Materials System Specification

17-SAMSS-008
Junction Boxes for Cathodic Protection

16 April 2012

Document Responsibility: Cathodic Protection Standards Committee

Saudi Aramco DeskTop Standards

Table of Contents
1

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

Conflicts and Deviations................................. 3

References..................................................... 3

Qualification Requirements............................ 4

Site Conditions............................................... 5

Design............................................................ 6

Testing............................................................ 8

Packing and Shipping.................................... 8

Previous Issue: 31 March 2008 Next Planned Update: 16 April 2017

Revised paragraphs are indicated in the right margin
Primary contact: Zubail, Saleh Abdullah on 966-3-880-9599
CopyrightSaudi Aramco 2012. All rights reserved.

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Document Responsibility: Cathodic Protection Standards Committee

Issue Date: 16 April 2012
Next Planned Update: 16 April 2017

17-SAMSS-008
Junction Boxes for Cathodic Protection

Detailed Table of Contents

1 Scope .............................................................................................................................. 3
2 Conflicts and Deviations .................................................................................................. 3
3 References ...................................................................................................................... 3
3.1 Saudi Aramco Documents ...................................................................................... 3
3.2 Industry Codes and Standards ................................................................................ 4
4 Qualification Requirements.............................................................................................. 4
4.1 SME Approval ......................................................................................................... 4
4.2 Quotation Information Requirements ....................................................................... 4
4.3 Purchase Order Information Requirements ............................................................. 5
5 Site Conditions ................................................................................................................ 5
5.1. Temperature and Humidity ...................................................................................... 5
5.2 Onshore Environment ............................................................................................. 5
5.3 Near Shore Environment ......................................................................................... 5
5.4 Offshore Environment ............................................................................................. 6
6 Design ............................................................................................................................. 6
6.1 Non-Classified Areas .............................................................................................. 6
6.2 Classified Areas ...................................................................................................... 7
7 Testing ............................................................................................................................ 8
7.1 Factory Acceptance Requirements ......................................................................... 8
7.2 Certification ............................................................................................................. 8
8 Packing and Shipping ...................................................................................................... 8

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Document Responsibility: Cathodic Protection Standards Committee

Issue Date: 16 April 2012
Next Planned Update: 16 April 2017

17-SAMSS-008
Junction Boxes for Cathodic Protection

Scope
This Specification defines the requirements for junction boxes to be used with cathodic
protection systems.

Conflicts and Deviations

2.1

Any conflicts between this specification and other applicable Saudi Aramco
Materials System Specifications (SAMSSs), Engineering Standards (SAESs),
Standard Drawings (SASDs), or industry standards, codes, and forms shall be
resolved in writing by the Company or Buyer Representative through the
Manager of the Consulting Services Department of Saudi Aramco, Dhahran.

2.2

Direct all requests to deviate from this specification in writing to the Company or
Buyer Representative, who shall follow internal company procedure SAEP-302
and forward such requests to the Manager of the Consulting Services Department
of Saudi Aramco, Dhahran.

References
The design, product fabrication and selection of material covered by this standard shall
comply with the latest edition of the references listed below unless otherwise noted.
3.1

Saudi Aramco Documents

Saudi Aramco Engineering Procedure
SAEP-302

Instructions for Obtaining a Waiver of a Mandatory

Saudi Aramco Engineering Requirement

Saudi Aramco Standard Drawings

AA-036108

Cathodic Protection, Offshore Negative Terminal

Junction Box

AD-036132

Termination Detail and Cable Identification

AA-036145

Cathodic Protection, Junction Box - Cable Splice

AA-036157

Cathodic Protection, 3-Pin Test Station

AB-036274

Cathodic Protection, Junction Box-5 Terminal

AB-036275

Cathodic Protection, Junction Box-12 Terminal

AA-036276

Cathodic Protection, Multi-Purpose Junction Box

AA-036277

Cathodic Protection, Bond Box-5 Terminal

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Document Responsibility: Cathodic Protection Standards Committee

Issue Date: 16 April 2012
Next Planned Update: 16 April 2017

3.2

17-SAMSS-008
Junction Boxes for Cathodic Protection

AA-036347

Cathodic Protection, Junction Box-20 Terminal

AA-036349

Cathodic Protection, Bond Box-3 Terminal

AA-036350

Cathodic Protection, Bond Box-2 Terminal

AA-036384

Cathodic Protection, Offshore Anode Junction Box

AB-036540

Cathodic Protection, Junction Box - Mounting

Support Details

AB-036907

Cathodic Protection, Kilometer Marker and CP Test

Stations for Buried Pipelines

Industry Codes and Standards

American National Standards Institute
ANSI B1.20.1

Pipe Threads General Purpose

ANSI C80.1

Rigid Steel Conduit Zinc Coated

National Electrical Manufacturers' Association

NEMA ICS 6

Enclosures for Industrial Controls and Systems

NEMA 250

Enclosures for Electrical Equipment

Qualification Requirements
4.1

SME Approval
Cathodic protection junction boxes shall be inspected by the Saudi Aramco
SME for workmanship and compliance with the applicable standard drawing
and this material specification. Refer to Section 7 of this specification for
additional details.

4.2

Quotation Information Requirements

The following information shall be provided with the quotation if the junction
boxes used for the quotation contain any material or dimensional deviations
from the applicable standard drawing listed in Section 3.1 of this specification:
a)

Construction drawings of the junction box

b)

Detailed list of materials

c)

Copy of SME Type Approval

Commentary Note:
The above information is necessary only if there are deviations from the

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Document Responsibility: Cathodic Protection Standards Committee

Issue Date: 16 April 2012
Next Planned Update: 16 April 2017

17-SAMSS-008
Junction Boxes for Cathodic Protection

applicable standard drawing. The information will be used to complete the

technical evaluation of the quotation.

4.3

Purchase Order Information Requirements

The following information shall be specified in the Purchase Order:

a)

Type of junction box, i.e., Bond Box - 5 Terminal for near shore
environment

b)

Applicable Standard Drawing

c)

Hazardous area classification (if applicable)

Site Conditions
5.1.

Temperature and Humidity

Relative Humidity:

Temperature:

Ultraviolet Radiation

5.2

Minimum

0%

Maximum

100% (Condensing)

Minimum

0C (32F)

Maximum

55C (131F)

Hourly mean (Dec)

14 W/m

Hourly mean (July)

28 W/m

Onshore Environment
The normal air-borne dust concentration is 1 mg/M. During sand storm
conditions, dust concentrations may reach 500 mg/M and winds may gust to
112 km/hr. 95% of all dust particles are less than 20 micrometers, and 50% of
all particles are less than 1.5 micrometers in size. The dust may contain sodium,
calcium, magnesium, silicon, and aluminum compounds. During high humidity
conditions, these compounds function as electrolytes and can result in severe
corrosion. Other pollutants which may be present are: H2S (1 to 5 ppm), CO
(50 to 100 ppm), NOx (1 to 5 ppm), SO2 (1 to 5 ppm), and hydrocarbons (10 to
50 ppm).

5.3

Near Shore Environment

Cathodic protection junction boxes which are situated onshore, but within one
kilometer from the shoreline of the Arabian Gulf or the Red Sea shall be
considered to be located in a near shore environment. Near shore equipment are
subjected to the environmental conditions noted in Section 5.2 plus wind blown

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Document Responsibility: Cathodic Protection Standards Committee

Issue Date: 16 April 2012
Next Planned Update: 16 April 2017

17-SAMSS-008
Junction Boxes for Cathodic Protection

sea water spray with accumulation of associated mineral salts on exposed

surfaces.
5.4

Offshore Environment
Offshore equipment is subjected to a severely corrosive environment due to
cyclic wet/dry conditions from wind blown sea water spray and the
accumulation of associated mineral salts on exposed surfaces. Other pollutants
which may be present are: H2S (1 to 5 ppm), CO (50 to 100 ppm),
NOx (1 to 5 ppm), SO2 (1 to 5 ppm), and hydrocarbons (10 to 50 ppm).

Design
6.1

Non-Classified Areas
Polymeric cathodic protection junction box enclosures shall be fabricated from a
UV stabilized material suitable for the exposure detailed in Section 5.1 of this
material specification.
All cathodic protection junction box enclosures for non-classified areas shall
have:
a)

a continuous full length hinge located on the left hand side when facing the
front of the enclosure

b)

two quick release toggle latches located on the right hand side of the
enclosure

c)

hinges and latches fabricated from material that is galvanically compatible

with the enclosure metal and of equal or better corrosion resistance.
Non-metallic components may be used for hinges and latches.
Exception:
Grade 304L stainless steel latches may be used on grade 316 or 316L
stainless enclosures.

6.1.1

Onshore and Nearshore cathodic protection junction box enclosures

placed in non-classified areas shall be NEMA 4X compliant and shall be
constructed of:

type 5052 aluminum alloy, or

type 1050 aluminum (or comparable metallurgy) with a light colored

(white or light green) baked powder (polyester or phenolic) coating
with a minimum dry film thickness of 90um (3.5mils).

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Document Responsibility: Cathodic Protection Standards Committee

Issue Date: 16 April 2012
Next Planned Update: 16 April 2017

304 (or better) stainless steel, or

UV stabilized polymeric material

17-SAMSS-008
Junction Boxes for Cathodic Protection

The thickness of metal sheeting used for the enclosure construction shall
comply with Table 7-1 or Table 7-2 of NEMA ICS-6. Welding shall be
done by Gas Tungsten Arc Welding or Gas Metal Arc Welding.
Aluminum enclosures shall be welded with aluminum 5356 filler metal.
6.1.2

Offshore cathodic protection junction box enclosures for non-classified

areas shall be NEMA 4X compliant and shall be constructed of:

316L stainless steel, or

UV stabilized polymeric material.

316, 316L Stainless Steel or non-metallic breathers and drains shall be

installed for all offshore cathodic protection junction boxes.
6.1.3

6.2

One pin and three pin test stations shall be manufactured from one of the
following material:

Malleable or ductile cast iron coated with 1 mil electroplated zinc, or

Feraloy or Grayloy alloy coated with 1 mil electroplated zinc, or

Copper free aluminum, or

UV stabilized polymeric material.

Classified Areas
6.2.1

Cathodic protection junction box enclosures and fittings for Class 1,

Division 2 areas shall not be required to be explosion proof (NEC Article
501.10(B)(4)) and shall meet NEMA 4Xrequirements in accordance with
NEMA 250. The enclosure shall be marked to show the appropriate
classified area location, Class number and gas group letter designation
(i.e., Class/Zone/Group).

6.2.2

The enclosure shall be provided with taper threaded openings to fit

ANSI C80.1 field conduit connections. The number and size of such
openings shall be in accordance with the applicable Standard Drawing
referenced in the Purchase Order. Each conduit entry shall be capped
with a sealing plug. Plugs with recessed heads are not acceptable.

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Document Responsibility: Cathodic Protection Standards Committee

Issue Date: 16 April 2012
Next Planned Update: 16 April 2017

17-SAMSS-008
Junction Boxes for Cathodic Protection

Testing
7.1

Factory Acceptance Requirements

All cathodic protection junction boxes shall receive a Type Approval
inspection completed by the Saudi Aramco SME before an approved
Manufacturer ships their first purchase order.
After Type Approval is received, materials and components used for
construction of the junction boxes shall not be changed or modified without
written authorization by the SME.

7.2

Certification
Cathodic protection junction box enclosures imported into Saudi Arabia shall be
certified, labeled or listed by an approved and recognized testing organization to
indicate full compliance with NEMA ICS 6 and NEMA 250 for the applicable
NEMA rating.
Cathodic protection junction box enclosures manufactured in Saudi Arabia for
non-classified areas shall comply with Saudi Aramco standard drawings and the
appropriate NEMA standard. However, they are exempt from requiring the
above certification labeling or listing provided the required testing has been
completed with documentation to confirm performance and quality.

Packing and Shipping

The export packing, marking and shipping shall be as specified in the Purchase Order.

16 April 2012

Revision Summary
Revised the Next Planned Update. Reaffirmed the content of the document, and reissued with
minor revisions as follows:
- Revised enclosure material to include type 1050 aluminum with powder coating.
- Revised enclosure requirements to align with NEC and allow non-explosion proof enclosures in
Class 1 Div 2 areas provided there are no current interrupting equipment in the enclosure.
- Replaced RSA with SME to be in line with the new RVL procedures.
- Removed the reference to vendor
- Combined paragraph 6.1.1 and 6.1.2.

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