KUWAIT OIL COMPANY (K.S.C.

STANDARDS PUBLICATION

KOC RECOMMENDED PRACTICE

FOR

EXTERNAL C ODIC PROTECTION OF

ON-GRADE NEW STEEL TANK BOTTOM

I STANDARDSTEAM I
DOC. NO. KOC-L-026 Page 1 of 31 REV. 2

KUWAIT OIL COMPANY (K.S.C.)

STANDARDS PUBLICATION

KOC RECOMMENDED PRACTICE

FOR

EXTERNAL CATHODIC PROTECTION OF

ON-GRADE NEW STEEL TANK BOTTOM

STANDARDS TEAM
-
 DOC. NO. KOC-L-026 Page 2 of 31 REV. 2

KOC RECOMMENDED PRACTICE

FOR

EXTERNAL CATHODIC PROTECTION OF

ON-GRADE NEW STEEL TANK BOTTOM

ISSUING AUTHORITY:

STANDARDS TEAM

2 14/08/2006 Issued as KOC RP Task Force

(T F-CP102 )
\
Rev. Date Description Prepared by Snr. Engr. Standards Ag. T m Leader Standards

Tel61407 Tel. 61896

 TABLE OF CONTENTS

Page No.

FOREWORD 5

SCOPE 7

APPLICATION 7

TERMINOLOGY 7
3.1 Definitions 7
3.2 Abbreviations 8

REFERENCE STANDARDS AND CODES 9

4.1 Conflicts 9
4.2 List of Standards and Codes 9

ENVIRONMENTAL CONDITIONS 10

HEALTH, SAFETY AND ENVIRONMENT 10

CATHODIC PROTECTION SYSTEM DESIGN 11

7.1 Objective 11
7.2 Design Life 11
7.3 Potential Range 12
7.4 Current Requirement and Density 12
7.5 Membrane Liner 12
7.6 Tank Bottom Soil Backfill 12
7.7 Reference Electrodes 13
7.8 Electrical Continuity1 Isolation 13
7.9 Electrical Connections 14
7.10 Cathodic Protection for Tanks During Tank Bottom
Replacement 14

CATHODIC PROTECTION DESIGNER & INSTALLER 14

MATERIALS & EQUIPMENT REQUIREMENTS 14

9.1 Selection o f Equipment and Materials 14
9.2 Anodes 14
9.3 Titanium Conductor 15
9.4 Cables 15
9.5 Transformer Rectifier (TIR) 15
9.6 Junction Boxes 16
9.7 Reference Electrodes 16
 INSTALLATION OF CP SYSTEM 16

PRE-COMMISSIONING & FINAL COMMISSIONING 17

11.2 Natural Potential 17
11.3 Preliminary Adjustment 18
I 1.4 Potential Measurement 18
11.5 Interference Testing 18
11.6 Final Commissioning 18

QUALITY ASSURANCE /QUALITY CONTROL 19

MARKING 19

CALCULATIONS AND DOCUMENTATION 19

AS BUILT DRAWING 20

APPENDICES 21-29
16.1 Appendix-A: Inspection and Test Plan for
Tank Bottom (Impressed Current
Cathodic Protection System) 21
16.2Appendix- B: Check Lists for 22-28
- Tank Bottom Cathodic Protection
System (Grid System 1
- Reference Electrode Function Test
- Boxes (J. B and Test Box)
- TIR Rectifier Check List
- Pre-commissioning Checklist for Impressed
Current Cathodic Protection S y s t e ~
(New Tank Bottom External)
- Tank Bottom CP Summary Data Sheet
16.3 Appendix -C: Drawing No. CP-002 :
Typical Cathodic Protection Details for
Underside o f Tank Bottom Using
Grid System 29

ACKNOWLEDGMENT 30
FOREWORD

The document "KOC Recommended Practice for External Cathodic Protection of

On-Grade N e w Steel Tank Bottom (Rev.1)" has been revised t o incorporate latest
practices and current requirements for CP systems t o be followed with a view t o
ensure better functions, reliability, inspection and maintenance of new steel tank
bottom CP system within KOC Facilities.

This KOC RP (Rev.2) has been approved by Standards Team in consultation with
Standards Technical Committee (STC) for consistent use throughout the corporate
engineering and operational functions of Kuwait Oil Company (K.6.C).

The purpose of this RP sets out t o achieve the following objectives:

a. To describe current technical practices in industry and general procedures for

establishing cathodic protection system in order t o minimize corrosion of the
external surfaces of steel tank bottom that is in contact with ground.

b. To provide general technical input and guidance for developing project

specifications with a view t o ensure quality, safety and reliability.

c. To set out minimum requirements and guidance for monitoring compliance of

materials and testing.

d. To act as a tool for internal communication from which future safety,

environmental and technological changes can be measured.

Feedback as well as any comments or suggestions derived from the application of

this RP at any stage of design, construction, maintenance and figld experiences are
encouraged and should be directed to:

The Team Leader Standards

(Chairman, Standards Technical Committee)
P.O.Box-9758, Ahmadi 610 0 8
State of Kuwait
 DOC. NO. KOC-L-026
I Page 6 of 31
I REV. 2

Task Force Responsible for this Recommended Practice

The Preparation of this Recommended Practice has been entrusted by the Standards
Technical Committee (STC) of the Task Force No (TF-CPI021 comprising of the
following members:

Mr. Abdul Razzaq A1 Shamar.i Insp.& Corr.(NWK) TF Leader Tel No 6 14 2 6

Mr. Hasan Sabri Imp.& Corr.(SEK) Member Tel No 67489
Mr. Govinda Mishra Design Team Member Tel No 61 0 9 7
Mr. Liakat Ali Maintenance (WK) Member Tel No 20061
Mr. Uppara Saibaba HSE Systems Member Tel No 7 1837

Revision 2: Summarv of Maior Changes

Clause No. Changes Made Date

7 .O Deleted soil resistivity test, Stray current interference, May, 2006
Protection from Transients and electrical bonding. Tq
be incorporated for piping CP. I
7.3 Protection criteria is between -0.850 & -1.200 volts May, 2006
8 .O Requirements for the CP designer and CP installer May, 2006
9 .O Deleted backfill material & graphite, High Silicon May, 2006
Chromium, & Polymeric anode type from the
Recommended Practice.
Appendices Added ITP, check lists and drawing. May, 2006
 DOC. NO. KOC-L-026 I Page 7 of 31
I REV. 2

SCOPE

This Recommended Practice (RP) covers the minimum general requirements

for system design, equipment, material, installation, inspection 1 testing and
commissioning of permanent impressed current cathodic protection systems,
with a view t o minimize corrosion from the external surface of on-grade steel
tank bottom in contact with soil, by providing adequate external protection to
new steel storage tank bottoms.

This document is for guidance only and does not desigqate specific system
design or practices for every application. Therefore, the CP system designer
shall investigate all system requirements and other pre-design requisites such
as tank design, tank bottom materials, tank size, etc.

APPLICATION

The materials, equipment, system design, installation, ingpectionltesting and

commissioning of cathodic protection (CP) system for tank bottoms shall
conform t o the requirement of this Recommended Practiqe and the reference
standardslcodes mentioned herein.

Any exceptions or deviations from this document, along p i t h their merits and
justifications, shall be brought t o the attention of KOC controlling Team for
their review, consideration and amendment by Standards Team (if required).

Compliance with this KOC Recommended Practice does not of itself confer
immunity from legal or statutory obligations.

TERMINOLOGY

Definitions

For the purpose of this RP, the following definitions apply.

Cathode

The electrode of an electrochemical cell at which reduction occurs.

Cathodic Protection

A technique t o reduce the corrosion of a metal surfqce by making that

surface the cathode of an electrochemical cell.

Current Density

The current flowing t o or from a unit area of an electrode surface.

- -
Electrical Isolation

The condition of being electrically separated from other metallic structures or

the environment.

Foreign Structure

Any metallic structure that is not intended as part of cathodic protection

system.

Impressed Current

Direct current (DC) supplied t o a CP system by an external power source

such as rectified commercial AC, batteries or electric generators.

Membrane Liner

A thin, continuous sheet of non-conductive material (palyethylene) installed

beneath the storage tank bottom in or on the pad tank foundation, to contain
any accidentally escaped product.

On-Grade Storage Tank

A tank constructed on sand or earthen pads, concrete ringwalls, or

concrete pads.

Reference Electrode

An electrode whose open-circuit potential is constant under similar

conditions of measurement, which is used for meqsuring the relative
potentials of other electrodes.

Stray-Current Corrosion

Corrosion resulting from current through paths other than the intended
circuit, e.g., by any extraneous current in the earth.

Abbreviations

AJB Anode Junction Box

CP Cathodic Protection
DC Direct Current
HSE Health Safety and Environment
ICCP Impressed Current Cathodic Protection
ITP Inspection and Test Plan
JB Junction Box
KOC Kuwait Oil Company (K.S.C.)
MMO Metal Mixed Oxide
TIR Transformer Rectifier.
 DOC.NO. KOC-L-026 I Page 9 of 31
I REV. 2

4.0 REFERENCE STANDARDS AND CODES

In the event of conflicts between this Standard and the standards / codes
referenced herein, or other contractual requirements, the most stringent
requirement shall apply. In case further clarificationg are required, the
subject shall be brought t o the attention of KOC Controlling Team.

In general, the sequence of precedence shall be followed as:

a. Kuwait Governmental Rules and Regulations

b. This KOC RP (KOC-1-026 )
c. KOC Technical Specifications
d. International codes and standards
e. Contractor's standards and specifications

4.2 List of Standards and Codes

The latest edition of the following standards, codes and specifications shall
apply:

4.2.1 International 1 National Standards

API 650 Welded Steel Tanks for Oil Storage

API 651 Cathodic Protection of Above Ground Petroleum Storage

Tanks

ASTM B 265 Specification for Titanium and Titanium Alloy Strip, Sheet,
and Plate

ASTM G57 Test Method for Field Measurement of Soil Resistivity

using the Wenner Four Electrode Methpd.

BS 7361 Part 1 Cathodic Protection, Code of Practice for Land and Marine
Applications

NACE RP 0 1 7 7 Mitigation of Alternating Current and Lightning Effects on

Metallic Structures and Corrosion Control System

NACE RP 0 1 93 External Cathodic Protection On-grade Metallic Storage

Tank Bottoms

NACE RP 0572 Design, installation, Operation and Maintenance of

Impressed Current Deep Ground Beds

NACE T M 0101 Measurement Techniques Related t o Criteria for Cathodic

Protection

-
DOC. NO. KOC-L-026
W Page 10 of 31 REV. 2

4.2.2 KOC Standards

KOC-C-003 KOC Standard for Geotechnical Investigation

KOC-C-026 KOC Standard for Storage Tank Foundation

KOC-E-004 KOC Recommended Practice for Selection, Installation and

Parts 1t o 6 Maintenance of Electrical Equipment in Hazardous Areas

KOC-E-008 KOC Recommended Practice for Design, Selection and

lnstallation of Electric Cables, Cable Systems and Wiring

KOC Standard for Electrical Power Cables and Wiring

KOC Standard for Hazardous Area Classifipation

KOC Standard for Packing, Marking and Documentation

KOC Standard for Basic Design Data

KOC Standard for Spare Parts and Maintenance Data

KOC Standard for Cathodic Protection Material Specification

KOC Standard for Field Erected Steel Storgge Tanks

KOC Standard for PaintinglCoating of Metal Surfaces-New

Construction

KOC Fire & Safety Regulations

ENVIRONMENTAL CONDITIONS

The environment of Kuwait is severe, and must be considered carefully for

selection and before procurement of plant and equipment.

For environmental conditions in Kuwait, refer t o KOC Standard for Basic Design
Data, (KOC-G-007), which provides the detailed design iqformation regarding
the environmental, site and utility supply conditions prevailing throughout the
KOC facilities.

HEALTH, SAFETY AND ENVIRONMENT

The designer / contractor shall assure the compliance of necessary HSE

design requirements t o minimize the consequences and impacts of hazards on
the surrounding environment and adjoining facilities.

All relevant safety requirement of the KOC Fire & Safety Pegulations and the
KOC Health, Safety and Environment (HSE MS) procedures shall be adhered
to within KOC areas.
DOC. NO. KOC-L-026 Page 11 of 31 REV. 2

The Cathodic Protection Systems shall be installed and csntinuously operated

under safe conditions.

CATHODIC PROTECTION SYSTEM DESIGN

Obiective

The corrosion control of tank bottom external shall be achieved by

protective coatings and supplemented by cathodic prqtection. Impressed
Current Cathodic Protection (ICCP) systems shall be used t o protect the
external surface of tank bottoms. The CP systemk) shall consider the
following in the design parameters:

The design requirements of storage tank bottom and tqnk foundation shall
be in accordance with "KOC Standard for Field Erected $tee1 Storage Tank"
(KOC-MV-007)" and "KOC Standard for Storage Tank ~bundation"(KOC-C-
026), respectively.

Deliver and distribute sufficiently uniform magnetic flux with DC current t o

the tank bottom t o ensure adequate protection against corrosion.

Soil conditions such as chemical composition, soil resistivity and pH in

order to provide easy control for anticipated changes in current
requirements with time.

Placement of anode bed system, cables, junction bqxes, transformer /

rectifier and test stations where the possibility of ~ h y s i c a ldamage is
minimal.

The CP potential of the entire external bottom surface pf the tank shall be
monitored with adequate monitoring means to ensure proper corrosion
protection.

The CP systern(s) shall cause no interference t o foreigp structures. If any

interference occurs, it shall be recorded and be limited t q the minimal.

The Cathodic Protection System shall be continuously operated t o maintain

polarization.

Design Life

The minimum design life of the Impressed Current cathodic Protection

system is 35 years.
DOC. NO. KOC-L-026 I Page 12 o f 31 1 REV. 2

Potential Ranqe

The minimum accepted negative value at any point of the protection

potential for steel (IR corrected, instant off) shall be -0.85 V, with reference
to Copper / Copper Sulphate (CuICuSO,) saturated electrode.

The maximum negative potential value permissible (IS corrected, instant

off) shall not exceed -1.2 V with reference t o CuICuSO, (saturated).

The maximum "ON" negative value permissible shqll be -2.5 V with

reference t o Cu I CuSO, (sat.)

Current Reauirement and Densitv

For design purpose the minimum protective current density shall be 2 0

r n ~ l m for
* underside of tank bottoms.

Design including anode type and layout must ensure un/forrn distribution of
protective current t o the tank bottom surface.

The design of all impressed current CP systems shall include a minimum

30% excess current capacity over the design life t o compensate for coating
degradation and possible current drainage t o other structures.

Membrane Liner

Anodes shall be placed between the membrane and tank bottom so that a
uniform current will flow t o the metallic surfaces requiriqg protection.

Impressed current anodes must not contact the metallic surfaces of the
tank and the tank rimlfoundation. It is recommended that the grid system
shall be a t least 5 0 m m away from the membrane line at the tank
rimlfoundation.

Adequate space shall be provided between the tank bottom and the
membrane liner t o allow installation of the cathodic prolection system with
uniform current distribution. The tank foundation requi&ments specified in
"KOC Standard for Storage Tank Foundation" (KOC-C-026) shall be
considered in this regard.

Tank Bottom Soil Backfill

The sand backfill between the anode ribbon bed and the tank underside
shall be conductive clean washed sand. A sample of the sand fill t o be
utilized shall be tested for contamination (chlorides, sulphates, etc).
Proposed sand shall have a pH value between 6 and 11.5.
 DOC. NO. KOC-L-026 I Page 13 of 31 REV. 2

7.7 Reference Electrodes

Tank test facilities shall comprise CuICuSO, reference electrodes and test
boxes as follows:

a. One permanent reference cell at the centre.

b. For tanks less than 20 m in diameter, Four (4) permanent reference

cells equidistantly located one (1) m from the edge of the tank.

c. For tanks of size larger than 20 m in diameter, additional four (4)

permanent reference cells shall be equidistantly located midway
between the centre of the tank and the edge.

d. Two (2) perforated UPVC pipes of 3" dia. with mipimum thickness of
6.7 m m shall be installed for retractable reference electrodes. For tank
size above 45 m in diameter, three (3) parallel UPVC pipes shall be
installed.

e. The UPVC pipes shall be provided with perforation of 10 m m diameter

at 9-12-3 o'clock position. The pipes shall also be necessarily provided
with Geo-textile cloth socks t o avoid entry of sand in the pipe.

7.8 Electrical Continuitv I Isolation

If tank is NOT provided with an oil leak containment non-conducting

impervious membrane below the anode grid system, intgrference of existing
CP and earthing system t o the new tank shall be investigated. The tank may
require being electrically isolated from the plant electrical' earthing system by
the provision of:

a. insulating flanges on all pipeltank connections.

b. insulating flanges on tanks instrument pipeltank connections to maintain

isolation between the instrument cable armoring and the tank.

c. insulating glands on power cables t o light fittings in electrical contact

with the tank t o maintain isolation between cable armoring and the
tank.

d. each insulating flange and joint shall be fitted with ap appropriate device
to provide electrical isolation of CP DC voltage$ and currents but
provide a path for the safe passage of AC fault and lightning currents.

e. polarization cells between the tank safety earth ring and the plant main
earth system.
DOC. NO. KOC-L-026 Page 14 of 31 I REV. 2

Electrical Connections

The cable connections t o tank shell shall be by means of bolted cable iug
connections t o carbon steel plates welded t o the structure. The steel plates
shall be welded t o the structure prior t o the application of coating. The
steel plate and weld method shall be compatible with the structure material.
The steel plate coating shall be removed t o facilitate the bolted cable
connection. Only highly rated pure Brass bolts and nuts $hall be used.

Cathodic Protection for Tanks Durinq Tank Bottom Re~lacement

This Recommended Practice can be utilized for existing tank if the tank
bottom is being replaced.

Information on the degree of the tank bottom corrosion is useful for the
design of the Cathodic Protection.

Necessary modifications shall be carried out t o the lank foundations in

order to install the cables.

CATHODIC PROTECTION DESIGNER & INSTALLER

The design and installation of the Cathodic Protection Systems shall be

carried out by a cathodic protection specialized pre-qualified Contractor,
and shall be approved by KOC.

The design and commissioning of cathodic protection systems shall be

carried out by a Cathodic Protection Specialist Engineer (NACE certified as
CP-Specialist or equivalent).

A NACE certified Technician of Level ll (or equivalent) shall present a t all

time at site t o supervise and report periodically the installation of all parts
of the cathodic protection system.

MATERIALS & EQUIPMENT REQUIREMENTS

Selection of Equipment and Materials

All necessary CP materials shall be as per "KOC Stqndard for Cathodic

Protection Material Specification" (KOC-1-012).

Anodes

The anode material shall be catalyzed Titanium anode ribbon coated with
highly conductive Mixed Metal Oxide (MMO). The Titanium base shall be of
ASTM 9265 Gradel. MMO shall comprise a mixture of ljidium and Tantalum
oxides. Vendor shall provide technical data sheet of The proposed MMO
anode clearly mentioning the oxides, MMO applic$tion method, and
thickness of the MMO, breakdown voltage across the substrate oxide and
maximum voltage across the MMO film.
1 DOC. NO. KOC-L-026 I Page 15 of 31 l REV. 2

The M M O coating shall be dimensionally stable and shall have a proven track
record that their resistances t o earth do not increase with time.
Manufacturer test certificate shall provide all the above ipformation including
a test for each of the anode under various charge densitigs.

MMO anode shall be corrosion, acid and high abrasion registant.

Titanium Conductor

The Titanium conductor bar and power feed connecting rod shall be of
ASTM B265 Grade 1. The titanium rod shall be factpry spot welded a t
minimum three (3) locations using high powered resiqtance welder. The
exposed rod shall be compression crimped t o the positive cable and the
connection insulated with adhesive lined heat shrink a t least 6 0 m m either
side of the connection.

Cables

Cables shall be Cu XLPEIPVC. The cable sizes shall be determined t o suit the
current rating and voltage drop requirements of the CP design. However, the
following types with minimum sizes shall be used:

a. Power Feed Cables 10 mm2

(From AJB to each Conductor bar)

b. Cathode main cables 50 mm2

(From T/R to AJB and Tank shell)

c. Test Cables 25 mm2

(From Tank Shell to test JBI

d. Permanent reference cell cables 2.5 mm2

(Reference electrode cable shall be of low noise screened cable)

Transformer Rectifier (T/R)

A TIR unit shall supply only one CP system. e.g one TIR unit for the
protection of one tank bottom.

AH TIR units shall be installed outside the fence of GCs, BSs etc and
protected under a shelter. For firewater storage tanks, tbe T/R units shall be
located adjacent t o the tanks.

The T/R unit output ratings for external CP systeqs shall satisfy the
following requirements:

Output voltage: 50V DC

Minimum output current rating: 5 0 A DC

L
DOC. NO. KOC-L-026 Page 16 o f 31

9.6 Junction Boxes

9.6.1 Junction boxes shall be certified for use in respective classified area with
minimum degree of protection as 1P55: The system dqsign shall have the
following types of junction boxes:

a. AJB: Anode junction boxes.

b. TJB: Test junction boxes.

9.6.2 Inside the AJB & TJB, layout drawing with a glass cover shall be fixed t o
show the arrangement of permanent reference electrgdes & power feed
cables.

9.7 Reference Electrodes

The Contractor shall supply the following reference elecjrodes:

a. The Permanent reference electrodes shall be saturated Cu/CuSO,

installed at under the tank bottom. It shall be of non-drying robust
type with proper conductive backfill. Proposed reference electrode
shall have proven track record and comply with the test requirements
of NACE "Durability Test for Copper I Copper Sulfate Permanent
Reference Electrodes for Direct Burial Applications"

b. Portable reference electrode shall be CuICuSO, type suitable for

retractable through a UPVC conduit pipe, which shall be installed at
the same level of permanent reference electrode. It shall be covered
with a tight fit cylindrical sponge.

10.0 INSTALLATION OF CP SYSTEM

10.1 Materials and design requirements shall be checked for conformance with this
Recommended Practice, and the reference standardsls~ecificationsprior t o
installation. The Contractor shall propose the materials for approval with all
relevant information as needed elsewhere in this Recommended Practice.
Before start of installation all materials shall be inspectgd and verified with
Manufacturer's test certificate and approved ITP.

10.2 The installation of anodes and reference electrode? shall be closely

coordinated with the construction of the tank and its foundation in
accordance with KOC-MV-007 and KOC-C-026. The complete design
including calculations, materials and procedure for installation of Reference
Electrodes & Anodes and the laying of associated cables up t o field
connection box, Inspection & Test Plan (1TP) shall bq provided for KOC
review and approval prior to commencement.

10.3 All cables shall be clearly identified and numbered such that no confusion
exists as t o their purpose or point of origin or termination.
DOC. NO. KOC-L-026 1 Page 17 of 31 1 REV. 2

Provisions shall be made to cathodicafly protect the drain sump.

Anode t o conductor bar and conductor bar t o conduclor bar connections

shall be made by resistance spot welder. A t least t w o (2) samples shall be
made for physical testing and the welder parameters shall be fixed.

The factory sealed power feed cable Ti rods shall be welded t o the
conductor bar at the designated locations. Required No. of power feed
cables shall be calculated such that the voltage drop in the anode circuit is
less than 300 mV. In any case, the power feeds shall be uniformly
distributed on any conductor bar and typically at the center of the anode if
one power feed on a single conductor bar as below.

a. The maximum distance between conductor bars is 4 m t o 6 m.

b. The maximum distance between anode ribbons is 1 m t o 2 m.

c. Each conductor bar shall have at least one separatq power feed cable.

d. One perpendicular conductor bar shall be installed t o all other

conductor bars.

Anode grid resistance shall be checked before and after backfilling between
each power feed cables. In no case, the resistance shall be more than one
(1) Ohm.

Reference electrodes shall be function tested before qnd after backfilling

with reference t o a known calibrated portable sqturated CuICuSO,
reference electrode. Acceptance criteria shall be as per approved ITP.

Samples of installation check lists are attached in Appendix 8 of this RP. The
Contractor shall make suitable additions or changes fqr the particular job
work.

PRE-COMMISSIONING & FINAL COMMISSIONING

Pre-commissioning shall be carried out by CP Engineer t q ensure high quality

performance. The procedure shall be as follows:

a. All terminations inside the junction boxes, test boxes, T/R shall be
checked.

b. Anode grid resistance shall be checked.

Natural Potential

Structure t o soil potential shali be measured at all the measuring points,

insulating joints, etc.
DOC. NO. KOC-1-026
I Page 18 of 31
I REV. 2

1 I .3 Preliminary Adiustment

Before energizing, the T/R output shall be kept at 10% of design current
output. After 48 hours, potential shall be measured and the output shall be
increased, if required to meet the following criteria.

a. It is required that the midpoint potentials shall not be less negative than
-0.850 V (IR corrected, instant off) with referencg to Cu/CuSO, (sat.)
and the station current outputs shall then be adjusted to achieve the
required midpoint potential.

b. The current output shall not be increased t o produce a more negative

potential at the drain point greater than -1.2 V volts (IR corrected,
instant off) with reference to Cu/CuSO, (sat.).

11.4 Potential Measurement

Following the adjustment of cathodic protection station putputs to meet the

structure t o soil potentials, a complete set of potentials shall be recorded at
all the measuring points and other positions measured earlier.

1 1.5 Interference Testing

11.5.1 The Contractor shall perform all interference testing and shall be fully
responsible for contacting all the responsible Authorities and arranging for
their presence at all required tests.

1 1 -5.2 Should any interference test results show a positive chqnge in the potential
of a foreign installation or structure of more than 20 mV, the Contractor shall
take remedial action to eliminate the interaction.

1 1.6 Final Commissioning

Final commissioning shall consist of:

Measuring tank to soil potentials at all measuring points.

Measuring total current output from each station and the current in each
direction where current measurements are possible.

Measuring settings of power sources: transformer/ rgctifiers.

Measuring current and resistance if remedial bond fitfed.

Calibrating all current measurement points.

DOC. NO. KOC-L-026 I Page 19 of 31 I REV. 2

QUALITY ASSURANCE /QUALITY CONTROL

The Manufacturer/Contractor shall operate a quality system to ensure that the

requirements of this Recommended Practice are achieved, The quality system
shall be preferably based on IS0 9000 series of standards and the
Manufacturer/Contractor shall demonstrate compliance by providing a copy
of the accredited certificate or the manufacture's / contractor's quality
manual.

Verification of the Manufacturer's / Contractor's quality system is normally

part of the pre-qualification procedure, and it is therefore not detailed in the
core text of this document.

The Contractor shall submit their Quality System Manual & Quality
Assurance Plan that include all the activities in chronological order with
responsibilities. Inspection & Test Plan (ITP) for CP system installation and
commissioning shall be submitted for KOC approval. Columns shall be
provided so that KOC can mark up its "Witness" (W) points and "Hold" (H)
points.

A sample ITP is attached in Appendix A which is only typical; and the

Contractor shall make suitable additions or changes f ~ the
r particular job
work.

MARKING

For all relevant requirements and on Marking / Packing refer to "KOC

Standard for Packing, marking and Documentation" (KOC-G-004).

CALCULATIONS AND DOCUMENTATION

All correspondence, drawings, instructions, data sheets, design calculations,

or any other written information shall be in English Langgage. In the case of
dual languages, one language shall be English.

All dimensions, units or measurements, physical constant, etc, shall be in SI

units, unless otherwise specified.

Deliverables

The following documentation, drawings, inspection & test plans and check
lists shall be submitted for approval:

a. Schematic drawing of the entire CP systems

b. Anode ground bed detail drawings
c. T/R unit electrical schematic diagrams
d. T/R unit general arrangement and mounting detail drawings
e. CP equipment layout drawing
DOC. NO. KOC-L-026 Page 20 of 31 REV. 2

CP cable layout drawing & sizing, color schedule

Test facility detail drawings
Junction boxes and support stands construction drayvings
Junction boxes termination drawings
Cable connection detail drawings
CP electrical installation specification
Installation procedure
Pre-commissioning procedures
Operation and maintenance procedures
Inspection & Test Plan.

14.4 CP calculations shall include:

a. Protected structure CP current demand

b. Foreign structure CP drain currents
c. Soil resistivity calculations
d. Ribbon anode length, No. of conductor bars, power feed cables, Anode
grid system & cable resistance, output current, voltage drop calculations
e. Maximum Anode current density based on maximum current density and
Spacing
f. Anode life
g. CP TIR unit voltage including both the anode and cathode circuit
h. CP TIR unit current rating.

Construction Idesign drawings shall be updated to reflect field modifications

to the original design to show the as-built cathodic protection system. The
as-built drawings shall show the type and location (GPS coordinate) of
cathodic protection equipment and cables. The Contractor shall also update
the existing CP drawings of the particular facility / area iqcorporating the new
system. All of the above shall be stored and submitted on a CD.
 16.0 APPENDICES

16.1 APPENDIX A: INSPECTION AND TEST PLAN

ITP FOR TANK BOTTOM (IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM]

Inspection Status
Reference Acceptance Inspection
No.
I Activity Description
Document Criteria Record sug-
Contrqctor
Contractor KOC

1 Design and drawing I R

2' Pre insoection meetina
3 Material Purchasing
4 Material Inspection
Identification of the Drain Sump
5 location
6 Anode installation
7 Conductor Bar Installation
8 Spot welding
9 Power Feed Cable Welding
10 PVC installation

Permanent Reference cell

11 installation
12 Resistance measurement
13 Reference cell Function test.
14 PVC accessibility
15 Backfilling
Resistance measurement after
16 backfilling
17 PVC accessibility after backfilling

Reference cell Junction Box

18 lnsta~~ation

19 Power feed Junction Box

lnstallation
20 Negative cable installation

Negative cable junction box

21 installation
22 TIR Installation
23 re-Commission
24 Commissioning

R: Review
S: Surveillance
W: Witness
DOC. NO. KOC-L-026 I Page 22 of 31 I REV. 2

16.2 APPENDIX B :iNSPECTION & TEST SHEETS AND CHECK LISTS

1.0 Tank Bottom Cathodic Protection System (Grid System)

2.0 Reference Electrode Function Test
3.0 Boxes (J.B and Test Box)
4.0 TR / Rectifier Check List
5.0 Pre-commissioning Checklist for Impressed Current Cathodic Protection
System (New Tank Bottom External)
6.0 Tank Bottom CP Summary Data Sheet

1 6.3 APPENDIX C : DRAWING NO. CP-002

Typical Cathodic Protection Details for Ungerside of Tank

Bottom Using Grid System.
 DOC. NO. KOC-L-026 Page 23 of 31 I REV. 2

APPENDIX B (contd.1)

TANK BOTTOM CATHODIC PROTECTION SYSTEM (GRID SYSTEM)

Tank No: Date:

St.
I Results

Act- I 1
I

Sub-Contractor
Inspection
I

Contractor
I

No. Activity Description NA KOC

Depth of the polyethylene membrane liner with
1 respect to the Tank Bottom (M)
2 1 Anode spacing (M) I I 1
3 1 Anode depth with respect to the tank bottom (M) I
I 1
4 Anode quantity (M)
5 Conductor bar spacing (M)
6 Number conductor bar (No)
1 Anode/conductor bar and power feed cable I
7 welding

8 Conductor bar and power feed cable connection

9 No of power feed cables (No)
10 ] Cable routing I 1 I I
1 Number of PVC pipes for the portable reference I
11 I electrodes (No) I I I 1
/ Depth of the PVC pipes with respect to the tank 1
12 bottom (M)
Installation of permanent reference cells is as per
13 drawing
14 Reference cell soaked in water

15 Number of permanent reference cell (No)

Reference of cell depth with respect to the tank
16 bottom (M)
17 Reference electrode Function test
Potable reference electrode passes through the
18
19
monitoring pipe before backfilling
Reference cell cables are all marked
I
t I

20 1 Power feed cable are all marked 1 I 1 I

21 1 Resistance measurement before backfilling
22 1 Backfilling 1 1 1
23 Resistance measurement after backfilling
Potable reference electrode passes through the
24 monitoring pipe after backfilling

Comments:

1 Sub-Contractor ! Contractor 1 KOC I

Name 1
Signature
Date

Acc : Accepted
Rej : Rejected
NIA : Not applicable
APPENDIX B (contd.1)

REFERENCE ELECTRODE FUNCTION TEST

Tank No: Date:

lnppection
Potential of Calibrated Zinc
Sub-Contractor Contractor KOC
SI. No. Reference Electrode No. w.r+ Portable Ref. cell (mV)
1
2
3
4
5
6
7
R I

Comments:

1 Sub-Contractor Contractor KOC

Name
Signature
Date
 DOC. NO. KOC-1-026
I Page 25 of 31 I REV. 2

BOXES (J.B AND TEST BOX)

Tank No: Date:

Results Inspection
Sub-
Contractor
SI. No. Description. Acc. Rej, N / A contractor KOC
1 Support as per detail drawings
2 Foundation location and details correct
3 Installation as details drawing
4 Cable connections as per termination diagram
5 Cables installed & termination complete
6 All cable clearly identified with tags
1 I 1 I 1 I

1 Comments: I

Sub-contractor Contractor KOC

Signature
Date 1 1
DOC. NO. KOC-L-026 Page 26 of 31 REV. 2

APPENDIX B (contd J )

TR 1 RECTIFIER CHECK LIST

TR IRectifier No.: Date:

TR IRectifier Rated Capacity :

Type : Manual Automatic

AC Input : Volts Phase DC Output : Volts Amps

Tap : Coarse Medium Fine

Results Inspection
Acc, Rej, Sub-
Contractor
SI. No. Description. NI A contractor KOC
1 Equipment Undamaged
2 Orientation and Alignment Correct
3 Accessories Installed
4 Earth as per detail drawing
5 Insulation Resistance:
5.1 Primary Winding - Earth
5.2 Secondary Windrng - Earth
5.3 Primary Winding - Secondary Winding
6 Oil Filling complete and no leakage
7 Condition of Silica Gel
8 AC Supply
9 AC Setting

I Comments:

Sub-Contractor Contractor KOC

Name
Signature
 DOC. NO. KOC-L-026 Page 27 of 31 REV. 2

APPENDIX B (contd.!)

PRE-COMMISSIONING CHECKLIST
FOR
IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM
JNEW TANK BOTTOM EXTERNAL)

Description ...................................................................................................
I I I Inspector I Date ( Remarks ]
1 Pre-commissioning
Check if anode grid installation checklist are approved by Company
I
Check if all anodes cable are terminated and labeled i n the anode
Junction Box (JIB).

Check if the negative cable (from structure) is terminated i n a Junction

box.

Check if all JIBS and test posts are marked and labeled inside and
I outside. I
1 Check if all JIBS shunt and resistor rating as per specifications.
Check i f all TiRs capacity, location, labeling, oil level,,silica gel are as per
specification.
Check if the TlR positive cable is connected to anode JIB and negative
cable is connected t o Structure JIB.
I Check if all reference cells and coupons are installed as per drawings. 1
Check if the isolation joint (IJ) are installed and there is no short circuit. I
Witness potential natural reading for all test posts before energizing the
TIRs.

2 After energizing the TIRs. 1

Verify if TlRs meters are functioning.
Witness if potential "OnJOff" readings are meeting the protection 1
criterion at test posts.

Check for any interference. 1 I

Notes:......................................................................................................................... ......
..........................................................................................................................................
...........................................................................................

Reviewed By: ................................. Approved by : ............................. (Snr Engrl

 DOC. NO. KOC-L-026 Page 28 of 31
I REV. 2

APPENDIX B Icontd.1)

TANK BOTTOM CP SUMMARY DATA SHEET

Tank No.: Location:

Type of CP system: Drawing No. :
Project & Contract Number: CP Designer:

I I
Description
Total Surface Area To Be Protected:
Material
I
1
Value
I
Units
Sqr Meter

Membrane Liner Thickness mm

-
I
1
Depth with respect to the Tank Bottom
Material type
Manufacturer
I
I
Meter
I
Dimensions mm

II Anode
Quantity
I I

Meter I
Spacing I Meter
Meter
I
Depth with respect to the tank bottom
Material type
Manufacturer
Conductor Bar Dimensions mm

I Spacing 1 Meter
I I
Size of power feed cables mm
Power Feed
No of cables No
Number No
UPVC
Depth with respect to the tank bottom Meter
Manufacturer
Permanent
Cable size mm

-
Reference of
Cell Number No
Depth with respect to the tank bottom Meter

I Manufacturer
I Retractable
Cable size mm
Reference of
Cell Number No
Depth with respect to the tank bottom Meter
Manufacturer
1 Transformer
Serial Number
/Rectifier
Capacity AmpN
1 Commissioning Average CP Potential , mV
I

1 ] Required Current I 1 Amp I

-
I DOC. NO. KOC-L-026 1 Page 29 of 31 1 REV. 2 1

16.3 APPENDIX C : TYPICAL CATHODIC PROTECTION DETAILS FOR

UNDERSIDE OF TANK BOTTOM USING GRID SYSTEM
 DOC. NO. KOC-L-026
I Page 30 of 31 I REV. 2

ACKNOWLEDGEMENT

This Standard has been approved by the Standards Technical Committee (STC)
consisting of the following:

Mr. A/Redha Al-Haddad Standards Team Chairman

Mr. Mohammad Emam Insp. & Corr. Team (S&E) Deputy Chairman
Mr. S. Kumar Standards Team Secretary1 Member
Mr. Henry Hill Opns. Tech. Svcs. Team (SK ) Merqber
Mr. A. Unnikrishnan Standards Team Merqber
Mr. Khalaf Hamada Design Team Merqber
Mr. N. Ramanathan Export Facilities Team Meqber
Mr. Ali Hassan Al-Failakawi HSE System Team Menqber
Mr. Daniel Pino Utilities Team Merrjber
Mr. Abdul R. Al-Shamari Insp. & Corr. Team (N&WK) Meqber
Mr. Khalid Al-Ahmad Gen. Project Team Merriber
Mr. Abdul Aziz Akbar Project Mgmt. Team (NK) ~e4ber
Mr. Moataz Khalaf Information System Team Meriber

The draft of this Standard had been circulated t o the KOC User Teams for review
and the responses were received from the following:

ENGINEERING GROUP MAJOR PROJECTS GROUP (I)

Team Leader Design Team Leader Export Fqc. Projects.

AHMADI SERVICES GROUP HSE GROUP

Team Leader Utilities Team Leader Safety

Team Leader Project Design Team Leader HSE Systems
Team Leader H&E

OPERATIONS GROUP (SK) OPERATIONS GROUP. (WK)

Team Leader Opns. Tech. Svcs. Team Leader Opns. Tech. Svcs

OPERATIONS GROUP (EK) OPERATIONS GROUP.(NK)

Team Leader Opns. Tech. Svcs Team Leader Opns. Tech. Svcs.

EXPORT & MARINE OPNS GROUP DRILLING OPNS GROUP

Team Leader Export SVGS Team Leader Drilling & WlOver Svcs.

MAINTENANCE GROUP (EK) SUPPORT SVCS. GROUP ISEK)

Team Leader Maintenance Team Leader General Rrojects

HSE GROUP (SEK)

Team Leader HSE (SEK)

-
 DOC. NO. KOC-L-026 I Page 31 o f 31 I REV. 2

Task Force Res~onsiblefor this Recommended Practice

The Preparation of this Recommended Practice has been entrusted by the Standards
Technical Committee (STC) of the Task Force No (TF-CPl02) Comprising of the
following members:

Mr. Abdul Razzaq A1 Shamari Insp.& Corr. (NWK ) TF Leader Tel No. 61426
Mr. Hasan Sabri Insp. & Corr.(SEK) Member Tel No 67489
Mr. Govinda Mishra Design Team Member Tel No 61 097
Mr. Liakat Ali Maintenance (WK) Member Tel No 20061
Mr. Uppara Saibaba HSE Systems Member Tel No 71 837