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A8GA-51000-97-SP-003
Guinea Bauxite Export Project Date: 22OCT15
Contract No: A8GA Page 2 of 17
Record of Revisions
Rev. No. Date Description
A8GA-51000-97-SP-003_RC.docx Marine
Guinea Alumina Corporation Document No. A8GA-51000-97-SP-003
Guinea Bauxite Export Project Date: 22OCT15
Contract No: A8GA Page 3 of 17
TABLE OF CONTENTS
1.0 GENERAL ...........................................................................................................5
1.1 Overview ....................................................................................................................... 5
1.2 Abbreviations/Acronyms ................................................................................................ 5
1.3 Definitions, Project Identification: .................................................................................. 5
2.0 DESIGN REFERENCE ........................................................................................6
2.1 Codes, Standards, and Guidelines ................................................................................ 6
2.2 Project Documents ........................................................................................................ 6
3.0 GENERAL REQUIREMENTS .............................................................................7
3.1 General.......................................................................................................................... 7
3.2 Scope of Supply ............................................................................................................ 7
3.3 Design Life .................................................................................................................... 7
3.4 Design Documentations and Drawings ......................................................................... 7
4.0 DESIGN REQUIREMENTS FOR CATHODIC PROTECTION ...........................8
4.1 Design Current Density ................................................................................................. 8
4.2 Design Electrochemical Properties ............................................................................... 8
4.3 Anode Distribution ......................................................................................................... 8
4.4 Anode Construction ....................................................................................................... 8
4.5 Anodes on Steel Piles ................................................................................................... 9
4.6 Electrical Continuity ....................................................................................................... 9
4.7 Electrical Isolation ......................................................................................................... 9
5.0 ANODE CHEMICAL REQUIREMENTS AND TESTING ..................................10
5.1 Chemical Composition ................................................................................................ 10
5.2 Sampling and Testing Procedures .............................................................................. 10
5.3 Sampling ..................................................................................................................... 10
5.4 Testing Methods .......................................................................................................... 10
5.5 Acceptance Criteria ..................................................................................................... 10
6.0 ANODE ELECTROCHEMICAL REQUIREMENTS AND TESTING ................11
6.1 Electrochemical Requirements .................................................................................... 11
6.2 Sampling and Testing Procedures .............................................................................. 11
6.3 Sampling ..................................................................................................................... 11
6.4 Testing Methods .......................................................................................................... 11
6.5 Acceptance Criteria ..................................................................................................... 11
7.0 ANODE WEIGHT, DIMENSIONS, AND MARKING .........................................12
7.1 Weights ....................................................................................................................... 12
7.2 Dimensional Tolerances .............................................................................................. 12
7.3 Casting Defects ........................................................................................................... 12
7.4 Marking ........................................................................................................................ 12
A8GA-51000-97-SP-003_RC.docx Marine
Guinea Alumina Corporation Document No. A8GA-51000-97-SP-003
Guinea Bauxite Export Project Date: 22OCT15
Contract No: A8GA Page 4 of 17
A8GA-51000-97-SP-003_RC.docx Marine
Guinea Alumina Corporation Document No. A8GA-51000-97-SP-003
Guinea Bauxite Export Project Date: 22OCT15
Contract No: A8GA Page 5 of 17
1.0 GENERAL
1.1 Overview
The Guinea Bauxite Export project (the Project) is a bauxite exploration and mining project located in the
Boke region, Republic of Guinea, West Africa. The Project is developed by Guinea Alumina Corporation SA
(the Company), a fully owned subsidiary of Emirates Global Aluminium (EGA).
The Project includes the mining and crushing of high quality bauxite at the mine face and the transport of
bauxite to the port area where it is stored before being loaded into ships for export.
This specification covers the requirements, as a minimum, for design, engineering, material supply,
manufacture, assembly, inspection and testing, preservation, packing, delivery, site installation and
commissioning of the marine cathodic protection system for the NKB1 Jetty of the GAC Bauxite Export
Project.
This document shall be read in conjunction with other related design criteria, project specifications, and
applicable codes and standards.
1.2 Abbreviations/Acronyms
CP Cathodic Protection
DNV Det Norske Verita
GAC Guinea Alumina Corporation
ISO International Organization for Standardization
NACE National Association of Corrosion Engineers
NKB1 New Kamsar Berth 1
1.3 Definitions, Project Identification:
Project Title: GAC Bauxite Export Project
Owner / Company: GAC
Company Representative: Fluor
Contractor: The party to be contracted to implement the work
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Guinea Alumina Corporation Document No. A8GA-51000-97-SP-003
Guinea Bauxite Export Project Date: 22OCT15
Contract No: A8GA Page 6 of 17
Design of the cathodic protection system shall comply with the following standards and project documents.
2.1 Codes, Standards, and Guidelines
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Guinea Alumina Corporation Document No. A8GA-51000-97-SP-003
Guinea Bauxite Export Project Date: 22OCT15
Contract No: A8GA Page 7 of 17
3.1 General
The Contractor shall provide the work complete in every aspect in accordance with the project contract,
design standards, specifications, and internationally recognized standards referenced in this document.
All equipment and materials supplied shall be new and meet industrial quality standards. The design shall be
suitable for the respective application for which it is intended to be used.
Steel structures in contact with marine water shall be protected by a sacrificial anode based cathodic
protection system, designed in accordance with the requirements of NACE SP0176, DNV-RP-B401, or EN
13174.
Some exterior surfaces of steel elements will be coated. Design in accordance with NACE SP0176 does not
account for any reduction in cathodic protection requirements due to the presence of coating. Design in
accordance with DNV-RP-B401 permits such reduction in certain circumstances; if design is performed in
accordance with DNV-RP-B401, the Contractor shall submit for approval full explanations of the proposed
Coating Category and Coating Breakdown Factors.
3.2 Scope of Supply
The cathodic protection system shall be designed for 50 years with anodes replacement at every 15 years.
3.4 Design Documentations and Drawings
Contractor shall prepare and submit the following design documents for approval:
a. Confirmation that coating systems will not be susceptible to any damage caused by cathodic protection.
b. All documentation required by Section 7.13 of DNV-RP-B401 (regardless of whether design is in
accordance with DNV-RP-B401 or with NACE SP0176).
c. Anode distribution drawings shall show locations of each individual anode on protected elements.
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Guinea Alumina Corporation Document No. A8GA-51000-97-SP-003
Guinea Bauxite Export Project Date: 22OCT15
Contract No: A8GA Page 8 of 17
Bracelet anodes and flush-mounted anodes shall have an approved marine coating, with dry film thickness of
at least 100 m, applied to their surface facing the protected structure, to avoid build-up of corrosion
products there which could distort and eventually fracture the anode.
Stand-off anodes shall provide at least 300 mm clear distance between the anode and the protected steel
surface.
Mass of each anode shall be limited to approximately 70 kg (gross) to facilitate replacement if necessary and
to ensure reasonable spatial distribution of anodes on structural elements.
A8GA-51000-97-SP-003_RC.docx Marine
Guinea Alumina Corporation Document No. A8GA-51000-97-SP-003
Guinea Bauxite Export Project Date: 22OCT15
Contract No: A8GA Page 9 of 17
Anodes to be applied to steel piles may be elongated stand-off anodes, bracelet anodes, or elongated flush-
mounted anodes.
It is highly desirable that for each pile the cathodic protection system be active as soon as the pile is installed.
With his bid, the Contractor shall propose a plan to repair or replace all anodes and anode connections
damaged during pile handling and installation.
4.6 Electrical Continuity
All connections between anodes and the protected structure shall be such as to guarantee electrical continuity
for the full design life of the cathodic protection system. This is most reliably obtained by welding the anode
core to the protected structure.
However, if the Contractor wishes to propose alternatives to welding, these may be offered, with full
explanations for offering them. If bolted connections are used, the connection shall be double-nutted and
include redundant electrical bonding.
The Contractor shall submit for approval a test procedure to confirm electrical continuity between all
elements for which such continuity is required by the design. For brazed and mechanical connections
designed for electrical continuity, the procedure shall include requirements that measurements be carried out
with an instrument capable of verifying an electrical resistance of 0.1 ohm maximum.
4.7 Electrical Isolation
a. The cathodic protection system shall be isolated electrically from other electrical sources. Neither
the cathodic protection system nor any of these other sources shall be compromised by grounding or
bonding arrangements that may connect them to each other.
b. In cases where ships will be moored alongside cathodically-protected structures, electrical
interaction can be minimized by locating anodes on the side of the structure away from the vessel or
within the peripheral boundary of the structures outer piling.
c. Where cathodically-protected structures are attached to concrete topsides, no mountings (including
stainless steel) shall be allowed to touch steel reinforcement in the concrete.
A8GA-51000-97-SP-003_RC.docx Marine
Guinea Alumina Corporation Document No. A8GA-51000-97-SP-003
Guinea Bauxite Export Project Date: 22OCT15
Contract No: A8GA Page 10 of 17
Prior to beginning work, the Contractor shall submit for approval the proposed procedures for sampling and
testing of chemical analysis of anodes. As a minimum, the procedures shall address sample locations, how
the sample is obtained, how contamination of the sample will be avoided, and the procedures for testing.
5.3 Sampling
a. Samples for chemical analysis shall be collected at three intervals for each heat or for each batch of
melts representing 5 tonnes of produced alloy.
d. Samples shall be taken from the start, middle, and end of pour. The chemical composition of all
three samples shall be tested and recorded. Test samples and data shall be retained by the Material
Supplier for five years from the date of anode delivery.
e. All alloy samples shall be hard-stamped with the heat number and a serial number for that heat.
5.4 Testing Methods
Spectrographic analyses shall be carried out to confirm that the alloys used comply with the approved
composition. Three methods of chemical assay are acceptable: Atomic Absorption, Optical Emission, or
Inductively Coupled Plasma.
5.5 Acceptance Criteria
All samples must show chemical composition within the limits of this specification. If any sample falls
outside the specification, two additional samples from the anodes produced in that heat may be retested. If
both of these samples are within the specification, all anodes in the heat will be accepted. If either of the
samples is out of specification, all anodes in the heat will be rejected.
A8GA-51000-97-SP-003_RC.docx Marine
Guinea Alumina Corporation Document No. A8GA-51000-97-SP-003
Guinea Bauxite Export Project Date: 22OCT15
Contract No: A8GA Page 11 of 17
The electrochemical properties of the alloy shall conform to the following requirements when operating at
temperatures within the range (+)4C to (+)12C.
Closed Circuit Potential 1.07 to 1.15 volts
Current Capacity 2500 A-hr / kg
Potentials are expressed as volts negative versus Silver/Silver Chloride reference electrode in seawater.
6.2 Sampling and Testing Procedures
Prior to beginning work, the Contractor shall submit for approval the proposed procedures for performing
electrochemical testing of anodes.
6.3 Sampling
a. One sample for electrochemical testing shall be collected from each heat or each batch of melts
representing 5 tonnes of produced alloy. The sample shall be representative of the finished anode
material and shall be drawn from the middle of the pour.
b. Samples for electrochemical testing shall be obtained and prepared in accordance with NACE
TM0190. The test samples shall be obtained from production anodes or from separately-cast
cylinders which have the same nominal cross-section and which experience similar cooling rates as
do production anodes.
c. The collected sample shall be stamped with the heat number and the Contractor's identify.
6.4 Testing Methods
a. Electrochemical testing shall be performed in accordance with the recommendations of NACE
TM0190.
b. This testing shall confirm the Closed Circuit Potential and Current Capacity stated in Section 5.1 of
this Specification.
6.5 Acceptance Criteria
Failure of any sample to meet the criteria shall result in rejection of all anodes from the same heat as the
sample.
A8GA-51000-97-SP-003_RC.docx Marine
Guinea Alumina Corporation Document No. A8GA-51000-97-SP-003
Guinea Bauxite Export Project Date: 22OCT15
Contract No: A8GA Page 12 of 17
7.1 Weights
The net aluminium and gross anode weight shall be recorded for each anode. The core weight shall be
determined as the average weight of 10% of the cores and shall be determined before casting.
Measurements and tolerances for anode weights shall conform to NACE SP0387.
If any variation in the dimensions is required to achieve the required alloy weight, the Contractor shall vary
only the anode width and height; the length shall remain unaltered.
7.2 Dimensional Tolerances
Measurements and tolerances for anode dimensions shall conform to NACE SP0387.
Measurements and tolerances for anode core dimensions and location within the anode shall conform to
NACE SP0387 requirements for anode inserts.
7.3 Casting Defects
Measurements and tolerances for surface irregularities, cracks, and internal defects shall conform to NACE
SP0387.
7.4 Marking
7.4.1 Stamping
All anodes shall be hard stamped immediately after casting and before removal from the mould with a
unique heat number, net weight of anode, and a unique sequential serial number. The Contractor shall
maintain a record of all anodes by serial numbers, including any that are rejected. This list shall be used to
correlate all quality control records.
7.4.2 Color Code
The exposed core material shall be color-coded after casting with details of alloy type and customer. It shall
be hard stamped with the heat number from the mill certificate.
A8GA-51000-97-SP-003_RC.docx Marine
Guinea Alumina Corporation Document No. A8GA-51000-97-SP-003
Guinea Bauxite Export Project Date: 22OCT15
Contract No: A8GA Page 13 of 17
Two anodes of each size shall be subject to destructive testing to verify absence of internal defects and to
verify adequate location of anode inserts. The sectioning procedure and acceptance criteria of NACE
SP0387 shall apply.
A8GA-51000-97-SP-003_RC.docx Marine
Guinea Alumina Corporation Document No. A8GA-51000-97-SP-003
Guinea Bauxite Export Project Date: 22OCT15
Contract No: A8GA Page 14 of 17
Following installation of all structural elements requiring cathodic protection, the Contractor shall perform a
base-line below-water survey to provide baseline potential measurements of the performance of the cathodic
protection system.
The survey shall use silver/silver chloride drop cells and the survey shall be performed in accordance with
NACE SP0176.
The survey shall be performed by personnel certified by NACE to CP 1 Cathodic Protection Tester.
Prior to beginning work, the Contractor shall submit for approval the Survey Plan.
A8GA-51000-97-SP-003_RC.docx Marine
Guinea Alumina Corporation Document No. A8GA-51000-97-SP-003
Guinea Bauxite Export Project Date: 22OCT15
Contract No: A8GA Page 15 of 17
10.1 General
It is the responsibility of the Contractor to conduct all testing and inspections as specified herein.
Prior to beginning work, the Contractor shall submit for approval the Inspection and Testing Plan for all
required testing and inspections.
Independent certification of all sampling and testing results is required and certificates shall be submitted for
approval.
The Company and/or Company Representative may witness any or all phases of the testing and inspection.
The Contractor must give the Company advance notice with a minimum of 10 working days prior to carrying
out any test.
10.2 Reports
a. All inspection and testing shall be properly documented to the Company and the Company
Representative. Submission of satisfactory test documentation, including certificates from the
independent reviewer, is a condition for shipment release.
b. Documentation required for each heat inspection and testing in accordance with this specification
shall include the following:
Purchase order number
Contractor's name
Core material mill certification
Heat number and number of anodes per heat
Anode alloy name
Chemical analysis report
Closed circuit potential test results
Current capacity test results
Dates of Casting and Testing
Net and gross weight of each anode
Identification Number of each rejected anode and reason for rejection
Raw (bulk) aluminium alloy chemical certificates for each to establish purity of aluminium
Results of electrical continuity tests on installed structures
Results of baseline underwater cathodic protection survey
c. Documentation must be retained by the Contractor for five years.
A8GA-51000-97-SP-003_RC.docx Marine
Guinea Alumina Corporation Document No. A8GA-51000-97-SP-003
Guinea Bauxite Export Project Date: 22OCT15
Contract No: A8GA Page 16 of 17
a. Anodes shall not be released from the Contractor's works until the results of chemical and
electrochemical testing related to those anodes are approved.
b. The Contractor shall submit his proposals for packing, storage, handling, and shipment of the anodes
by road and sea freight. The anode heat number shall be left visible.
c. Anodes shall be securely packed on open pallets suitable for road and sea transport and handling by
forklift trucks in a manner which will ensure that the anodes are not damaged or have their physical
characteristics altered in any way. Separation of anodes shall be such that no one anode comes in
contact with any other anode during shipment or storage. Spacers shall be non-metallic, either wood
or plastic.
d. Packaging shall be designed such that anodes kept in storage on the pallets do not come into contact
with wet ground.
e. The bill of lading must clearly show the number of anodes shipped and their respective heat
identification numbers.
f. The Contractor shall be responsible for transport to his designated receiving location. Removal from
transport upon arrival at designated receiving location shall be by the Contractor.
A8GA-51000-97-SP-003_RC.docx Marine
Guinea Alumina Corporation Document No. A8GA-51000-97-SP-003
Guinea Bauxite Export Project Date: 22OCT15
Contract No: A8GA Page 17 of 17
12.0 WARRANTY
A warranty covering all components and parts supplied by the Contractor shall be presented to the Company
Representative on the date of mechanical handover.
A8GA-51000-97-SP-003_RC.docx Marine