Aogc 036 El Ess 003 (B0)

CLIENT: CONSULTANT:
National Iranian Oil Company

Arvandan Oil and Gas Company ENERCHIMI ENG. CO.
SOHRAB WELL HEAD NO.1 FLOW LINE TO

Project: SOUTH AZADEGAN NORTH CLUSTER
Client Project No.: 14-71-148 Page 1 OF 42
Doc. No.: AOGC-036-EL-ESS-003 Consultant Project No.: 19381 Rev.: B0
Document Title: SPECIFICATION FOR CATHODIC PROTECTION SYSTEM
SPECIFICATION
FOR
CATHODIC PROTECTION SYSTEM

CLIENT: CONSULTANT:


Revision Summary Index

Modified In Rev. Number Modified In Rev. Number Modified In Rev. Number
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B0 B0
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Revision B0
Issued for TENDER
Date 92.12.20
Consultant
Prepared P.J
Checked R.P
Approved M.N
CLIENT: CONSULTANT:


TABLE OF CONTENTS
Page
1.0 INTRODUCTION ....................................................................................................... 5
2.0 CODES AND STANDARDS....................................................................................... 7
3.0 SITE CONDITION ...................................................................................................... 9
4.0 DESIGN .................................................................................................................... 10
5.0 CATHODIC PROTECTION UNIT ............................................................................. 16
6.0 IMPRESSED CURRENT GROUND BED................................................................. 18
7.0 REFERENCE ELECTRODES .................................................................................. 20
8.0 GALVANIC ANODES .............................................................................................. 21
9.0 TEST POINTS .......................................................................................................... 22
10.0 INSULATION FITTINGS ......................................................................................... 23
11.0 PIPELINE INSULATION LOCATION ....................................................................... 24
12.0 SPECIAL INSULATION POINTS ............................................................................. 24
13.0 PROTECTION OF PARASITIC CURRENTS ........................................................... 25
14.0 INSULATION FITTING PROTECTION SYSTEM..................................................... 26
15.0 GALVANIC COUPLES ............................................................................................ 27
16.0 MATERIAL AND EQUIPMENT STANDARD ........................................................... 27
17.0 INSPECTION AND TESTING .................................................................................. 35
18.0 PREPARATION OF SHIPMENT .............................................................................. 35
19.0 DRAWINGS AND DOCUMENTATION .................................................................... 36

CLIENT: CONSULTANT:


20.0 SPARE PARTS ........................................................................................................ 36
21.0 VENDOR RESPONSIBILITY & GUARANTEE ....................................................... 36
22.0 MIN ACTIVITIES DURING COMMISSIONING ........................................................ 37
TABLE 1 : LOCATION OF ELECTRICAL TEST POINTS FOR POTENTIAL

MEASUREMENT............................................................................................................. 41
TABLE2 : LOCATION OF ELECTRICAL TEST POINTS FOR CURRENT

MEASUREMENT............................................................................................................. 42
CLIENT: CONSULTANT:


1.0 INTRODUCTION
Arvandan Oil and Gas company intends to construct an 8" N.B. buried flowline
from Sohrab WH1 to South Azadegan North Cluster.
Sohrab Field is located at North of Azadegan Field, and 115 Km North West of
Ahwaz right along the international border with Iraq.
The major sections of the project are:
- Wellhead facilities (at WH No.1).

- 8" N.B, 50 Km (Approx.) buried flow line.
- Receiving trap facility at South Azadegan North Cluster.
1.1 Terms and Definitions

Owner/ client: Arvandan Oil & Gas Company (AOGC)
EPC Contractor: Shall Mean The Contractor Responsible

For Engineering, Procurement &
Construction Of The Project.
Consultant: Enerchimi Engineering Company (EEC)
Vendor/ Supplier: Refers to firm or person who will supply

and/or fabricate the equipment or
material.
Will: is normally used in connection with the

action by the "company" rather than by a
contractor, supplier or vendor.
May: is used where a provision is completely

discretionary.
Should: is used where a provision is advisory

only.
Shall: is used where a provision is mandatory.

CLIENT: CONSULTANT:


1.2 SCOPE
This specification covers the minimum requirements for the supply of the cathodic
protection equipment to be used for the protection system.
These equipment include:
- Transformer/rectifier(s)
- Anodes
- Earthing cells
- AC and DC cables
- Test/bond boxes
- Thermit-welds
- Joint equipment
- Control box
- Cable accessories
- Isolating joint and accessories (coupling)
- Spark gaps
- Miscellaneous equipment
If not specified otherwise, engineering and supply of mentioned cathodic protection

material shall be in scope of VENDOR.
1.2.1 Engineering
Engineering scope to be considered as follows:
- Layout drawing of branch-circuits

- Layout drawing of location of all sub-distribution panels and junction boxes
inside plant area
- MTO of all the required equipment and installation material
- Complete design of anodes, cathodes, ground beds, rectifiers, connection sets,
local sub-distribution panels, junction boxes, feeder cables.
- System components shall be standardised as much as possible in
consideration to economical criteria.
1.3 Equipment
All necessary cathodic protection equipment and material specified according to this
and attached documents shall be in VENDOR’s scope of supply.
1.4 Abbreviations and Definitions
AC Alternating Current
DC Direct Current
LV Low Voltage (below 1000 V)
CLIENT: CONSULTANT:


PURCHASER Company issuing the inquiry and order

VENDOR Company issuing the proposal and/or receive the order
2.0 CODES AND STANDARDS
2.1 Document Priority
All electrical equipment, materials and installations shall be in accordance with

the applicable portions of the latest edition of the relevant codes and standards
referred to in this document at the time of contract award.
In the event of conflict between codes and standards and/or this specification, the
matter shall be highlighted for Client's attention/approval. The priority of
references stated in this Specification is as follow:
- Requisition / Purchaser Order

- Data Sheets
- This Job Specification.
- Drawings & Other Documents.
- Other Job Specification Mentioned In This Document
- Iranian Petroleum Standards (IPS)
- Referenced Design International Codes & Standards
In any case the vendor shall inform purchaser and obtain clarification before
proceeding with any work.
2.2 Reference Codes and Standards
The following codes, standards and regulations form a part of this specification.
The design of electrical power system and equipment shall be in accordance with all
applicable sections of the latest edition and their current amendments:
IPS (IRANIAN PETROLEUM STANDARDS)
E-TP-820 "Engineering Standard for Electrochemical Protection"
E-EL-100 "Engineering Standard for Electrical system Design"

CLIENT: CONSULTANT:


E-EL-110 "Engineering Standard for Hazardous Area"
I-TP-820 "Inspection Standard for Monitoring Cathodic Protection Systems"
C-TP-820 "Construction Standard for Cathodic Protection"
M-TP-750 "Material and Equipment Standard for Cathodic Protection"
M-EL-155 "Material and Equipment Standard for Transformer Rectifiers for

Cathodic Protection"
BSI (BRITISH STANDARDS INSTITUTION)
BS-7361 "Cathodic Protection"

Part-1: Code Practice for Land and Marine Applications.
BS-7430 "Earthing"
BS-1377 "Method of Test for Soils for Civil Engineering Purposes"
NACE (NATIONAL ASSOCIATION OF CORROSION ENGINEERS)
RP-01-69 "Control of External Corrosion on Underground or Submerged"
RP-01-86 "The Electrical Isolation of Cathodically Protected Pipelines"
RP-05-72 "Recommended Practice for Control of External Corrosion on

Underground or Submerged Metallic Piping Systems"
NFPA (NATIONAL FIRE PROTECTION ASSOCIATION)
NFPA-70
IEC (INTERNATIONAL ELECTROTECHNICAL COMMISSION)
IEC-529 "Classification of Degrees of Protection Provide by Enclosures"
IEC-296 "Specification for Unused Mineral Insulating Oils for Transformer

and Switchgear"
IEC-146 "Semiconductor Converters"

CLIENT: CONSULTANT:


ASTM (AMERICAN SOCIETY FOR TESTING AND MATERIALS)
ASTM-A-518 "Corrosion-Resistant High Silicon Iron Casting"
ASTM-A-123 "Zinc Coatings on Products Fabricated from Rolled, Pressed &

Forged Steel Shapes, Plates, Bars and Strips (Hot Galvanized)"
2.3 Specification Deviation
Deviation from this specification are only acceptable where the VENDOR has listed
in his quotation the requirements he cannot, or does not wish to comply with, and
the PURCHASER has accepted in writing the deviations before the order is placed.
In the absence of a list of deviations, it will be assumed that the VENDOR complies
fully with this specification.
3.0 SITE CONDITION
3.1 Site Location
Sohrab Field is located at North of Azadegan Field, and 115 Km North West of
Ahwaz right along the international border with Iraq.
3.2 Climatic Data
The equipment and all its components should be entirely suitable for service
under the conditions specified in Process design basis No AOGC-036-PR-ESS-001.
NOTES :
(1) The maximum temperature given are for calculating the maximum temperature
rise of the equipment.
(2) Repertoire black body surface temperature under direct sun radiation, without
forced cooling.
CLIENT: CONSULTANT:


4.0 DESIGN
4.1 General and Basic Requirements
A cathodic protection system shall be installed for all buried or submerged facilities
to mitigate corrosion that might result in structural failure. A test procedure shall be
developed to determine if adequate cathodic protection has been achieved.
Temporary cathodic protection to be used if main CP system is predicted to be
energized later than 2 months after complete burial.
Design and selection of the cathodic protection system to be utilized shall be based
upon this specification and sound engineering judgement, substantiated by:
- Adequate corrosion survey data

- Review of historical data from similar facilities
- Economics
- Material, operational and environmental requirements
The resultant cathodic protection system shall be designed to eliminate any adverse
corrosive effect upon nearby structures, equipment, pipe, cables, etc. owned by
others or by the government. In addition, design drawings shall clearly define the
location of all cathodic equipment incorporated on the pipeline, the system and all
other facilities, whether above or below ground, that could affect or be affected by
the cathodic protection system. The system design life is 20 years.
Metallurgical problems, such as stress, corrosion, cracking, shall be considered.
Materials and equipment shall conform to the referenced standards or as approved

by PURCHASER for special requirements. If required, representative sample batch
materials suitable for destructive testing shall be furnished to PURCHASER for
quality control inspection and approval prior to delivery of corrosion prevention
materials. A copy of VENDOR‘s analysis or test results shall be furnished with the
representative sample. All other equipment will be subject to PURCHASER‘s
acceptance inspection.
4.2 Surveys
The survey method to be used for this project shall consist of rapid or spot testing of
soil resistivities as typical points along the structure. The environmental conditions,
size, physical layout, economics and need for design information will determine
which variables require field measurements.
CLIENT: CONSULTANT:


4.3 Data Accumulation
Proper data recording in the field is mandatory. In addition to electrical

measurement, recorded data shall include dates, weather conditions, soil conditions,
terrain description, entry roads, potential sources of electric power, locations suitable
for sacrificial anodes and other such pertinent information.
Survey data shall also indicate the location of all buried structures on and adjacent
to the job site, the condition of exposed metal surfaces and the insulating qualities of
any coatings and structures.
Detailed location measurements, such as for possible cathodic protection locations,

shall be properly referenced by a triangular system to property lines, kilometre posts
and/or established survey stations.
4.4 Design Studies and Documentation
The VENDOR shall prepare detailed designs of proposed protection system.

Proposals shall:
- be based on a continuous operation of the system for the specified design life
of the structure or equipment to be protected.
- include installation requirements of any bonds necessary between structures

which may be subject to cathodic interference.
- include details for system commissioning, the design and location of insulating
joints and monitoring points.
- proposal information as per above mentioned items shall be approved by the

PURCHASER‘s engineer.
4.5 Protection Criteria
The cathodic protection system shall be designed so that the potential at any point
of the protected pipeline shall be minimum -0.85V.
The potentials are measured in the "Instantaneous off" condition when the power
supply from the rectifier is disconnected.
In case of sulphate reducing bacterial (SRB) existence the min. negative potential
shall be considered as -0.95 V.
CLIENT: CONSULTANT:


POTENTIAL LIMITS FOR CATHODIC PROTECTION OF COATED BURIED PIPES (IPS-E-TP-820(1) )
OFF POTENTIALS,
COATING SYSTEM
VOLT (Ref. Cu/CuSo4)
Epoxy powder fusion-bonded - 1.1
Asphalt and coal tar enamel - 2.0
Tape wrap (laminated tape system) - 1.1
Epoxy coal tar - 1.5
Polyethylene (2 layers) - 1.0
Polyurethane pu -1.1
Cold applied petrolatum and - 1.1
petroleum wax tape
3 ply cold applied plastic tape -1.1
4.6 Current Density Requirements
The Contractor shall carry out pipeline attenuation calculations to determine the
pipeline current demand and spacing between cathodic protection stations as
required during the pipeline design life.
The current density values as specified in IPS shall be considered. Current

densities are to be related to the total pipeline surface area and take into account
coating deterioration during the referred life of the pipeline. Following current
densities in shall be used as minimum design values:
According to IPS-E-TP-820,B.1.2, page 91
- Uncoated pipe: 20 mA/sq.m

- Tape or coal tar/bitumen: 1.25 mA/sq.m
- Fusion bonded epoxy or 0.25 mA/sq.m
3 Layer Polyethylene:
It is assumed that pipeline construction is carried out in a manner to avoid coating

damage during construction and operation.
CLIENT: CONSULTANT:


CHARACTERISTICS OF PRINCIPAL ANODE MATERIALS (BS-7361)
MAXIMUM
MAXIMUM PROBABLE
OPERATING CONSUMPTION
MATERIAL DENSITY OPERATING UTILIZATION REMARKS
CURRENT RATE
VOLTAGE FACTOR
DENSITY
g/cm3 A/m2 Mass/A year V %
Steel 7.85 5 9 kg 50 30 to 50 Used with carbonaceous
Impregnated back fill
1.1 10 0.5 kg 50 50
graphite
Higher consumption
occurs in chloride
containing environment
High silicon iron 7.0 50 02 ~ 1.0 kg 50 50 to 90 unless chromium or
molybdenum is add4ed.
Only used in conjunction

Carbonaceous
0.7 to 1.1 5 1 to 2 kg 50 50 with other anode
Backfill
materials
Magnetite 5.8 100 < 5g 50 60
Lead alloys 11.3 300 25 g 25 80
Cannot withstand current
reversal.
Operating current density
under oxygen evolution
Platinum on
81) conditions should not
titanium, niobium 21.5 1000 10 mg 90
402) exceed 200 A/m2. Wear
or tantalum
rates of platinized (and
platinum/iridium) anodes
increase with decreasing
chloride levels
1) Platinum on titanium
2) Platinum on niobium and Platinum on tantalum
MMO Anodes:
The mixed metal oxide coating is a crystaling electrically conductive coating that
activates and enables a titanium/Platinum substrate to function as an anode.
MMO anode shall be Rod type according to top schedule specification.
4.7 Temporary Cathodic Protection System
Complete cathodic protection design parameters shall be obtained by installing a

temporary cathodic protection system and measuring the quantity of protective
current required to adequately protect a given buried system. Details of these
temporary cathodic facilities are given below:
CLIENT: CONSULTANT:


4.7.1 Location
The temporary ground bed shall be located at the site selected for the proposed
permanent facility.
4.7.2 Temporary Power Sources
Temporary electrical test power may consist of engine driven generators, storage
batteries, existing cathodic protection units, portable rectifiers combined with
available commercial power, etc. This equipment shall be capable of providing well-
regulated constant direct current voltage and amperage or required magnitudes for
the particular test duration.
4.7.3 Temporary Ground Beds
Temporary ground beds may consist of buried junk pipe, abandoned buried metallic
structures, aluminium foil in burrow ditch water, etc, which may be utilised to provide
sufficient electrical ground contact to allow stimulation of the proposed ground beds.
Temporary wiring used for connecting the ground beds shall have sufficient
insulation to prevent uncontrolled circuits and to provide personnel safety.
4.8 Current Measurement
After the system has stabilised at the required protective levels, measurements shall
be made of current drainage at all current sources including control bands.
All current measurements shall be obtained across calibrated shunts or from

instruments permanently connected in the circuit, whereby resistance will remain
constant during the tests.
4.9 Soil to Pipeline Potential Measurement
Soil to pipeline potentials shall be obtained at all test leads, both sides of insulation
joints or unions, foreign pipeline or other buried metallic structure crossings, or like a
structure in a close proximity to the structure being protected (where such readings
are practical and obtainable), and elsewhere, as deemed necessary, to establish the
effectiveness of the proposed cathodic protection and to assure against induced
parasitic current corrosion on structures not to be included into the cathodic
protection system.
All voltage levels shall be recorded to the nearest suitable precision mili volt-meter
using instruments and standard copper/copper-sulphate half-cell reference
electrodes or silver/silver-clorure (Ag/AgCl) half-cell reference electrodes.
CLIENT: CONSULTANT:


Voltage level measurements shall be taken at sufficient intervals to prevent

overlooking a non-protected or corroding portion of the buried structure to be
protected. Measurements shall also be obtained to ascertain that the cathodic
protection system being designed will not create non-controllable interference
problems upon other buried structures. In location subject to volatile explosion, such
as station and tank farm installations, additional potential readings shall be in
sufficient number to detect any hazardous condition which may result from the
cathodic protection installation.
The electrode position, with respect to the buried structure, shall be recorded for
each potential measurement.
4.10 Measurement Conditions
No applied current:
This is the so-called ‘normal’ or native electrical condition of the buried structure.
These conditions are to be ‘shifted’ by applied cathodic protection to an electrical
state meeting one or more of the applicable protective criteria. Choice of criteria
shall be governed by economics, coating conditions, environment and type of buried
structure to be protected.
Using the temporary simulated cathodic protection system, enough protective

current shall be drained from the structure to establish protection over the entire
structure meeting the minimum levels acceptable for criteria being applied.
Maximum protective level:
After the minimum protective current requirements have been determined, the
current output of the temporary simulated cathodic protection system shall be
increased until the upper limits of the acceptable protective levels have been
reached. Protective attenuation across the entire structure shall then be measured.
4.11 Soil Resistivity Surveys
Soil resistivity survey measurements shall be obtained using the four-electrode

method (Wernner) mentioned below.
The single-electrode method will be acceptable only if the four-electrode method
cannot be used because of space or other limitations.
Client's representative(s) shall be present throughout the soli resistivity test.
4.11.1 Pipeline route
Where resistivity measurements is required along the pipeline, it shall be made at

maximum intervals of 1 km (or less, when the soil conditions change) using
electrode spacing equivalent to pipe depth.
CLIENT: CONSULTANT:


4.11.2 Ground bed sites
Resistivity measurements at proposed ground bed locations shall be taken to allow

complete resistivity contouring at each alternate proposed ground bed site.
4.11.3 Anode sites
Resistivity measurements at proposed galvanic anode sites shall be taken along the
pipe at suitable intervals using potential electrode spacing as required. Resistivity
measurements shall be corrected to consider the worst resistivity condition, that is
summer conditions.
4.11.4 Soil Samples
Suitable soil samples shall be obtained, if necessary, to determine additional soil

characteristics such as soluble salts, moisture content, pH value, etc. The content of
sulphate shall be determined to detect the presence of sulphate reductor bacteria.
4.12 Location of Buried Pipelines
Electronic pipe locators may be used to locate underground pipelines or other

metallic buried facilities. Spotting bars shall be used only to verify underground
location. Coating on the buried structure shall not be damaged by use of the bars.
5.0 CATHODIC PROTECTION UNIT
5.1 General
These facilities include such as rectifiers, ground beds and galvanic anodes that
supply protective current through a cable connection to the buried metallic structure.
Anticipated changes in soil characteristics and in coating efficiency shall be
considered in case of choosing and sizing cathodic protection equipment.
Rectifiers will usually provide the most economic power supply where AC power is
available and where the current demand will exceed that economically obtained from
galvanic anodes.
Surface ground beds will normally provide maximum long-term economies.

Deep-well ground beds are generally higher in first cost than surface beds, however,
they may be the long-term economic choice in arid areas or locations where right-of-
way acquisition is difficult.
Galvanic anodes provide specific economic and operational advantage in high-

interference areas, such as offshore environments and, if used with ‘hot-spot’, high-
dielectric coatings.
CLIENT: CONSULTANT:


Galvanic anodes are the most economic cathodic protection for short pipeline
systems.
5.2 Location of the Units
Rectifier units shall be located in the nearest position to the under ground pipe lines
distribution center.
5.3 Spacing of Units
- Spacing shall be governed by the following factors:

- Rectifier and ground bed capacity
- Parasitic current effect
- Allowable potentials on coating
- Protective coatings, insulating and dielectric qualities
- Economics
- Soil conditions
5.4 Type of Units
Catalogue units manufactured in accordance with appropriate standards are

preferred. Type selection is determined by the following:
Oil cooled transformer rectifier shall be supplied with the first complete of oil
which shall comply with the requirements of IPS-M-EL-155(1) "Material and
Equipment Standard for Transformer Rectifiers for Cathodic Protection"
Generally, 63 steps transformer shall be used.
The rectifier shall be of the silicon or selenium type, connected for full wave
rectification in accordance with the requirements of IPS-M-EL-155(1) "Material and
Equipment Standard for Transformer Rectifiers for Cathodic Protection".
Suitable surge protection shall be provided for:

- Input to transformer
- Input to rectifier and,
- Rectifier output
Unless otherwise specified.
5.5 Specialized Units

Rare design problems will require the use of special cathodic protection devices
such as the constant potential or constant current unit. Problems like variations
ground bed resistance, high voltage direct-current interference problems, will
generally require automatic regulation in cathodic protection current output for
complete and economic protection. Special cathodic protection units such as engine
CLIENT: CONSULTANT:


driven generators or alternators shall be selected from VENDOR’s standard

equipment.
6.0 IMPRESSED CURRENT GROUND BED
6.1 Location
The location selection of ground bed sites shall be based on:
6.1.1 Current Utilization

Ground beds shall be located for the maximum utilization of protective currents with
a minimum flow of interfering currents in soil circuits.
6.1.2 Accessibility
The design should strive to minimise right-of-way procurement problems while
providing maximum accessibility for installation, inspection and maintenance.
6.1.3 Soil to Structure Potential

The potential between the coated structure and the soil contacting shall not exceed
the following levels as measured to copper/copper-sulphate electrode located
directly over the pipe:
POTENTIAL LIMITS FOR CATHODICPROTECTION OF COATED BURIED PIPES (IPS-E-TP-820 (1) )
OFF POTENTIALS,
COATING SYSTEM
VOLT (Ref. Cu/CuSo4)
Epoxy powder fusion-bonded - 1.1
Asphalt and coal tar enamel - 2.0
Tape wrap (laminated tape system) - 1.1
Epoxy coal tar - 1.5
Polyurethane pu -1.1
Cold applied petrolatum and - 1.1
petroleum wax tape
3 ply cold applied plastic tape -1.1
All measured protection potentials shall be "instant-off". Cathodic protection
system shall be equipped with synchronized interrupters for this purpose.
CLIENT: CONSULTANT:


6.2 Type
The choice of surface versus deep-well ground beds shall be governed by such
variables as annual rainfall, soil conditions, interference problems and right-of-way
acquisition costs.
6.3 Anode Selection
Generally, passive (graphite, cast iron, lead silver or MMO) rather than sacrificial
type anodes shall be used. Such anodes shall be surrounded with tamped soft coal
or calcined petroleum coke breeze, if practical, in order to increase effective anode
size.
Ferro-silicon anodes shall be used for deep-well beds and are preferred for surface
beds.
6.4 Anode Placement
Where feasible, anode placement shall be designed to allow discharge of nearly

equal currents from all anodes in the ground bed.
Surface ground bed anodes shall normally be installed in the preferred horizontal
position, but where rock or other obstructions are encountered, the anodes may be
installed vertically to take advantage of soil conditions at the particular installation.
6.5 Deep-well Ground Beds

Depth of deep-well beds shall be such that the anodes are located in low resistant
strata, such as ‘red beds’ or similar clays. A resistivity log of the hole shall be taken
and used to position anodes in the lowest resistant soil strata.
Other design criteria include:
- Low current drain (3-4 amps per anode) to minimise gassing and promote
longevity.
- Anode spacing to take advantage of favourable strata, 1500 mm minimum
- Adequate asbestos pipe for gas venting
- Anode centralizers
- Coke slurry injection from bottom
- Inert or non-corrosive structural materials to determine anodes effective life,

including asbestos vent pipe, nylon support rope, stainless steel clamps and
centralizers, plastic casing to top-of-coke fill, etc.
CLIENT: CONSULTANT:


6.6 Current Density
Maximum design current for graphite anodes shall be 3 amperes for 75 mm x 1500
mm anodes and 4 amperes for 100 mm x 2000 mm anodes. For other anode types it
depends on current density (mA/cm3) which could be supported by anode material.
6.7 Ground Bed Design Aids
Ground bed resistance may be lowered by increasing number of anodes, anode

length, diameter, burial depth or spacing and by decreasing soil resistivity adjacent
to the anodes.
‘Spread’ or ‘throwing power’ may be increased by increasing the distance between

the ground bed and the protected structure by improving the coating on the buried
structure adjacent to the ground bed or by utilising mutual interference between
anodes to focus the bed output away from the structure.
Continuous ground bed output may be assured by providing for future water
replenishment.
Gas elimination devices such as vent pipes and drain tiles must be used to assure
continuous full current output. Vent pipes installed in deep-well ground beds shall be
drilled with adequately spaced and properly sized holes to insure against plugging
and to provide adequate gas venting.
7.0 REFERENCE ELECTRODES
7.1 Application
For rectifier control and continuous measurement of potential, each rectifier is fitted
with two reference electrodes.
One of these electrodes is permanently connected to the rectifier. The second

electrode serves for comparison purposes.
7.2 Location
Reference electrodes shall be installed close to the system to be protected. Each

pair of reference electrodes shall be installed closely.
7.3 Type
The reference electrodes shall be one Cu/CuSo4 electrode and one Zn electrode.
CLIENT: CONSULTANT:


Electrode size, shape, weight, purity and backfill shall be governed by the
requirements of the particular installation in accordance with materials specified
herein.
8.0 GALVANIC ANODES
8.1 Application
In general, galvanic anodes may be advantageously installed on sections of buried

structures where control of interfering currents is difficult, particularly in congested
and urban areas.
They may serve for installations remote from electric power or for protection of small
insulated sections in a large unprotected system.
Magnesium anodes are frequently the most economic cathodic protection choice for
long or complex piping systems coated with long-life, high dielectric.
8.2 Location
Galvanic anodes shall be installed in battery groups at distributed locations along the
system to provide complete protection and to allow for future inspection and
maintenance.
Soils having the best combination of low electrical resistivity, high chemical
concentration and maximum moisture content shall be selected for the galvanic
anode site. Distance for buried structure should not exceed 3000 mm.
8.3 Type
Galvanic anode selection shall be restricted to commercially available magnesium or

high-purity zinc anodes.
Zinc anodes shall be used only in low-resistance soils say up to 500 ohm.cm and
where low current outputs and resultant low solution potentials are tolerable.
Anode size, shape, weight, purity and backfill shall be governed by the requirements
of the particular installation in accordance with materials specified herein.
Anodes shall be of magnesium type high potential alloys assembled with lead wires
in accordance with the following compositions: (IPS-M-TP-750)
- Aluminium 0.01% max

- Manganese 0.9-1.2%
- Copper 0.02% max
- Iron 0.03% max
- Nickel 0.001% max
CLIENT: CONSULTANT:


- Other, total elements 0.3% max

- Magnesium Remainder
Zinc anodes compositions should be as following:
- Aluminium 0.005% max

- Cadmium 0.003% max
- Iron 0.0014% max
- Lead 0.003% max
- Copper 0.002% max
- Other elements, total 0.012% max
Zinc Remainder
Performance properties of galvanic anode alloys:
Anode Type Open Circuit Current efficiency Energy Consumption

Potential negative Volts % (min) capability rate
(cu/cuso4 electrode) Amp-Hr/kg Kg/Amp-year
(min) (max)
Zinc 1.1 90 780 11.2
Magnesium 1.7 50 1200 7.3
* : 14 day test, with reference to ASTM test method G97.
9.0 TEST POINTS
9.1 General
Test points are defined as those points or locations along the protected buried
metallic system at which electrical-current or potential measurements are made to
evaluate the level or status of cathodic protection.
These points shall be provided within the limits of economical and logical feasibility,
in sufficient quantities and at appropriate intervals to minimise the possibility of
overcooking a non-protected corroding portion of the buried metallic structure.
9.2 Potential Measurement
At readily accessible locations convenient to public roads and/or waterways (see

table 1 in appendix).
Test points for potential measurements shall consist of welded, metallic contacts to
the buried structure which provide for efficient clip-on measurements and reliable
repetitive readings. Use of such points shall provide for minimum damage to
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decorative coatings and eliminate notch penetrations into the metallic structure by
repeated base metal contacts.
In most instances, properly sized and insulated stranded copper wire shall be used
to transfer metallic contact from buried structures to conveniently located above-
ground test terminals.
Protruding bolt threads (softer than steel test clips) shall provide the testing
connections at the wire terminal. Suitable rigid conduit connections, risers and boxes
are used to protect the test points.
Casing vent pipes, pipeline risers, valves, etc., may provide the metallic transfer path
from buried structure to above-ground. In such instances, short lengths of solid or
tubular copper shall be welded or soldered to the structure to provide a test point.
9.2.1 Current Measurement
Refer to table 2 (in appendix) for location of electrical test points for current
measurement.
Test points for measurements of electrical current shall generally consist of shunt-
type measuring facilities which allow measurements of current without breaking the
cathodic protection circuit.
Standard one mili-volt per one ampere (0.001 ohm) suitable capacity shunts shall be
used, if possible. For galvanic anode installations and low current rectifiers, the ten
mili-volt per one ampere (0.01 ohm) shunt may be used. The shunts shall be
contained in proper housings.
Where sacrificial anode systems are used, potentials measurements shall be made
faraway from the anodes.
10.0 INSULATION FITTINGS
Insulating fittings shall be designed for above-ground installations to control the flow
of electrical currents. Where fittings are buried, properly sized leads on both side of
the insulation shall be brought above ground for current measurements and control.
On off-shore insulated unions or other ‘hard-to-reach’ insulators, spare leads shall

be installed during construction.
Insulation fittings shall be provided at sufficient intervals along the metallic cathodic
protection circuit to result in adequate circuit control.
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Selection and design of the insulation fitting to be used shall be governed by the
requirements of the particular application. Material shall be selected from standard
VENDOR items.
11.0 PIPELINE INSULATION LOCATION
Insulation shall be provided at the following locations:

Main lines shall be insulated from station and terminal structure, river crossings and
injection connections.
Storage tanks shall be insulated from connected buried metallic structure and
production tanks shall be insulated from OSBL system.
Flow lines shall be insulated from wells.
Coated pipeline sections shall be insulated from adjacent un-coated pipeline

sections.
Buried flanges and above-ground flanges shall be provided with sufficient insulation
to insulate fully each bolt from both flanges.
12.0 SPECIAL INSULATION POINTS
Typical locations, which require special insulation provisions, are as follows:
Valves in valve box shall be insulated at the support point by two sheets of metal
separated by a sheet of insulating material. This insulator combination shall be
completely coated.
Pier supports shall be isolated from pipelines by multiple layers of glass wrapper
saturated with coating material of sheet-insulating material.
A minimum space of 300 mm shall be provided between cross lines for insulation
purposes. If this spacing cannot be obtained, insulation insurance can be obtained
by using sheet insulating material. Thickness of insulating sheet will be governed by
distance between lines, but should not be less than 6.35 mm (1/4 in). If practical, the
space between parallel lines of 6’’ and larger should be a minimum of 2.5 times the
diameter of the largest line.
Electrical ground connections and conduit shall be isolated from coated pipeline
sections. Bare copper ground cables shall be spaced at least 300 mm from other
buried dissimilar metallic structure.
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Public sewer, gas and electricity lines shall be insulated from government’s buried
metallic structures.
Buried dissimilar metallic structures shall be insulated from each other.
13.0 PROTECTION OF PARASITIC CURRENTS
Corrosion prevention design of all buried metallic structures shall minimise the
probability of parasitic currents flowing between existing and/or proposed facilities.
Adequate coatings and/or insulation shall be provided at anticipated trouble points to
minimise the flow of parasitic currents. Design shall normally incorporate appropriate
bond circuits between buried metallic structures to prevent the corrosive effect of
parasitic currents.
13.1 Typical Bond Applications
13.1.1 Cathodic Protection Currents
Cathodic protection currents shall be controlled to prevent parasitic current damage

by provisions for solid, resistance, unidirectional, electrolytic or rectifier bonding as
required by the particular application. Where foreign pipelines are involved, a joint
interference testing program is generally required.
13.1.2 Alternating Currents
Where parasitic or induced alternating currents will be encountered on a pipeline

(generally, where a well-coated line is parallel to a high-voltage transmission line),
electrolytic drains, such as zinc or magnesium rods, shall be installed to ground the
alternating current. This induced alternating current, specially with yard-coated lines,
can be extremely hazardous during construction. Temporary grounding facilities
shall be provided to protect the pipe as it is being installed.
13.2 Typical Bond Circuits
13.2.1 Solid Bond
A solid low resistance metallic circuit connecting electrically the offending and
offended structures.
13.2.2 Resistance Bond
Similar to solid bond with the exception that a resistor is placed in the circuit to
restrict the operating bond current.
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13.2.3 Electrolyte Bond
Similar to resistance bond with the exception that an electrolyte is used in place of
the resistor. Galvanic anodes may be buried close together or near a buried metallic
structure to utilize the soil as the electrolyte resistance.
13.2.4 Surge-gap Bond
Similar to resistance bond with the exception that an air gap resistance is used in
place of the resistor.
13.2.5 Unidirectional Bond
A half-wave rectifier that allows current to flow from a buried structure through a
metallic conductor to the offending structure, but blocks current flowing from the
offending structure through the metallic conductor. This type of bond must be
provided with properly designed surge protection for continued performance.
13.2.6 Rectifier Bond
Independent cathodic protection rectifiers connected to a common ground bed.
14.0 INSULATION FITTING PROTECTION SYSTEM
14.1 Insulation Joint

The purpose of insulating joints is to provide electrical isolation between sections
of pipelines to prevent detrimental electrochemical interaction between the
sections. Insulating joints are used also to ensure effective current distribution for
cathodic protection systems.
The insulating joint is intended to be installed under/above ground or above
water. It is intended to be girth welded between two pipeline sections.
14.2 Alternating Currents

Electrolytic bonds, such as a prefabricated zinc anode grounding cell, shall be
provided across insulation joints, where it is desirable to insulate the direct current
only.
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15.0 GALVANIC COUPLES
15.1 General
Dissimilar metal connected by an electrical conductor and exposed to a conducting

solution can corrode one component while protecting the other. These are termed
galvanic couples. Corrosion prevention design shall exclude connection of metals
with differences in potential, particularly in wet or buried services. Metals having the
least potential differences shall be selected if galvanic coupling is necessary.
15.2 Protection Methods
Where contact between dissimilar metals can occur, as with galvanised piping,
copper ground wires, zinc grounds, steel pipe, cast iron structure, etc., protection
shall be provided with sufficient coating to exclude moisture, electrical insulation or
cathodic protection to prevent corrosion damage.
15.3 Corrosion Rate
The magnitude and direction of current flow between dissimilar materials in a

conducting solution determine the corrosion rate on a coupling member.
16.0 MATERIAL AND EQUIPMENT STANDARD
16.1 General
This section will provide the basic criteria, including quality control and acceptance,
for material and equipment required for cathodic protection facilities associated with
the handling of crude oil transported by flow line or associated facilities.
The transformer rectifier units shall comprise a main transformer and a rectifier with
manual output regulation equipment. They shall all be installed either:
 In a welded weatherproof steel tank for oil filled type; (with transformer, rectifier
and regulating equipment all below oil level) or:
 In a standard cast iron pillar / weather proof steel cabinet, in case of dry type
transformers.
The unit shall be suitable for plinth mounting.

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16.2 Main Transformer
The main transformer shall be a double wound type in accordance with IEC
publication No. 76, suitable for connection to a supply system rated at voltage and
current given in data sheet and for environmental conditions.
An earthed shield shall be placed between primary and secondary winding.
All coils for transformer, chokes, wire wound resistors etc., shall be fully
impregnated with suitable oil resistant insulating varnish, either by vacuum
application or by preheating to a minimum 100°C, fully immersing the coil in
varnish while still hot, allowing the coil to cool in the varnish and then over drying
all in accordance with the varnish manufacturer's instructions.
All assembled electrical components which are not oil immersed shall be protected
with fungicide materials when required.
The transformer shall be equipped with rotary selector switches for adjusting the
output in 63 steps unless otherwise specified.
16.3 Rectifiers
The rectifier shall be of the silicon or selenium type, connected for full wave
rectification in accordance with the requirements of IEC 146.
Suitable surge protection shall be provided for:
- Input to transformer
- Input to rectifier and,
- Rectifier output
Unless otherwise specified.
16.3.1 Enclosure
Adequately designed enclosures shall have protection measures to prevent

accidental contact and to be resistant against temperature variations. They will be
properly galvanised or coated to resist atmospheric corrosion. Air-cooled units shall
be screened to prevent insect entry.
For fixation of enclosure on concrete base, tolerances of civil design shall be

considered.
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16.3.2 Interior Frame
Component parts shall be mounted so that all connections are accessible. In

general, galvanised steel or other atmospheric corrosion prevention coatings shall
be used for the interior frame and bolts in air-cooled rectifiers.
16.3.3 Transformers
There shall be a separate transformer for each electrical phase used in the rectifier.
16.3.4 Rectifying Assemblies
All rectifiers shall contain automatic controlled bridge-connected rectifying

assemblies mounted to minimise heat transfer to each other.
16.3.5 Terminals and Connections
Bolt connections shall have double nuts with cable connections soldered to the first
nut. All cable terminals shall be crimped and soldered to the cable.
16.3.6 Instruments
Rectifier shall have readily accessible direct-current voltmeters and external shunt-
type ammeters.
In areas with a high frequency of lightning strikes, disconnecting blades will be

added to the meter circuits allowing metering isolation when not in use.
16.3.7 Protective Devices
In rectifiers manually operated circuit breakers or magnetic starters with property

sized instantaneous and time delay trips shall be used.
16.3.8 Special Auxiliaries
Faraway located units require a DC system failure detector consisting of a visible

light driven by a DC magnetic relay.
Special inputs frequencies, silver-plate connections, lightning protection, constant

current transformation, etc., shall be specified if required by design.
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16.4 Time Switch
16.4.1 When required a single phase adjustable time switch complete with suitable
contactor to IEC 158 capable of switching the unit at full output on a "3" minute on
"2" minute off cycle shall be fitted.
16.4.2 A double pole selector switch shall be provided to enable a selection to be made
for either continuous operation or time switch controlled operation of the unit.
16.5 Control Box
16.5.1 A control box shall be installed on the outside of the tank and shall be provided with
a hinged lockable door, suitably stiffened to prevent distortion and provided with a
reinforced glass for viewing the meters.
16.5.2 The control box shall house the following:
- The manual control of the regulation device, and the time/ continuous supply
control switch, where applicable.
- Suitable d.c. voltmeter and d.c. ammeter.
The instrument cases shall be earthed unless manufactured of insulating

materials.
The voltmeter shall be protected by a fuse in each lead of the instrument.
- There shall be a schematic circuit diagram on the inside of control box door of
the transformer rectifier.
This diagram shall be engraved on non corrosive and non deteriorating

material.
- Three positive and three negative output terminals shall be provided in a

suitable location for easy access and cable connections.
16.6 Impressed Current Ground Beds
16.6.1 Anode Material
Unless otherwise specified, impressed current anodes shall be composed of

graphite rods sized to meet the current requirements of the installation. The rods
shall be fully impregnated with wax or suitable binding material. Alternate anode
materials, used only in special problem areas, are junk steel, high silicon cast iron
and lead silver. Except in rare cases where construction conditions prohibit it, each
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anode shall be encased with well-compacted soft coal or calcined petroleum coke
breeze screened to proper particle size requirements.
16.6.2 Cable and Wiring
Cable from the rectifier unit to ground-bed shunt junctions and to the protected
structure shall be sized to carry the system’s total current without undue voltage
drop.
Generally single conductor, stranded-copper cable will suffice. Insulation should be a

material such as high-molecular-weight polyethylene, which will withstand long-term
soil burial without deterioration. Smaller cable or more durable insulation may be
specified as determined by current requirements and environmental conditions of the
specific project.
On all anodes, special care shall be taken with anode-to-cable junction. This flexure
area is subject to damage and is a known cause of many past ground bed failures.
Rigid inspection enforcement is mandatory for this sensitive anode region.
16.6.3 Shunts and Shunt Junction Boxes
Each anode and all protective current connecting cables require current
measurement methods. Generally, calibrated shunts are the simplest method for
such measurements. These voltage-drop shunts shall be housed in adequately
sized surface cabinets, if possible. Where below-ground shunt installations are
required, they shall be fully insulated to the soil.
16.6.4 Cable Splicing Material
Underground splicing of cathodic protection cables should be avoided, if possible.
Under no circumstances should below-ground splices of positive cables in deep

anode ground beds be allowed. Above ground splices are permissible. Where
splices are made, proper material should be used to ensure a long-lasting, low
resistance splices. Typical materials are:
Appropriately sized copper solder lug
50% tin / 50% lead solder with non-corrosive flux
Pressure-sleeve connectors
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16.6.5 Insulation
Buried negative cable splices shall be insulated with one of the following materials:
Hot-applied asphalt or coal-tar pipeline enamel poured into a properly formed and
sized container over primed surface.
Individual sized epoxy insulating compound kits

Two component cold-cured epoxy
Canvas-based phenolic insulating board material shall be used for special insulating
problems, such as positioning bolted connection in above-ground junction boxes.
16.6.6 Casing
Adequately sized polyethylene-, PVC-or glass-reinforced plastic pipe shall be

installed as casing in the above coke breeze segment of deep anode ground beds.
16.7 Galvanic Anodes
16.7.1 Anode material
In low resistance soils (less than 1.500 ohm/cm), zinc or high potential magnesium
anodes shall be used in series with a suitable resistor.
16.7.2 Anode back-fill
All galvanic anodes used for soil applications require proper low resistance drilling
mud type back-fill material with moisture retention characteristics to insure
dependable anode output.
16.7.3 Anode Weight and Shape
Anode weight, size and shape shall be chosen from standard economically available
materials according to individual installation requirements.
16.7.4 Shunts
Calibrated shunts shall be used to allow evaluation of galvanic anode maintenance.

Where small current output are expected, ten mili volt for 1 ampere (0.01 ohm) shunt
should be used. If possible, these shunts should be housed in above ground
galvanised cabinets.
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16.8 Electrical Test Points
16.8.1 General
Electrical test points are required to evaluate cathodic protection effectiveness. Both
voltage (soil to pipe potential) and current drainage measurements are required.
These test leads shall be constructed of properly sized, stranded copper cable with
polyethylene insulation suitable for soil burial. Above ground, where repeated
readings are required, stub-type materials made of copper or aluminium (in sulphur-
contaminated atmospheres) provide the most effective, long lasting contact
mechanism.
Test leads shall be brought into adequately sized above ground galvanised terminal
boxes via standard-weight rigid galvanised conduit. In severe atmospheric corrosion
areas, plastic conduits and junction boxes shall be used.
16.8.2 Test Lead Terminal Conditions
The test lead may be connected to the metallic structure where it is to serve by
either arc welding, thermit welding, brazing, soldering or bolting. Thermit weld
connections shall not use powder charges larger than Caldwell’s n°15 cartridge or
equivalent.
Other connections, such as cable-to-cable or cable-to-shunt, shall use appropriately

sized solder lugs, bolts and washers. Above ground connections require silicon /
bronze bolts for long life.
16.9 Electrical Insulation Devices and Materials
16.9.1 General
Standard manufactured insulation devices and materials are required to insulate

coated or cathodically protected structure from adjacent bare, non protected metallic
structure.
16.9.2 Insulated Joints

Material for the pressure containing parts of the insulating joints shall meet the
requirements which specified on IPS-M-TP-750/Part 8 "Material and Equipment
Standard for Cathodic Protection / Insulating Joint" and special requirement on
related data sheet.
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The metallic parts of the insulating joint shall be of forged steel conforming to the
requirements of MSS-SP-44.
Insulating materials shall be made of age resisting laminated epoxy resin
reinforced with glass fiber conforming to ASTM specification D 709 Type IV Group
G 10/G 11 or equivalent standard.
The primary and secondary sealing gaskets shall be made of fluorinated
elastomers like PTFE and/or Butadieneacrylonitrile copolymers like Nitrile rubber
according to ASTM specification D 2000, or equivalent standard.
Filling materials shall be of adhesive sealant elastomer having a compressive
strength greater than 1500 kg/cm².
16.9.3 Pipeline Insulation Union
Insulating pipeline unions can be used, if they meet pipeline hydraulic requirement.
In areas subject to high lightning strike (high resistance soil regions, etc), arrestors
shall be installed across the union.
16.10 Casing Insulators
16.10.1 General
Depending upon individual project conditions, insulating of the pipeline from casings
at highway and railroad crossings shall use one of the following techniques and
materials:
16.10.2 Built-up Abrasion Pads
Coated pipelines can be insulated from their casing sections with built-up abrasion
and support pads fabricated in the field with coating materials used on the line.
16.10.3 Mechanical
Plastic or neoprene insulating devices shall be used for insulating pipelines from
carrier casings. The following material requirements apply in their selection:
Pipe sizes up to 12 Inch:
Glass reinforced epoxy or polyester-moulded insulators shall be used. Non-

reinforced material or other plastics should not be used because of undesirable ‘cold
flow’ characteristics.
Pipe sizes above 12 Inch:

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Skid-type insulating devices are required to support weights involved with the large
pipelines. Insulators shall be steel-banded with inside and edges insulated and with
skids made of either glass-reinforced epoxy, polyester or phenolic based material.
Minimum width of insulator shall be 8 inch with the more durable 12 inch insulator
being specified for larger-diameter pipe as governed by weights involved. Paper-
based phenolic, non-reinforced plastics, or plastics other than above are not
acceptable because of ‘cold flow’ or moisture absorption tendencies.
16.11 Casing Seals
Like casing insulators, casing seals may either be fabricated in the field using the
pipeline’s coating materials or by installing purchased mechanical seals. Purchased
seals shall be neoprene. Either the pull-on or the wrap-around seal will serve,
depending upon characteristics of the pipeline system involved.
16.12 Galvanic Couples
Dissimilar metallic components, assembled according to VENDOR’s specifications,

shall be inspected, tested and evaluated for damaging galvanic couples prior to
acceptance. Where corrosive galvanic couples are found, remedial changes, such
as installation of insulating devices or replacement of dissimilar metallic parts or
compatible metals, shall be carried out prior to accepting the items involved.
17.0 INSPECTION AND TESTING
In general, all materials and equipment of cathodic protection system shall be

subject of VENDOR’s permanent quality control with all necessary inspections and
tests.
18.0 PREPARATION OF SHIPMENT
The concerned equipment shall be suitably protected to prevent mechanical damage

and corrosion during shipment and for storage on site for a minimum period of 18
months.
Sensitive parts shall be packed separately thus to avoid damage during shipment.
Each item is to be securely labelled with indestructible tags with the following
markings:
a) Destination
b) Purchase order number
c) PURCHASER's equipment number
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Boxes containing loose parts are to be clearly identified by description, the major
equipment with which they are associated, the purchase order number and the
equipment number.
A bill of material shall be attached to each shipment package or container.
19.0 DRAWINGS AND DOCUMENTATION
The VENDOR shall provide the PURCHASER with drawings and documentation for
the purpose of design explanation, actual design and instruction for installation,
service and maintenance as indicated below:
 Reports of test measurements

 Arrangement drawings of protected piping with locations of anodes, cathodes
and terminal boxes
 Cable list
 Circuit and connection diagrams for rectifier units
 Operation manual of rectifier units and operating instructions of complete
cathodic protection system.
20.0 SPARE PARTS
The VENDOR shall specify in his proposal the recommended spare parts for the
commissioning period a two year operation period, type and number specified in
PURCHASER’s data sheets with individual prices for each item.
21.0 VENDOR RESPONSIBILITY & GUARANTEE
21.1 The manufacturer shall be responsible for the conformity to all codes, standards and
recommendations referred in this specification. Any special certification
requirements or inspections by other authorities shall be arranged by the contractor.
21.2 If any mal-performance or defects occur during the guarantee period, VENDOR shall
make available repaired, altered or replacement parts free of any charges whatever
direct on the PURCHASER's job site. VENDOR shall make available free of charge
to the PURCHASER qualified representatives as he deems necessary to supervise
the removal, repair and replacement of the defective parts in such manner that the
guarantee be maintained.
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21.3 The guarantee period for repaired or replaced parts shall be 12 months after start up
of repaired equipment but not more than 18 months after the repaired parts and/or
equipment are shipped. The guarantee period for the remaining equipment its
operation is dependent upon the proper performance of the repaired part shall be
extended by the number of days of fraction thereof that the equipment had been
inoperative because of defects. Field labor charges for works during the guarantee
period shall be subject to negotiation between the PURCHASER and VENDOR.
NOTE: For cathodic protection, contractor shall purchase required equipment
from approved vendors by A.O.G.C and all cathodic protection equipment and
facilities shall be meet requirement of IPS-M-TP-750 "Material and Equipment
Standard for Cathodic Protection".
22.0 MIN ACTIVITIES DURING COMMISSIONING

After complete installation of cathodic protection system, necessary tests shall be
carried out in order to make sure that the pipeline are properly cathodically protected.
Details of such tests are given in sections 10 and 11 of BS 7361 : part 1. The tests
must be carried out in the presence of the company representative.
It shall be the responsibility of the contractor to perform all pre-commissioning and
commissioning checks on the cathodic protection systems.
It shall be the responsibility of the contractor to supply all test equipment and
procedures required for all the necessary tests to perform the tests and
measurements.
The contractor shall carry out and also shall document all test under the supervision
of the company representative.
The inspection and testing shall not cause danger to persons or livestock and shall
not cause damage to property and equipment.
Under no circumstances shall any cathodic protection system be energized before
inspection and testing is completed.
All materials and equipments shall be factory tested according to relevant IEC or
equivalent BS standards and witnessed by the company representative.
22.1 During Work Period

During works period, the following checking shall be carried out :
 Visual inspection and holiday detection on all coated surfaces prior to laying
and backfilling, any found damage being suitably repaired.
 Insulation testing by suitable instrument of isolating joints resistance before and
after welding.
 Electrical continuity testing at joints or screwed assembly, at pits where piping
is interrupted. After bonding and at cables connection to structure before
insulation.
 Soil resitivity measurements of anodes and ground bed locations.
 Visual inspection of cathodic protection anodes and cables.
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 Visual inspection of transformer-rectifiers, test boxes and points prior to

installation.
 Resistance measurement of deep well casing upon completion.
 Potential readings of permanent reference electrodes with respect to a
calibrated one on the same electrolyte conditions prior to laying.
After cathodic protection removable links inside the accessible equipment shall be
left opened and no impressed current stations shall be energized without Company’s
approval.
22.2 Start-up
Upon completion of the whole cathodic protection works, it shall be proceeded to:
a) Without any impressed current station energized:
 Checking of all accessible cathodic protection equipment, terminations and

cables tagging.
 Where existing, all variable resistors shall be set to zero.
 Potential reading of permanent reference electrodes with respect to a calibrated
electrode.
 Providing that isolating joints be operational, free potential survey on the whole
structures including foreign ones from permanent or portable references.
 Checking or main AC supply of each transformer-rectifier.
b) Separate testing of each impressed current station at different DC voltage up to

the nominal value. Where several anodic circuits, tests shall be carried out by
connecting alternatively each one and then all of them. At each stage, the
operating parameters at the positive and negative test stations (potential and
current) shall be recorded, the existing variable resistor(s) being first to zero
and then to maximum value.
22.3 Commissioning
The commissioning shall be carried out under the supervision of a qualified Cathodic
Protection engineer.
Upon completion of all works on the plant which may affect the cathodic protection
system operation, its commissioning shall include :
 The bonding of all negative and positive circuits, resistors being set back to
zero, potential survey on the whole structures including the foreign ones which
are connected in the test boxes, impressed current stations being maintained
off.
 A first adjustment of the impressed current stations, according to the design
parameters and a preliminary checking of potential levels.
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 A complete record of all operating parameters (potential and current) after 72

hours polarization period minimum.
 A final adjustment of each impressed current station and relevant DC current
control means according to the results of survey.
 Interference measurements with each foreign structure upon final adjustment in
presence of its representative.
 All work shall be executed in strict accordance with the company – approved
drawings and specification. The written approval of the company representative
is required for any deviations by the contractor from these drawings and
specifications.
 The contractor shall be responsible for the protection and security of all
materials and equipment during all stages of commissioning.
 The contractor shall not perform any tests that would either void the vendor
warranty or damage the materials and equipment.
 The contractor shall tie-in the AC power source to the transformer/rectifier(s)
with all work carried out by qualified electricians.
 The contractor shall be responsible for all aspect of the system(s) start-up.
 An “Adjustive Survey” shall be provided to the company within thirty (30) days
of systems, start-up.
 The contractor shall submit with the “Adjustive Survey” the following additional
documentation on cathodic protection systems(s).
a) Copies of accurately dimensioned “As-Built” drawings of all installations.

b) Copies of operating and maintenance manuals for all equipment provided
and installed by the contractor.
The above information, when available shall be incorporated in the plant data
book.
 Written programs for commissioning of cathodic protection system shall be

developed by the contractor. These programs shall include detailed check
sheets and shall be submitted for acceptance to the company at least 45 days
prior to the scheduled commencement of the checkout and commissioning
activity.
 The commissioning programs shall detail the final test to be conducted on all
equipment after the checkout program is complete. The commissioning
program shall demonstrate the proper of the complete cathodic protection
system.
 All checkout and commissioning shall be witnessed by the company
representative.
 The contractor shall submit a full report to the company at completion of
commissioning.
A complete technical dossier inclusive as-built drawings, material and equipment
data and results report shall be established.
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The design documents shall be submitted to the company for approval, covering the
following requirements :
a) Results of any site surveys and soil investigations that have been carried out.
b) Justification of the selected cathodic protection system and made materials.
c) Calculations of current requirements, pipeline attenuation, resistance and
current output of ground beds.
d) A summary of the used formulate and standards.
e) A schematic diagram of the proposed cathodic protection system.
f) A list of the estimated number and types of cathodic protection system.
g) Any sensitivities in the proposed cathodic protection system that requires
special attention.
h) Any other information that is regarded by the contractor as essential for this
stage of the cathodic protection design.
The design documents shall also cover the following requirements :

a) A schedule of materials
b) A complete set of design drawings
c) Installation procedures
d) Commissioning procedures
e) Operation and maintenance instructions
An operating and maintenance manual is required to ensure that the cathodic
protection system is well documented and that operating and maintenance
procedures are available for the future operator.
The above mentioned document shall contain :
a) A description of the system and system components
b) The commissioning report
c) As built drawings
d) Manufacturer documentation
e) A schedule of all monitoring facilities
f) Potential criteria for the system
g) Monitoring schedules and requirements for monitoring equipment
h) Monitoring procedures for each of the types of monitoring facilities installed on
the pipeline.
i) Guidelines for the safe operation of the cathodic protection system
Note : All above mentioned documents should be in English.

The complete cathodic protection system shall be guarantee, and contractor shall
replace any damaged equipment resulting from fault designs, defective materials
and/or poor workmanship.
The contractor shall also replace any equipment failed under the following conditions:
a) Failure under start-up and commissioning tests.
b) Failure under normal usage for a minimum of 12 months after being placed in
the specified service.
CLIENT: CONSULTANT:


APPENDIX
TABLE 1 : Location of electrical test points for potential measurement
TESTS
LOCATION REMARKS
POINTS
Coated pipeline, cased at roads, Measurements of pipe-to-soil and casing-to-
railways, canals soil potentials
1
casings less than 30 m in length 1 Measurements of pipe-to-soil and casing-to-
casings 30 m and greater in length 2 soil potentials at each end of casing
Coated pipeline greater than 750 m Measurements of pipe-to-soil potential near
2 1
between casings center
3 Long coated pipeline sections 0.5 km intervals Measurements of pipe-to-soil potential
Long bare pipeline section being
4 0,5 km intervals Measurements of pipe-to-soil potential
cathodically protected
Pipeline near foreign-owned rectifier Measurements of pipe-to-soil potential where
5 2
ground bed pipe enters and leaves anodic field
Pipeline opposite government-owned
6 rectifier ground bed within 300 m of 1 Measurements of pipe-to-soil potential
line
Joint interference at crossing of foreign Requires prior approval of regulatory agency
7 1
line and foreign company
8 Insulated joints or couplings 2 One on each side
9 Main line riser 1 Adjacent ground junction with riser
Buried structure opposite galvanic
10 1 Measurements of pipe-to-soil potential
anode battery
Measurements of buried structure-to-soil
Dissimilar metal systems near ground potential on affected metal as galvanized as
11 1
bed conduit, iron sewer line, copper ground cables,
steel anchors etc.
CLIENT: CONSULTANT:


TABLE2 : Location of electrical test points for current measurement
TESTS
LOCATION REMARKS
POINTS
1 Rectifiers and galvanic anode batteries 1 Measurements of total current output
2 Ground bed connected to rectifier 1 Measurements of individual ground bed
3 Power anode 1 Measurements of anode output
Measurements of return current from each
4 Buried metallic structure 1 structure connected to negative side of
cathodic output
Negative rectifier lead connected to Measurement of current magnitude and
5 1
buried structure direction flowing in the structure
Maximum 10 km Measurement of cathodic protection current
6 Long coated pipeline sections
intervals flow
7 Insulated joints 1 Measurement of possible current flow
Measurement of current magnitude and
At practical
8 Pipelines operated by others direction where ownership or operation
points
jurisdiction changes
Measurements of currents entering and
9 Long inaccessible pipeline sections 2 leaving sections such as major water crossings
and congested areas
Measurements of current as required for
10 Interfering and/or straying currents As required
specific instance

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CLIENT: CONSULTANT:

National Iranian Oil Company

SOHRAB WELL HEAD NO.1 FLOW LINE TO

CATHODIC PROTECTION SYSTEM

National Iranian Oil Company

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Revision Summary Index

National Iranian Oil Company

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1.0 INTRODUCTION ....................................................................................................... 5

2.0 CODES AND STANDARDS....................................................................................... 7

3.0 SITE CONDITION ...................................................................................................... 9

4.0 DESIGN .................................................................................................................... 10

5.0 CATHODIC PROTECTION UNIT ............................................................................. 16

6.0 IMPRESSED CURRENT GROUND BED................................................................. 18

7.0 REFERENCE ELECTRODES .................................................................................. 20

8.0 GALVANIC ANODES .............................................................................................. 21

9.0 TEST POINTS .......................................................................................................... 22

10.0 INSULATION FITTINGS ......................................................................................... 23

11.0 PIPELINE INSULATION LOCATION ....................................................................... 24

12.0 SPECIAL INSULATION POINTS ............................................................................. 24

13.0 PROTECTION OF PARASITIC CURRENTS ........................................................... 25

14.0 INSULATION FITTING PROTECTION SYSTEM..................................................... 26

15.0 GALVANIC COUPLES ............................................................................................ 27

16.0 MATERIAL AND EQUIPMENT STANDARD ........................................................... 27

17.0 INSPECTION AND TESTING .................................................................................. 35

18.0 PREPARATION OF SHIPMENT .............................................................................. 35

19.0 DRAWINGS AND DOCUMENTATION .................................................................... 36

National Iranian Oil Company

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20.0 SPARE PARTS ........................................................................................................ 36

21.0 VENDOR RESPONSIBILITY & GUARANTEE ....................................................... 36

22.0 MIN ACTIVITIES DURING COMMISSIONING ........................................................ 37

TABLE 1 : LOCATION OF ELECTRICAL TEST POINTS FOR POTENTIAL

TABLE2 : LOCATION OF ELECTRICAL TEST POINTS FOR CURRENT

National Iranian Oil Company

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The major sections of the project are:

- Wellhead facilities (at WH No.1).

1.1 Terms and Definitions

EPC Contractor: Shall Mean The Contractor Responsible

Consultant: Enerchimi Engineering Company (EEC)

Vendor/ Supplier: Refers to firm or person who will supply

Will: is normally used in connection with the

May: is used where a provision is completely

Should: is used where a provision is advisory

Shall: is used where a provision is mandatory.

National Iranian Oil Company

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If not specified otherwise, engineering and supply of mentioned cathodic protection

Engineering scope to be considered as follows:

- Layout drawing of branch-circuits

1.4 Abbreviations and Definitions

National Iranian Oil Company

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PURCHASER Company issuing the inquiry and order

2.0 CODES AND STANDARDS

2.1 Document Priority

All electrical equipment, materials and installations shall be in accordance with

- Requisition / Purchaser Order

2.2 Reference Codes and Standards

IPS (IRANIAN PETROLEUM STANDARDS)

E-TP-820 "Engineering Standard for Electrochemical Protection"