATTERS INSPECTION AND TEST PLAN FOR TEST STATION / J.B INSTALLATION
PROJECT OWNER CONTRACTOR CP CONTRACTOR REFERENCE DOCUMENT PERSONAL RESPONSIBLE

SR NO

ACTIVITY APPROVAL OF TEST STATION INSTALLATION PROCEDURE CHECK LOCATION CONCRETE FOUNDATION SIZE, RCC MIXTURE, REINFORCEMENT & CURING INSTALLATION TEST POST MOUNTING ABOVE FONDATION TERMINATION OF CABLES IN THE TEST STATION

CPC

CONTRACTOR OWNER

1 2 3

P P P

W W W

A RM RM

4 5 LEGEND

P P

W W

RM RM

A - APPROVAL / ACCEPTANCE; R - REVIEW OF RECORD; RM - RANDOM CHECK W - WITNESS ALL; P- PERFORM

CP DESIGN / PERM / CORRMATT

Page 25 of 48

CORROSION MATTERS

SITE INSPECTION REPORT FOR TEST STATION/ JUNCTION BOX INSTALLATION

PROJECT OWNER CONTRACTOR CP CONTRACTOR REF. DOC UMENT Test station Location ( Chainage in Km) Test Station Type Distance from Pipeline Foundation Test Station Mounting Cable Termination Final Restoration Notes : Acceptable /Not Acceptable Acceptable /Not Acceptable Acceptable /Not Acceptable Acceptable /Not Acceptable

CPC Name Signature Date

CONTRACTOR

OWNER

CP DESIGN / PERM / CORRMATT

Page 26 of 48

CORROSION MATTERS

PR C C P

UR F R

This procedure covers installation of Deep ground bed as per standard drawing & design document. M R
r o

R QU R
Material/ ool Make pplication/Purpose

Crimping Tool Excavation tools & Auggers Measuring Tape Petroleum coke breeze Canister Tubular anode

Standard Standard Standard Goa Carbons Standard Lida / SME / other approved Netco/Suyog Standard

For crimping cable with lug For Excavation Measurement Backfill material Sheet steed for Backfilling Anodes for Anode bed

Anode Tail cable Cu Sleeves/ Cable Lug/D clamps/Ferrules, PVC pipe & Warning mat etc. Electrical Tool Box Casing Pipe for Deep anode bed PVC Shrouding Pipe PVC Vent Pipe

Connection to pipe

Standard Standard Standard Standard Casing Pipe for Deep anode bed For Deep anode ground bed For Deep Well

PR C

UR F R

PW

Locate the Drilling Rig at approved deep well ground bed location. Start the drilling of borehole with suitable diameter drilling bit and drill a suitable depth as per approved document. borehole of

Lower the casing pipe one after the other.

mm one length at a time and coupling various lengths

with couplers

After lowering MS casing pipe, a PVC shrouding pipe equal to the inactive length of the deep well ground bed shall be lowered along the casing pipe from the top.

Mark length equal to the required depth on the tail cables of anodes to avoid excessive lowering.

CP DESIGN / PERM / CORRMATT

Page 27 of 48

CORROSION MATTERS
Tie all MMO anodes with vent pipe and cables to gather, and also install the centralizers for each anodes and End weight to last anode as per design approval. Anodes shall be lowered with suitable nylon rope. Nylon rope shall be binded with end weight. Mix the coke breeze with water to form slurry. Fill the slurry coke breeze inside the bore well up to the active length and rest backfill with metal gravel, this is to ensure proper filling of entire borehole. Backfilling to be done till overflowing from top of the pit, and than allow it to settle, fill the top of pit as per approved drawing, with metal gravel after settling time of two-three days. Clamp / Tie the anode tail cable and lay up to anode junction box All the tail cables and Header cable shall be laid and terminated in anode junction box. Prepare Anode pit and cover as per approved drawing.

F RH R Z Length of the ground bed shall be according to the approved design package. Total depth of excavation in horizontal ground bed shall be as per design document. Cross section of bottom of the trench should be as per approved design document, as the same is only considered for anode bed resistance calculation. The shape of excavated trench from top to bottom need not be precise. Moreover, it shall depend on nature of soil at the site. Pour back ill into the trench and tamp it to a level corresponding to . m from bottom of

trench. Pour sufficient water on coke breeze and mix with wooden plank to prepare slurry. Mark the locations of individual canister anodes alongside the trench as spacing indicated in the approved design package and place the individual anode horizontally within the trench on the bed of the backfill prepared. Anode tail cables of individual anodes should be coiled and kept on ground adjoining the trench. Pour backfill into the trench and tamp it to a level corresponding to design requirement. Take care while tamping the coke breeze so that the anode connection or cable is not damaged . Again pore sufficient water on top of the spread up coke breeze all over the anode so that slurry can be achieved. Lay Tail cable & header cables and bring them up to proposed anode junction box location as per standard drawing. PVC sleeve to be provided on all anode tail cables up to entry of anode junction box, for mechanical protection.

CP DESIGN / PERM / CORRMATT

Page 28 of 48

CORROSION MATTERS
At . m depth all anode tail cable and anode header cable to be laid as per cable laying

procedure. Earth restoration work with proper compaction to be carried out at cable laying and anode bed location. Layout of anode installation in anode bed shall be as detailed out in the drawing showing anode installation.

PR C U Lower anode carefully to avoid damage to tail cable, Canister anodes should never be handled by cables, but rope to be used for the same. After lowering clamp/Tie the cable to avoid further slide Tail cables and PVC conduits shall be of sufficient length so as to reach Anode Junction Box without any joint and providing sufficient slack for future maintenance purpose. Each shallow anode bed shall contain anodes with canisters positioned in the soil with suitable backfill at appropriate depth with due regards to type of configuration. Keep tail cable lengths sufficient so as to reach anode junction box without any joint and providing sufficient slack for future maintenance purpose

All cables are to be appropriately tagged before lowering cables in to trench/well. Provide cable core ferrules at end before final termination.

H,

Y&

VR

Hazard Identification and risk assessment will be carried out and Operational Control measures shall be adopted for Anode Installation Activities.
i. ii. Necessary PPE to be utilized Only trained personnel to be deployed for this activity.

QU

UR

C & QU

YC

Quality Assurance shall be maintained by ensuring the systematic implementation of this Procedure and ensure that necessary quality records are generated as per ITP.

CP DESIGN / PERM / CORRMATT

Page 29 of 48

CORROSION MATTERS P C H WH R Z P F R PW /

PR J C W C CP C R R C R R

R C

P R

CPC : SITE ENGINEER / SUPERVISOR CONTRACTOR/ OWNER : INSPECTOR CONTRACTO

SR NO

ACTIVITY

CPC R

OWNER

APPROVAL OF DEEP GROUND BED PROCEDURE CHECK LOCATION CHECK DEPTH CHECK CASING PIPE LOWERING CHECK ANODE LOWERING FILLING OF COKE BREEZE LEGEND

P P P P P P

R W W W W W

A A R R RM R

A - APPROVAL / ACCEPTANCE; R - REVIEW OF RECORD; RM - RANDOM CHECK W - WITNESS ALL; P- PERFORM

CP DESIGN / PERM / CORRMATT

Page 30 of 48

CORROSION MATTERS

SITE INSPECTION REPORT FOR DEEPWELL ANODE INSTALLATION

PR J C W C CP C R F R R R C R R C

R C C

LOCATION DISTANCE OF ANODE BED FROM PIPELINE DIA OF CASING PIPE LENGTH & DIAMETER OF BORE HOLE NO OF ANODES IN THE STRING ANODE RATING ANODE LOWERING COKE BREEZE FILLING Notes: OK / NOT OK OK / NOT OK

CPC ame ignature ate

R C

CP DESIGN / PERM / CORRMATT

Page 31 of 48

CORROSION MATTERS

PP

Pipe o Cable Connection y hermit Welding cope This procedure covers Thermit Weld for cable connection to pipeline for all type of cables related to Cathodic Protection System. Cable to Pipe connection during construction shall be done by Thermit welding method. Materials Required

r o

Material/ ool Crimping Tool Thermit Mould & Sparking Gun Cad Weld Powder, CA Cables Hammer & Chisel & CA

Make Standard Erico, USA Erico, USA Netco Standard

pplication/Purpose For crimping cable with lug/ferrule Thermit welding & Igniting Welding Connection to pipe Hammering test for Thermit & Coating cutting For sealing of Cable to pipe joints Coating Repair Filing. Sealing for PVC funnel For Cable Connections Surface Cleaning Surface cleaning For coating check

Epoxy DobefilHardnerPVC Funnel M seal / Mastic Cu Sleeves Fine File Sand Paper Holiday Detector

Doctor Beck Doctor Beck Local Mahindra / CPC Standard Local Local Caltech

Procedure Excavate wherever pipeline backfilled with soil a pit over the pipeline to expose the pipeline top surface at location of Thermit weld where cable to pipe connection is to be carry out as per design document. Care should be taken not to damage the coating of buried pipeline. Only manual excavation shall be carried out over pipeline. Mark where connection is to be carried out. If there are more than one connection as per design document, consecutive marking shall be minimum minimum mm apart. Connection location shall be

mm apart from other connection and Welding joint, Seam or Circumferential Weld

CP DESIGN / PERM / CORRMATT

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CORROSION MATTERS
Joint of the pipeline. The location for cable to pipe connection shall be selected such that the pipe joints and field-coated areas are avoided. Cut open the coating on the pipeline with care and without damaging the pipe for a size of approximately mm x mm suitable for thermit weld mould .

Clean the surface of the pipeline to white metal finish using sand paper and cleaning with fine file as required.

Depending on the size of cable select the model of cad weld material i.e. CAmould.

or CA-

and

Copper sleeve of suitable size shall be double Crimped on the cable up to

sqmm cable .

Place the mould on the exposed area and pour the cad weld material. Ignite using the gun and wait for minutes cool down period.The resistance of Cable to pipe at thermite connection point

shall not exceed . Test the connection by striking . Kg hammer directly over the connection. And if connection fails, the above procedure shall be repeated after waiting time of approx. pipeline surface. Place a plastic funnel around the exposed area such that about mm wide coating remains in min.to cool the

side the plastic funnel. Apply mastic/Mseal around the plastic funnel to prevent leakage of encapsulation materials. Mix proper quantity of epoxy-hardner and keep mixing with wooden rod till it gets heated, Fill up the conical funnel from the top by pouring mix of Epoxy Dobofil : and hardener at

ratio. / th of the cone to be illed with mix and remaining plastic cone to cut after setting of

the hardener. Allow the epoxy-hardener to set ensuring every metallic part of joint is completely insulated and test the insulation level by a holiday detector at KV.

Cable shall be laid in accordance with approval cable laying drawings. Cable route shall be carefully measured and cable cut to be required length from test station to pipe. A loop of approx . mtr.of cable shall be kept at both pipe and Test Station end.

Precautions a. b. c. Only Manual excavation to be done without damaging the coating. All cables are to be appropriately tagged. Location of cable to pipe connection shall be minimum mm apart from other connection

and from Pipe weld joint, Seam or Circumferential Weld Joint

CP DESIGN / PERM / CORRMATT

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CORROSION MATTERS
d. Check hardness of encapsulation before holiday test by applying pressure with thumb/Wooden Stick. e. f. Coating repair and holiday test should be completed before backfilling. Maximum grams Ignition powder shall be used for each connection. If one connection min for pipeline cooling and then repeat the procedure for

fails, wait of approx connection. Health, afety & nvironment

Hazard Identification and risk assessment will be carried out and Operational Control measures shall be adopted for Anode Installation Activities.
Necessary PPE to be utilized Only trained personnel to be deployed for this activity.

CP DESIGN / PERM / CORRMATT

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CORROSION MATTERS

SITE INSPECTION REPORT FOR THERMIT WELD CONNECTION

PR J C W C CP C R F R R R C R R C Chainage Thermit welding Length No. of Pipe to Cable Connection

R C C

Test Station Type Type of Cable to Pipe Connection Cable Size C x SQMM Cable Cx Cx SQMM Cable SQMM Cable

Resistance of cable to pipe at thermit connection point Hammer Test Holiday Test Pipe to soil potential Natural w.r.t. Zinc Reference Half cell C x SQMM Cable Cx Cx SQMM Cable SQMM Cable

Acceptable / Not Accebtable

OK / NOT OK

Sealing of exposed area of pipe with Epoxy Sealing material CPC

ignature ame ate

R C

CP DESIGN / PERM / CORRMATT

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CORROSION MATTERS

PR C
Purpose

UR F R C MM

G F PCP Y

To describe the procedure for commissioning of Permanent cathodic protection system and provide adequate quality assurance / control of workmanship and inspection at site.

cope This procedure will cover commissioning of the Impressed Current C.P system installed to protect under ground pipeline from external corrosion. quipments Soil resistivity meter Digital multimeters Portable reference electrodes Megger

Commissioning Procedure

On completion of installation of anode beds and other systems as envisaged in the specification, they shall be individually checked, tested and compared against the agreed specifications and procedure.

The CP commissioning shall be carried out with current interrupter provided in the output of the CPPSM unit to measure CP ON & OFF potentials.

Current dissipated by each anode shall be corrected through anode lead junction box. Electrical continuity of the entire pipeline shall be verified in conformity with design. Input resistance of the pipeline at all the drainage points shall be checked and recorded. All current measuring test stations shall be calibrated and recorded. Temporary protection facilities provided if any which do not form part of permanent CP shall be disconnected from the sytem & removed unless agreed otherwise.

The pipeline shall be allowed to depolarize for atleast if any of all other pipelines in the common R.O.W.

hours after switching off the protection

Before the pipeline is put on charge by switching on CP station, natural structure to-electrolyte potential values at all the test stations of the system shall be measured with respect to zinc reference cell.

CP DESIGN / PERM / CORRMATT

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CORROSION MATTERS
CP station shall be energized so as to achieve a maximum pipe soil potential PSP as specified at the test station nearest to the drainage point, and observations on either spread of protected portion of pipeline under this CP station shall be taken for PSP values pipeline current values across the cross section of the pipeline shall also be determined at all the intended test stations influenced by this CP station. Another complete set of PSP observations shall be taken after lines have stayed on charge for / hours. If there are appreciable differences in these observations as compared to those of hrs. Maximum drainage point

earlier set, a third set of observations shall be taken after

protective potentials shall not be allowed to go beyond the maximum PSP values as specified, in any case. The output of CP Station shall then be so adjusted that the sites of occurrence of least negative protective potentials are increased to . V. A full set of observations shall again be taken

hrs. after the adjustment of potentials and the protection system shall be left in this state of operation. Care shall be exercised to ensure that power supply remains uninterrupted during the period of commissioning. In case of an interruption, the test in progress shall be repeated after allowing time for polarization. More sets of observations may be advised to be taken by the owner/owner s representative in any of the above-mentioned steps. PSP values at each of the test stations of the existing pipelines shall be measured and plotted where existing pipelines run in parallel to the new pipeline and mutual interference situations between the pipelines shall be identified and necessary mitigation shall be carried out. Interference situations shall also be identified and mitigated by comparing different sets of readings taken at same test stations at different intervals of time under identical conditions where positive potential swing exceed MV.

Final records of testing and commissioning including graphical representation of final structure to electrolyte potential readings shall be complied with interpretation in consolation with owner/owner s representative and submitted.

If it is found during commissioning that the sites of occurrence of least negative or most negative protective potentials are less negative than . V even after hrs of operation, then the

drainage point potentials shall be adjusted depending upon anode ground bed currents in consultation with Owner/Owner s representative. In any case, the drainage point protective ON potential values shall not exceed the PSP values as per specification and the pipe to soil OFF potential shall not exceed a value more negative than . V at any location on the pipeline.

The current dissipated by the indiviual anodes shall be measured from the anode lead junction box and corrected for equal dissipation to the extent possible keeping the total ground bed current same.

CP DESIGN / PERM / CORRMATT

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CORROSION MATTERS

P C
PR J C W C CP C R F R P R R R C R R C R P

F R PCP C MM

R C C

CPC : SITE ENGINEER / SUPERVISOR CONTRACTOR / OWNER : INSPECTOR

SR NO

ACTIVITY Pre commissioning Tests At Anode Bed And TR Unit Disconnection Of Sacrificial Anode On Entire Spread And Allow For Depolarization After Hrs. Of Depolarization Collect Natural Potentials At

CPC S P

CONTRACTOR W W

OWNER A RM

RM

All Test Stations Energize The Cp Unit And Record The Reading To Find Attenuation Submission Of Records
LEGEND

RM

A - APPROVAL / ACCEPTANCE R - REVIEW OF RECORD RM - RANDOM CHECK

W - WITNESS ALL P- Performed by S Submitted by

CP DESIGN / PERM / CORRMATT

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CORROSION MATTERS

PR -C MM PR J C W C CP C R F R C R R C R R C

G CH CK R P R

R C C

C V Y Anode Bed Installation Termination Etc. CP unit Installation & Earthing , cable termination and tagging etc & No Load operational checks. CP system cable termination & taging CP unit working condition No load Surge Diverter Installation Reference cell Calibration mv REREOK/NOT OK OK/NOT OK

RV

OK/NOT OK OK/NOT OK OK/NOT OK

REMARKS

CPC

R C

Name: Sign: Date:

CP DESIGN / PERM / CORRMATT

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CORROSION MATTERS
P C R P R F R PCP C MM G( )

PR J C W C CP C R F R ate CP tation o GR U . . . . . . .
node o

R R C R R C

R C C

ocation

Groundbed Configuration & Type Groundbed Rating Voltage between Pipe and Anode Back EMF : TR Unit Output Total Anode bed Resistance Pin Voltage Current hms hms Anode Quantity

Total Anode To Cathode Circuit Resistance DC O/P Volts/Current Individual Anode current at Anode Junction Box
Potential cross the shunt (mV) Current (amps) node o Potential cross the shunt (mV)

Current (amps)

A A A A A REMARKS CPC

A A A A A Total Current: C R C R W R

Name: Sign: Date:

CP DESIGN / PERM / CORRMATT

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CORROSION MATTERS

P C PR J C W C CP C R F R R R C R R C

R P R F R PCP C MM

G (CP Unit)

R C C

Report o CP Station No: R Unit Parameters Hour Meter Reading : Input Voltage Volts DC output Voltage Volts Anode bed Loop Resistance Mode Coarse Control Switch C Chainage & Location :

ate:

Input Current Amp DC output Current Amps

Calculated V/I from above _______________________Ohm Auto/AVCC/Manual Fine Control Switch

Pipe to Soil Potential W.r.to Permanent Reference cell Cu-CuSO Reference -V Reference -V Reference -V

Set PSP in TR unit -V PSP at nearest TS Drainage -V

REMARKS

CPC

R C

Name: Sign: Date:

CP DESIGN / PERM / CORRMATT

Page 41 of 48

CORROSION MATTERS
P C R P R F R PCPC MM (Format PR J C W C CP R F R R R C R C C R R C VCM P P CH MP C R C M R C R-VCMate: R PR J C M R FR M RUC UR M of ) G (P P atural P P)

CPCRPG CPC-C

Report o
Readings From _______ km to _______km est station No Type Chainage Km Natural PSP

P P (-V) AC PSP Casing PSP

Remarks

REMARKS :- PSP after

hrs of disconnection of sacri icial anode connections to pipeline.

CPC

R C

Name: Sign: Date:

CP DESIGN / PERM / CORRMATT

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CORROSION MATTERS
P C F R PCPC MM PR J C W C CP R F R R R C R C C R R C ate: R P R of

G (P P reading First et ) Format

Report o
CP Unit n : Chainage & ocation __________________________ Readings From _______ km to _______km est station No Type Chainage Km `ON` PSP

P P (-V) AC PSP Casing PSP

Remarks

REMARKS : Setting of TR unit to be recorded in TR format with note for commissioning first set of readings purpose.

CPC

R C

Name: Sign: Date:

CP DESIGN / PERM / CORRMATT

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CORROSION MATTERS

INSPECTION REPORT FOR PCPCOMMISSIONING (PSP reading ) Format 3 of 3 PROJECT OWNER CONTRACTOR CP ONTRACTOR REFERENCE DOC. Report.No.
Test station No
Type

CP section (IJ to IJ) From _________ to __________km

PSP Initial (-V) ON PSP PSP 48 Hrs (-V) ON PSP PSP After 72 Hrs (-V). ON PSP AC PSP CASING

Date:
Remarks

Chainage Km

REMARKS

CPC

CONTRACTOR

OWNER

Name: Sign: Date:

CP DESIGN / PERM / CORRMATT

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CORROSION MATTERS

P
CP

C MM

G URV Y

URV Y

Purpose To define the procedure for the conduction of CIPL Survey on the commissioned Pipeline to evaluate the CP system and to provide adequate quality assurance / control.

quipment / ccessories Required Pipeline locators if required Data collector-Sincoder along with the reference cell Sticks. Current interrupts with synchronized timer circuits and adjustable time settings Rodometer Flexible cable/wire of required length.

Procedure

Before commencing the survey, confirm that the cathodic protection system is operating normally by checking the DC feeders, drain points, insulating joints with commissioning results.

Check the cathodic protection commissioning result to identify the area requiring special attention during the CIPL survey.

Locate the route of the pipeline using the pipeline locator and provide temporary markers Marking powder on the route to enable the survey to walk-on the route of the pipeline for carrying out the CIPL survey.

Install current interrupter with synchronized timer in the DC negative output of the DC power source CP System at the CP station of the section in which the survey is being carried out.

Set the interrupter switching cycle at a ratio of : ON:OFF. With the equipment connected and the pipeline located, move along the pipeline carrying the mobile data collector and Zinc reference cell and measure and store the pipe to soil potentials.

Check reference electrodes regularly for its operation. Record distance traversed and physical features such as roads, as descriptors to assist locating specific areas after processing the data.

CP DESIGN / PERM / CORRMATT

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CORROSION MATTERS
As each section between TLP connections is completed, real the fine wire for further use and shift continuous chart records to the next section. Transfer the data from the simcorder to a computer for producing the data print outs and plot of the PSP potential profiles. The data collected during the survey shall include i. Monitoring results of the sectional T/R Units ii. Data PSP Values ON and Instant OFF Distance location details as a descriptors. After completing the survey based on the above procedure, the readings in numeric and graphical manner shall be submitted after detailed interpretation.

CP DESIGN / PERM / CORRMATT

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CORROSION MATTERS

P C
PR J C W C CP R C R R R C R

F RC P

URV Y

R F R P R

C R

CUM P CPC : C R C G R/ W R / UP RV R: P C R R

S.NO

ACTIVITY

Performed By CPC P P P P P P

Verification Records Verification By By submission OWNER CONTRACTOR by CPC R R W R R R A RM RM RM RM R

Submission & Obtaining approval of Procedure TR Interrupter Setting Conduction of Survey Entering of Readings Entering of Location Description Final Report LEGEND A - APPROVAL / ACCEPTANCE R - REVIEW RM - RANDOM CHECK W - WITNESS

CP DESIGN / PERM / CORRMATT

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CORROSION MATTERS

nspection Report for C P PR J C W C CP R F R R C R C R R R C R-VCM-

urvey

C : CPC-C

Interrupter Setting

OK / NOT OK

Staring Location , Chainage

Ending Location , Chainage

TRU Section Conduction of Survey Entering of Datas / Locations Remarks OK / NOT OK OK / NOT OK

CPC Signature ame ate

R C

**********************

CP DESIGN / PERM / CORRMATT

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