Contract File Reference Page

Number:P1007 1007-DISQ-0-E-SS-27020-Rev.0 1 of 9

RWE Dea

Disouq Field Development

FEED

Cathodic Protection System Specification

Document number
1007-DISQ-0-E-SS-27020-Rev.0

0 10.11.11 Issued for Client comment M Magdy A Fawzy A Hamdan RWE

Rev Date Description Issued By Checked Approved Client
By By Approval
 Onspec Engineering Solutions
Disouq Field Development Project
Cathodic Protection System Specification

Changes List
Date
Rev. prepared Prepared by Description
(dd.MM.yyyy)

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 Onspec Engineering Solutions
Disouq Field Development Project
Cathodic Protection System Specification

Table of Contents

1 SCOPE ............................................................................................................................ 4
2 CODES AND STANDARDS............................................................................................. 4
3 DEVIATIONS ................................................................................................................... 4
4 ABBREVIATIONS ............................................................................................................ 4
5 DESIGN ........................................................................................................................... 5
6 SYSTEM COMPONENTS................................................................................................ 6
7 MONITORING ................................................................................................................. 9
8 DOCUMENTATION ......................................................................................................... 9

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 Onspec Engineering Solutions
Disouq Field Development Project
Cathodic Protection System Specification

1 SCOPE
This specification identifies the minimum requirements governing the design, supply and
installation of cathodic protection systems for onshore buried metallic piping and above ground
storage tanks.

2 CODES AND STANDARDS

NACE Standard RP-05-72: Design, installation, operation and maintenance of impressed
current deep ground beds.
NACE Standard RP-01-69: Control of external corrosion on underground of submerged metallic
piping systems.

3 DEVIATIONS
Any deviation from this specification shall be resolved through approved concession request
according to project scope and procedure.

4 ABBREVIATIONS
BPD : Barrels Per day
COMPANY : Owner of the project facility
CONTRACT : The agreement between COMPANY & CONTRACTOR
CONTRACTOR : Firm awarded the CONTRACT
Cu/CuSO4 : Copper Copper Sulphate Reference Electrode
CP : Cathodic Protection

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 Onspec Engineering Solutions
Disouq Field Development Project
Cathodic Protection System Specification

5 DESIGN

5.1 Pre-Design

CP Contractor to carryout site surveys and detailed design to make sure that the optimum CP
system for pipelines needs.
CP Contractor shall take into consideration the following:

Isolation
Coating system applied
Soil type and corrosively
Plant congestion
Pipeline routing if any
Power availability

5.2 Deign considerations

CP contractor shall consider the following while design CP system:

1. Total surface area of the piping and tanks.
2. Type of coating.
3. Total bare surface area to be protected will be a minimum of 25% of total surface
area.
4. Soil resistivity expressed in ohm-cm.
5. Minimum anode design life of twenty (20) years.
6. Selection dimensions, and layout of system components specified in this
specification.
7. Current densities as specified in Para. 6-3

5.3 Current density

The following current densities shall be applied for all metallic buried structures:

Soil Type Potential in mV VS Cu/CuSo4

Protective potential for steel in aerobic 850 mV

environment

Protective potential for steel in anaerobic 950 mV

environment

A maximum of 1200 mV off potential should not be exceeded to avoid coating disbanding.

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 Onspec Engineering Solutions
Disouq Field Development Project
Cathodic Protection System Specification

5.4 Basis of design

Cathodic protection system for buried piping and above ground storage tanks shall be designed
in accordance to earth potential rise by using Sacrificial Anodes or Impressed Current type
(distributed anodes system).Anodes shall be installed in low resistivity soil at or below pipe
invert level, at a horizontal or vertical distance from the pipe. The permanent monitoring facilities
connected to the piping shall be constructed simultaneously with the piping to facilitate
monitoring of the performance of the system. All anode locations shall be marked and recorded
.system placed directly to piping and designed to ensure a relatively uniform current distribution
that maintains all points in the pipes within the required protection criteria.

6 SYSTEM COMPONENTS

7.1 Impressed current Anodes

Impressed current anodes shall be mixed metal oxides (iridium, tantalum and
Titanium oxides) on titanium base or conductive polymeric cable anode.

CONTRACTOR shall submit the following information to the COMPANY for product approval:

Composition of anode coating (mixed metal oxides, platinum etc.)

Anode core data including dimensional data.
Anode shape and dimensional data.
Electrical properties of the anode including internal resistance, attenuation rating of the
anode, current rating and consumption data.
Cable data.
Cable to anode connection including sealing materials and methods.
Any other information that will affect CONTRACTOR approval.

7.2 Sacrificial Anodes

Zinc anodes shall be ASTM B-418, Type II with the following composition:
Al 0.005 percent max.
Cd 0.003 percent max.
Cu 0.002 percent max.
Fe 0.0014 percent max.
Pb 0.003 percent max.
Zn remainder

Magnesium anodes shall be of the following composition:

Al 0.01 percent
Cu 0.02 percent max
Fe 0.03 percent max
Mn 0.50-1.3 percent
Ni 0.001 percent max
Others 0.30 percent max
Mg Balance

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 Onspec Engineering Solutions
Disouq Field Development Project
Cathodic Protection System Specification

7.3 Backfill materials

Backfill for sacrificial anodes, shall consist of a mixture of :

Gypsum: 75 %
Bentonite clay: 20 %
Sodium sulfate: 5 %.

Backfill Materials for Impressed Current Beds in Soil

Metallurgical coke breeze with the following properties shall be used:
Maximum resistivity: 0.10 ohm-cm
Fixed carbon: 99.77 percent
Ash: 0.1 percent
Moisture: 0 percent
Volatiles: 0 percent
Particle size: 1.0 mm maximum, dust free.

7.4 Cables

Impressed current anode cables shall be tin coated stranded copper with Kynar primary
insulation and high molecular weight black polyethylene.
All other cables shall be tin coated stranded copper with HMWPE insulation.
The minimum rating for all cables and wires shall be 600 Volts.

7.5 Transformer rectifiers

Transformers/rectifier stations shall be equipped with an alarm system which automatically

signals when there is current interruption, and with a remote monitoring system. Rectifier
stations and other associated equipment shall be installed in non-hazardous areas wherever
practicable.

Transformers/rectifiers shall comply with IEC 146. Rectifiers shall be of a special design for
cathodic protection service and should be 3 phase units, 415 V-AC, 50 Hz.
Transformer/rectifiers shall be mounted on concrete plinths and all units supplied for specific
functions shall be by the same Manufacturer and shall be interchangeable on their plinth
mountings. All necessary hardware shall be furnished. All terminals, connectors, bolts and
contact hardware shall be copper, brass or bronze. The output voltage shall be limited to 100 V
and adjustable from zero to the maximum rated output when on load. A stepless (continuous)
adjustment shall be used.Automatic potential control shall be provided.
Transformer/rectifiers shall not be connected installed in series or in parallel in the same
positive cathodic protection circuit. The rectifier shall be constructed using high current density
selenium class or silicon diodes so arranged as to provide full wave rectification. The current
rating of the diodes shall be more than 1.25 times the maximum current rating of the rectifier
and have a minimum peak inverse voltage of 1200V.The output rms ripple current shall not
exceed 5 percent of the DC output current between 5 percent and 100 percent of the rated
current output.

The transformer/rectifier shall be provided with an isolator or Molded Case Circuit Breaker
(MCCB) on its incoming circuit and, where applicable, on its AC sub-circuits. Additionally,
suitably sized fuses (type G to IEC 269) shall be installed on the transformer/rectifiers phase
AC sub-circuits and negative DC output circuits.

The transformer/rectifier shall be capable of withstanding a short-circuit of up to 15 seconds

between output terminals without damage to any of its devices

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 Onspec Engineering Solutions
Disouq Field Development Project
Cathodic Protection System Specification

AC and DC cables shall be physically separated by an insulating panel. A built-in current

interrupter unit is required. The current interrupter unit shall be electronic and shall be capable
of switching the full output current on ON/OFF sequence infinitely variable and adjustable from 0
to 99 seconds independently for ON/OFF periods. If a pipeline, piping or plant area system is
cathodically protected by more than one transformer/rectifier, all transformer/rectifier interrupter
units shall be provided with a facility for synchronous switching. The cathodic protection system
in the plant shall be designed so that a synchronous switching can be achieved from a central
monitoring switching board. During normal operation, the built-in current interrupter shall be
bypassed and synchronous switching, switched off.
Incoming cables of oil cooled transformer/rectifiers shall be terminated in separate non oil filled
cable boxes and penetration into the tank shall be via bushings above oil level.
Transformer/rectifiers shall be installed in a non-hazardous area wherever practical. If this is not
possible, the construction of the rectifier units shall fulfill the requirements of the hazardous area
classification applicable for the site.
The enclosure shall have a minimum degree of protection IP 65 in accordance with IEC 529.
Transformer/rectifiers shall be suitable to operate under the prevailing service conditions. The
rectifier cabinet shall be of not less than 2.6 mm steel with aliphatic polyurethane coating in
accordance with Project Painting Specification
Each transformer/rectifier shall have:

Lifting lugs of suitable size and location to facilitate lifting of the unit when full of
oil.
An oil filling hole with screw cap.
An oil drain with a valve.
An oil tank breather provided with silica get cartridge and breather seal, complete
with spare desiccant cartridge.
An earthing terminal.
Surge arrestors across the output terminals of DC voltage sources
An oil thermometer and level gauge

A rating plate indicating Manufacturers name, model number, manufacturing date, AC rating,
DC rating, rectifier material, maximum operating temperature of the unit, weight of the oil and
weight of the unit plus oil, project purchase order number, equipment identification number and
date of purchase shall be provided.

7.6 Test posts

The CP CONTRACTOR shall clearly indicate the type of test post, bond box and distribution
box for each application in the detailed design. Test posts shall provide sufficient room for the
termination of test cables and for the installation of bonding cables and/or resistors. Test posts
head shall be orange colour. Big Fink test station with upright post shall be used in all areas
except directly in the traffic path.

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 Onspec Engineering Solutions
Disouq Field Development Project
Cathodic Protection System Specification

7 MONITORING
The permanent reference electrode shall consist of a copper-copper sulfate electrode which is
manufactured to remain stable (plus or minus 10MV) for minimum of ten (10) years. The
reference electrode to lead wire connection shall be encapsulated to prevent water migration.
The stationary reference electrode shall be positioned within the pipes area to provide the most
representative measurements for the submerged surface area(s). Cu/CuSO4 Portable
Reference Electrode will be also used for piping monitoring.

8 DOCUMENTATION
The cathodic protection Contractor shall submit the following submittal for approval by the
Company or Company representative.

1. Drawings showing system design/configuration and calculations.

2. Description of system components with takeoff list.
3. Classification for all system components located within the subject Structure.
4. Design calculations for required voltage, amperage & life expectancy.

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