WORK PROCEDURE FOR MONITORING AND MAINTENANCE OF CATHODIC PROTECTION SYSTEM 1.

0 Introduction The purpose of monitoring Cathodic Protection System is to check whether the system provides the required protection level to the pipeline as failure will allowed corrosion activities and thereby affect the overall structural integrity of pipelines. It involves Soil-to-Pipe potential measurement, Transformer/Rectifier inspections, Groundbed resistance measurement amongst others. To obtain accurate readings, the cable counting the reference electrode to the Multimeter shall have a low resistance compared with the internal resistance of the Multimeter. Soil-to-Pipe potential measurement are reported in (mV) with a negative polarity sign. 1.1 Pre-Departure i. Conduct a brief meeting with the team about the job to be embarked on ii. Check and confirm the status of all equipments, tools and materials iii. Pre departure brief with Operations Manager iv. Fill out the journey management form v. Load the equipments, materials and tools on the vehicle vi. Depart to Job site, and note the departure time on your time sheet 1.2 Arrival at site Note your arrival time on your time sheet and Off load the equipment, tools and materials ii. Intimate the facility supervisor of your arrival iii. Apply for work permit and obtain it (if not processed by the Company Site Representative (CSR) already) i. At Job Site i. Conduct safety briefing, note same on safety brief form ii. Discuss and finalize any concerns raised during the safety briefing iii. Note the job start time on your time sheet iv. Proceed to facility visual inspection procedure Visual Inspection Procedure Transformer Rectifier (TRR) Inspection i. Check the status of the TRR unit, ON or OFF and record on the facility inspection form (form xxx) ii. If ON, a. Check for indication light and humming sound to confirm that the unit is working b. Check and record the output Current (0-50A) and Voltage (0-50V) displayed on the unit panel on form xx c. Check and record the current regulator setting (ie the regulator pointer position) on form xx d. Check and record the oil level and temperature reading on the unit on form xx e. Check and record the status of the silica gel attached to the unit on form xx

1.3

2.0 2.1

iii. Open the panel door with keys , if there is an inbuilt current interrupter check the status and record on form xx iv. If OFF, a. Call the attention of the Company Site Representative (CSR) to it, record on form xx b. Proceed to Troubleshooting procedure (5.0) 2.2 Junction Box/Test Post Inspection i. Check out the physical appearance of the unit ii. Note any damage to the unit and request CSR attention if need be iii. Record all observations on the facility inspection form.

3.0 Soil to Pipe Potential The steps to carry out this activity successfully are as follows: i. Ensure that the porous ends of the Halfcell (Copper-Copper Sulfate or Silver-Silver Chloride) are not blocked. ii. On the TRR inbuilt interrupter, set the ON cycle to 4seconds and OFF cycle to 8seconds and activate it, If ON and OFF potential readings are to be taken, otherwise proceed to item iii. iii. Access the pipeline from the test post or on exposed surface at Above Ground Installation (AGI) locations iv. Place the porous plug of the Halfcell firmly into contact with the soil, moistening the area of contact if it is very dry. v. At offshore locations, partially submerged the Halfcell in water. vi. Connect the Halfcell to the common (COM) terminal (BLACK) of the multimeter vii. Connect the RED probe cable to the voltage terminal on the multimeter viii. Turn the multimeter on and set the pointer to DC voltage output ix. Place the RED probe terminal on the test post cable terminal or on exposed Pipeline surface at AGI locations. x. Ensure electrical continuity between the probe, soil electrolyte and the porous plug of the Halfcell. xi. Take the potential readings on the Multimeter display unit and record accordingly noting the distance along pipeline using GPS coordinates. xii. Repeat procedures in every test points. xiii. Pipe-to-Soil potential data recorded are analysis using graphs 4.0 4.1 Groundbed Resistance Measurement 2-Pin Method i. Open the Groundbed cover ii. Disconnect the Grondbed cable from the variable resistor at the groundbed Junction Box using appropriate spannars iii. Mark out a point A 15m from the Groundbed and another point B 15m from point A in a straight line. iv. Place the test rods firmly into the ground at the v. Connect the rod at point A to the P2 terminal on Earth Tester using test leads

vi. Connect the rod at point B to the P2 terminal on Earth Tester using test leads vii. Loop terminals C1 and P1 on the meter and connect it to the Groundbed cable viii. Press the lash button on the Earth Tester to take the Resistance (R) reading displayed on the screen ix. Using Wenner formula;

= .

Where resistivity(ohm-m) a distance between rods (ft) R Resistance (ohm) Resistivity Table Soil Resistivity Range (ohm-m) 0 - 20 20 - 100 100 300 Above 300 Corrosivity Severe Moderate to severe Mild Not likely

Also, an effective way of decreasing the electrode resistance to ground is by pouring water around it. The addition of moisture is insignificant for the reading; it will only achieve a better electrical connection and will not influence the overall results. Also a longer probe or multiple probes (within a short distance) may help. 5.0 Transformer/Rectifier (TRR) Troubleshooting Procedure This procedure is carried out when a TRR unit is not working 5.1 c. d. e. f. Preliminary Checks Open the panel door with key Open the input and output fuse doors and take out the fuses Test for the continuity on the fuses using multimeter Procedure for conducting continuity test i. Connect the probe cables to the multimeter as follows; black probe to the com terminal(black color), red probe to the red terminal marked V ii. Turn the switch on the multimeter and keep the pointer on the continuity icon iii. Contact the two probes with the two ends of the fuse and listen to a sound iv. If there is a continuous beep sound, then the fuse is ok, if there is no sound, then the fuse is bad Replace the fuses that are bad and record same on facility inspection form if spares are available, else, make a note for further maintenance work. If the TRR is still not coming on, proceed to step 5.2

g. h.

5.2 Troubleshooting TRR Units It becomes imperative to test TRR and check for malfunctions if the unit fails to come ON after trying step 5.1. Trouble shooting should be carried out by qualified personnel with Cathodic Protection (CP) experience, must be familiar with the CP system, drawings, manufacturers manuals and historical operating records available.

The problem of an AC powered Cathodic Protection System (CPS) can be grouped into the following basic areas: AC input, DC output, External CP cables, Anode junction box, Groundbed, and Structure (Pipeline or Tank).

5.2.1 AC Input Problem i. Check voltage at input terminal to rectifier ii. If no voltage present, problem is with the AC power source 5.2.2 DC output problem i. Use portable multimeter to confirm AC input to the unit ii. Use portable multimeter to confirm no DC voltage If AC exists but no DC voltage present, then problem lies within TRR unit a. Check circuit breaker b. Check AC and DC fuses c. Check the diodes d. DC volt but no current output e. Usually a problem with the external DC circuit f. Use dummy load to confirm fault is external of TRR g. Check negative connection to structure (pipeline) h. Check positive connection at Anode Junction Box i. Conduct continuity test of Groundbed (Positive) cable and Negative cables 6.0 REMEDIAL WORKS ON CPS Remedial works on CPS becomes necessary if after Potential gradient survey it is discovered that the minimum potential required to keep the pipeline protected is not met. It is carried out to resuscitate and re-commission ailing CPS in order to provide continuous protection for pipelines against corrosion. 6.1 Repair /Replacement of cables connected to TRR. i. Switch off the unit, and disconnected from the mains ii. The cable connecting ground bed to the TRR must be disconnected as well. iii. Remove the unit cover identify the faulty cable (visual inspection; check for burnt, loose terminations), then disconnect it from the unit iv. The appropriate length, size and type of the new cable will be measure and cut out. v. Continuity Test (5.1 f) will be done on the new cable, and cable lug fitted to the ends vi. The cable terminals will be connected accordingly vii. The TRR mains will be reconnected and the unit powered on. viii. The output meters (ammeter and voltmeter) are checked and reading noted.

6.2 Replacement of loop cables on Insulation Joints at Risers This is done to ensure continuity of the CP current, hence pipeline protection. i. The TRR providing current for the pipeline CPS will be put off and disconnected

ii. Inspect the riser and identify the bad loop cable iii. Use cable cutter to cut out old loop cables at risers or if connected with bolt and nut, the nut will be loosen using appropriate tools iv. Measure and cut out the new loop cable to be installed v. Conduct continuity test on the cable, and install cable lug fittings at both ends vi. Prepare the connecting surface and connect the new loop cable to the pipeline using the approved method vii. Grease is applied to the joint point, if on AGI , Marine paint (splash zone compound) is applied on submerged points 6.3 Installation of Test Post Test posts are installed to provide for a convenience point to measure pipe=to-soil potential. The procedures are; i. The TRR servicing the line will be put off and disconnected from the mains. ii. Mark out the point/area to install the test posts at designated locations. iii. The marked area is excavated using appropriate equipment to expose (but not damage) the pipeline. iv. Remove the pipeline coating at the point which the test cable will be connected v. Using Ultrasonic meter, verify the pipeline thickness integrity vi. Install test post structure at least 1m away but perpendicular to the pipeline, using concrete to form the base vii. Measure and cut out the required cable and check for continuity. viii. Clean the pipeline surface, then weld (Pin braze) the cable to the pipeline and connect the other terminal to the test post. ix. Using approved and appropriate pipeline coating, coat the point of weld to avoid corrosion, and the pipeline excavation backfilled. Note: TRR Transformer Rectifier Unit AGI Above Ground Installation