PDVSA 00-FELE-SP-0024 - 2009 - Carhodic Protection

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El Palito Refinery Expansion Project

Document Title Cathodic Protection

Document No. 00-FELE-SP-0024 Page 2 of 38


FWI Revision: C01
FWI Document No. BD0382A-78A4 Date: 03/02/2009

REVISION INDEX

PAGE REV DATE PAGE REV DATE


1 C01 03/02/2009 21 C01 03/02/2009
2 C01 03/02/2009 22 C01 03/02/2009
3 C01 03/02/2009 23 C01 03/02/2009
4 C01 03/02/2009 24 C01 03/02/2009
5 C01 03/02/2009 25 C01 03/02/2009
6 C01 03/02/2009 26 C01 03/02/2009
7 C01 03/02/2009 27 C01 03/02/2009
8 C01 03/02/2009 28 C01 03/02/2009
9 C01 03/02/2009 29 C01 03/02/2009
10 C01 03/02/2009 30 C01 03/02/2009
11 C01 03/02/2009 31 C01 03/02/2009
12 C01 03/02/2009 32 C01 03/02/2009
13 C01 03/02/2009 33 C01 03/02/2009
14 C01 03/02/2009 34 C01 03/02/2009
15 C01 03/02/2009 35 C01 03/02/2009
16 C01 03/02/2009 36 C01 03/02/2009
17 C01 03/02/2009 37 C01 03/02/2009
18 C01 03/02/2009 38 C01 03/02/2009
19 C01 03/02/2009
20 C01 03/02/2009

* Asterisk represents pages revised for this issue.

Initial issue
X Entire specification reissued
Revised pages only attached

Please replace revised pages with those now in your possession.

EACH REVISION SUPERSEDES PREVIOUS ISSUE, CHANGES ARE INDICATED IN MARGIN BY THE REVISION NUMBER OR A VERTICAL LINE.
This drawing embodies proprietary information of the Consortium. This drawing or the material described thereon may not be copied or disclosed in any form or medium to third parties, or used for other than
the purpose for which it has been provided, in whole or in part, in any manner except as espressly permitted by Consortium
clientfilename: 00-FELE-SP-0024
El Palito Refinery Expansion Project

Document Title Cathodic Protection

Document No. 00-FELE-SP-0024 Page 3 of 38


FWI Revision: C01
FWI Document No. BD0382A-78A4 Date: 03/02/2009

TABLE OF CONTENTS

1. GENERAL .....................................................................................................................................6

2. CODES, STANDARDS AND REGULATIONS...............................................................................7

3. BASIC ENGINEERING DATA .......................................................................................................8

4. EQUIPMENT AND STRUCTURES PROTECTED USING CATHODIC PROTECTION .................9

5. REQUIREMENTS ........................................................................................................................10

6. DESIGN .......................................................................................................................................13

7. CATHODIC PROTECTION UNITS ..............................................................................................17

8. IMPRESSED CURRENT GROUND BEDS ..................................................................................19

9. GALVANIC ANODES ..................................................................................................................21

10. TEST POINTS..........................................................................................................................22

11. INSULATION FITTINGS ..........................................................................................................23

12. PROTECTION FROM STRAY ELECTRIC CURRENTS ..........................................................25

13. INSULATING FITTINGS PROTECTION SYSTEMS ................................................................27

14. GALVANIC COUPLES ............................................................................................................28

15. MATERIAL AND EQUIPMENT STANDARDS.........................................................................29

EACH REVISION SUPERSEDES PREVIOUS ISSUE, CHANGES ARE INDICATED IN MARGIN BY THE REVISION NUMBER OR A VERTICAL LINE.
This drawing embodies proprietary information of the Consortium. This drawing or the material described thereon may not be copied or disclosed in any form or medium to third parties, or used for other than
the purpose for which it has been provided, in whole or in part, in any manner except as espressly permitted by Consortium
clientfilename: 00-FELE-SP-0024
El Palito Refinery Expansion Project

Document Title Cathodic Protection

Document No. 00-FELE-SP-0024 Page 4 of 38


FWI Revision: C01
FWI Document No. BD0382A-78A4 Date: 03/02/2009

TABLES INDEX

Table A – EQUPMENT AND STRUCTURES PROTECTED USING CATHODIC PROTECTION ....9


Table B – RECOMMENDED POTENTIAL CRITERIA for OFF-SHORE PIPELINES ......................11
Table C - LOCATION OF ELECTRICAL TEST POINTS FOR POTENTIAL MEASUREMENT.............37
Table D - LOCATION OF ELECTRICAL TEST POINTS FOR CURRENT MEASUREMENT ...............38

EACH REVISION SUPERSEDES PREVIOUS ISSUE, CHANGES ARE INDICATED IN MARGIN BY THE REVISION NUMBER OR A VERTICAL LINE.
This drawing embodies proprietary information of the Consortium. This drawing or the material described thereon may not be copied or disclosed in any form or medium to third parties, or used for other than
the purpose for which it has been provided, in whole or in part, in any manner except as espressly permitted by Consortium
clientfilename: 00-FELE-SP-0024
El Palito Refinery Expansion Project

Document Title Cathodic Protection

Document No. 00-FELE-SP-0024 Page 5 of 38


FWI Revision: C01
FWI Document No. BD0382A-78A4 Date: 03/02/2009

ATTACHED DOCUMENTS

Job Specifications

Number Description File name

00-PPRO-BD-0001 Basic Engineering Design Data 00-PPRO-BD-0001.doc


General Notes for Electrical Equipment
00-FELE-SP-0025 00-FELE-SP-0025.doc
and Materials
Reinforced Concrete Construction &
00-FSTC-SP-0005 00-FSTC-SP-0005.doc
Durability

EACH REVISION SUPERSEDES PREVIOUS ISSUE, CHANGES ARE INDICATED IN MARGIN BY THE REVISION NUMBER OR A VERTICAL LINE.
This drawing embodies proprietary information of the Consortium. This drawing or the material described thereon may not be copied or disclosed in any form or medium to third parties, or used for other than
the purpose for which it has been provided, in whole or in part, in any manner except as espressly permitted by Consortium
clientfilename: 00-FELE-SP-0024
El Palito Refinery Expansion Project

Document Title Cathodic Protection

Document No. 00-FELE-SP-0024 Page 6 of 38


FWI Revision: C01
FWI Document No. BD0382A-78A4 Date: 03/02/2009

1. GENERAL

1.1. Purpose

1.1.1. This specification defines the technical requirements governing design, supply
installation and testing of cathodic protection system for buried carbon steel
pipelines and other structures as required.

1.1.2. The Material Requisition and Data Sheet shall define the specific
requirements for each application, which take precedence over this
specification.

1.1.3. Compliance with this specification does not relieve the manufacturer nor the
vendor of the responsibility for furnishing equipment of proper design and
construction and fully suitable for all specified operating conditions.

1.2. Abbreviation and Definitions

Company Petróleos de Venezuela, S.A


Consortium PMT Consortium Project Management Team
(Directorate)
TEC Toyo Engineering Corporation
FWI Foster Wheeler Italiana
Y&V Y&V Ingeniería y Construcción
Vendor Supplier of requested Equipment

Project Name and References

Formal name El Palito Refinery Expansion Project.


Abbreviated name RELP
Location Refinería El Palito, Carretera Morón –
Puerto Cabello Municipio Mora, Sector
Punta Chavez, Edo, Carabobo
Venezuela

EACH REVISION SUPERSEDES PREVIOUS ISSUE, CHANGES ARE INDICATED IN MARGIN BY THE REVISION NUMBER OR A VERTICAL LINE.
This drawing embodies proprietary information of the Consortium. This drawing or the material described thereon may not be copied or disclosed in any form or medium to third parties, or used for other than
the purpose for which it has been provided, in whole or in part, in any manner except as espressly permitted by Consortium
clientfilename: 00-FELE-SP-0024
El Palito Refinery Expansion Project

Document Title Cathodic Protection

Document No. 00-FELE-SP-0024 Page 7 of 38


FWI Revision: C01
FWI Document No. BD0382A-78A4 Date: 03/02/2009

2. CODES, STANDARDS AND REGULATIONS

If not otherwise specified, design, engineering, equipment supply,


installation, construction, testing and commissioning shall be in
accordance with the following codes, standards, laws and reference
documents.

2.1. Local codes and regulations

- FONDONORMA 0200: 2004 - Código Eléctrico Nacional

2.2. International codes and standards

The latest edition of the following international standards, codes and


regulations shall be applied. Any deviation or contradiction of such
standards to the above mentioned Venezuelan codes shall be
highlighted and submitted by involved Manufacturer / Contractor to
PDVSA representative approval by written.

2.2.1. US Codes

API RP 1109 “Marking Liquid Petroleum Pipeline Facilities”,


American Petroleum Institute

API RP 651 Cathodic Protection of Aboveground Petroleum


Storage Tanks

ASTM A–123 “Standard Specification for Zinc (Hot-Dip


Galvanized) Coatings on Iron and Steel Products”,
American Society for Testing and Materials

ASME B31.3 Process Piping

ASME B31.4 “Pipeline Transportation Systems for Liquid


Hydrocarbons and Other Liquids”

AWWA C–203 “Coal-Tar Protective Coatings and Linings for Steel


Water Pipelines - Enamel and Tape - Hot Applied”,
American Water Works Association.

NACE RP01–69 “Control of External Corrosion of Underground or


Submerged Metallic Piping Systems”, National
Association of Corrosion Engineers

EACH REVISION SUPERSEDES PREVIOUS ISSUE, CHANGES ARE INDICATED IN MARGIN BY THE REVISION NUMBER OR A VERTICAL LINE.
This drawing embodies proprietary information of the Consortium. This drawing or the material described thereon may not be copied or disclosed in any form or medium to third parties, or used for other than
the purpose for which it has been provided, in whole or in part, in any manner except as espressly permitted by Consortium
clientfilename: 00-FELE-SP-0024
El Palito Refinery Expansion Project

Document Title Cathodic Protection

Document No. 00-FELE-SP-0024 Page 8 of 38


FWI Revision: C01
FWI Document No. BD0382A-78A4 Date: 03/02/2009

BS 7361-1 “Cathodic protection. Code of practice for land and


marine applications”

2.2.2. International Codes

ISO 15589 Petroleum and natural gas industries -- Cathodic


protection of pipeline transportation systems

3. BASIC ENGINEERING DATA

3.1. Project Design Conditions

3.1.1. For equipment design and the Site environmental conditions see the
documents No. 00-PPRO-BD-0001 “Basic Engineering Design Data (BEDD)”.

3.1.2. For Voltage Levels, See Doc. N° 00-FELE-SP-0 025, “General Notes for
Electrical Equipment and Materials”.

EACH REVISION SUPERSEDES PREVIOUS ISSUE, CHANGES ARE INDICATED IN MARGIN BY THE REVISION NUMBER OR A VERTICAL LINE.
This drawing embodies proprietary information of the Consortium. This drawing or the material described thereon may not be copied or disclosed in any form or medium to third parties, or used for other than
the purpose for which it has been provided, in whole or in part, in any manner except as espressly permitted by Consortium
clientfilename: 00-FELE-SP-0024
El Palito Refinery Expansion Project

Document Title Cathodic Protection

Document No. 00-FELE-SP-0024 Page 9 of 38


FWI Revision: C01
FWI Document No. BD0382A-78A4 Date: 03/02/2009

4. EQUIPMENT AND STRUCTURES PROTECTED USING CATHODIC PROTECTION

The Cathodic Protection will be used for equipment, piping and structures protection
as hereafter indicated in the following table:

Table A – EQUPMENT AND STRUCTURES PROTECTED USING


CATHODIC PROTECTION

EQUIPMENT AND CP SPECIFIC REQUIREMENTS STD.


STRUCTURES
Piping
1. Underground carbon Required only for piping buried in soils
steel piping system handling having resistivity less than 10,000 ohm-cm,
hydrocarbon if specified by the CONTRACTOR

2. Underground piping
systems handling cooling water Required only for piping buried in soils
or firewater, located outside of having resistivity less than 10,000 ohm-cm,
process unit areas. if specified by the CONTRACTOR

3. Underwater piping Required for complete system


systems
Tankage
1. External tank bottoms. In case tanks are installed on solid
concrete foundation without direct contact
with soil, the CP system is not required.

2. Underground storage Required unless it can be demonstrated


tanks. that there is no soil-side corrosion

Marine facilities
1. Steel piers Required for underwater structure.
2. Steel piles, pipe or Note: Cathodic protection achieved
structure through the use of sacrificial aluminium
3. Steel sheet pilling (if anode system preferred, provided its cost is
specified) competitive with the impressed current
4. Mooring buoys or other system taking into account installation
floating structures operating and maintenance costs.
Water storage tanks
Required for salt water. CONTRACTOR will
determine need in fresh water tanks
EACH REVISION SUPERSEDES PREVIOUS ISSUE, CHANGES ARE INDICATED IN MARGIN BY THE REVISION NUMBER OR A VERTICAL LINE.
This drawing embodies proprietary information of the Consortium. This drawing or the material described thereon may not be copied or disclosed in any form or medium to third parties, or used for other than
the purpose for which it has been provided, in whole or in part, in any manner except as espressly permitted by Consortium
clientfilename: 00-FELE-SP-0024
El Palito Refinery Expansion Project

Document Title Cathodic Protection

Document No. 00-FELE-SP-0024 Page 10 of 38


FWI Revision: C01
FWI Document No. BD0382A-78A4 Date: 03/02/2009

5. REQUIREMENTS

5.1.1. A cathodic protection system shall be installed for all the equipments and
structures mentioned in Table A – EQUPMENT AND STRUCTURES
PROTECTED USING CATHODIC PROTECTION to mitigate corrosion that
might result in structural failure. A test procedure shall be developed to
determine whether adequate cathodic protection has been achieved.

5.1.2. Recommended Potential Criteria required for ON-LAND Pipelines (and for the
equipment as listed in table Table A) are the following:

The CP system shall be capable of polarizing all parts of the buried


pipeline to potentials more negative than –850mV referred to GSE,
and to maintain such potentials throughout the design life of the
pipeline (and for the equipment as listed in table Table A). These
potentials are those which exist at the metal-to-environment interface,
i.e. the polarized potentials.

5.1.3. Recommended Potential Criteria for OFFSHORE Pipelines (and for the
equipment as listed in table Table A) are the ones indicated in the following
Table B – RECOMMENDED POTENTIAL CRITERIA :

EACH REVISION SUPERSEDES PREVIOUS ISSUE, CHANGES ARE INDICATED IN MARGIN BY THE REVISION NUMBER OR A VERTICAL LINE.
This drawing embodies proprietary information of the Consortium. This drawing or the material described thereon may not be copied or disclosed in any form or medium to third parties, or used for other than
the purpose for which it has been provided, in whole or in part, in any manner except as espressly permitted by Consortium
clientfilename: 00-FELE-SP-0024
El Palito Refinery Expansion Project

Document Title Cathodic Protection

Document No. 00-FELE-SP-0024 Page 11 of 38


FWI Revision: C01
FWI Document No. BD0382A-78A4 Date: 03/02/2009

Table B – RECOMMENDED POTENTIAL CRITERIA for OFF-SHORE


PIPELINES

Material Minimum Negative Potential Maximum Negative Potential


[V] [V]
CARBON STEEL
b)
Aerobic Environment -0.80 -1.10
Anaerobic Environment -0.90 -1.10 b)
AUSTENITIC STAINLESS
STEEL
c) d)
N PRE ≥ 40 -0.30 -1.10
c) d)
N PRE < 40 -0.50 -1.10

DUPLEX STAINLESS e)
d)
STEEL -0.50
e)
d)
MARTENSITIC STAINLESS -0.50
(13% Cr) STEEL
The potential given in the table, apply to saline mud and normal seawater compositions (salinity 3.2% to
3.8%).
The potentials are referenced to an SCE reference electrode, which are equivalent to a silver/ silver
chloride reference electrode (Ag/ AgCl/ seawater), in 30 Ω cm seawater.
a) These negative limits also ensure negligible impact of CP on pipeline coatings.
b) Where pipelines systems are fabricated from high strength steel (σ SMY > 550 MPa), the most
negative potential that can be tolerated without causing hydrogen embrittlement shall be
ascertained.
c) N PRE = % Cr + 3.3 % (Mo+0.5W) + 16 %N
d) For stainless steels, minimum negative potentials apply for aerobic and anaerobic conditions.
e) Depending on strength, specific metallurgical condition and stress level encountered, these alloys
can be susceptible to hydrogen embrittlement and cracking. If a risk of hydrogen embrittlement
exists, then potentials more negative than –0.8 V should be avoided.

5.1.4. The need of temporary cathodic protection system shall be evaluated and
applied, if, due to the construction schedule, underground pipelines shall not
be operational for more than one year. When cathodic protection already
exists, the new CP system for the new structure must be designed with the
consideration on that. Information about the existing CP shall be given to
Contractor /Vendor by PDVSA representative.

EACH REVISION SUPERSEDES PREVIOUS ISSUE, CHANGES ARE INDICATED IN MARGIN BY THE REVISION NUMBER OR A VERTICAL LINE.
This drawing embodies proprietary information of the Consortium. This drawing or the material described thereon may not be copied or disclosed in any form or medium to third parties, or used for other than
the purpose for which it has been provided, in whole or in part, in any manner except as espressly permitted by Consortium
clientfilename: 00-FELE-SP-0024
El Palito Refinery Expansion Project

Document Title Cathodic Protection

Document No. 00-FELE-SP-0024 Page 12 of 38


FWI Revision: C01
FWI Document No. BD0382A-78A4 Date: 03/02/2009

5.1.5. Design and selection of the cathodic protection system to be utilized shall be
based upon this specification and sound engineering judgment, substantiated
by:

- Adequate corrosion survey data


- Review of historical data from similar facilities
- Economics
- Material, operational and environmental requirements

5.1.6. 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 system and all other facilities, whether above or belowground that
could affect or be affected by the cathodic protection system. The system
design life is 20 years.

5.1.7. Cathodic protection system shall be designed with the consideration of pipe
external coating. The design basis for the pipe external coating shall be
approved by Contractor

5.1.8. Materials and equipment shall conform to the referenced standards or as


approved by Consortium for special requirements. When required,
representative sample batch materials suitable for destructive testing shall be
furnished to buyer for quality control inspection and approval prior to delivery
of corrosion prevention materials. A copy of the manufacturer’s analysis or
test results shall be furnished with the representative sample. All other
equipment will be subject to Consortium/ Company’s acceptance inspection.

5.1.9. The Vendor shall provide “as built” drawings of the installation.

EACH REVISION SUPERSEDES PREVIOUS ISSUE, CHANGES ARE INDICATED IN MARGIN BY THE REVISION NUMBER OR A VERTICAL LINE.
This drawing embodies proprietary information of the Consortium. This drawing or the material described thereon may not be copied or disclosed in any form or medium to third parties, or used for other than
the purpose for which it has been provided, in whole or in part, in any manner except as espressly permitted by Consortium
clientfilename: 00-FELE-SP-0024
El Palito Refinery Expansion Project

Document Title Cathodic Protection

Document No. 00-FELE-SP-0024 Page 13 of 38


FWI Revision: C01
FWI Document No. BD0382A-78A4 Date: 03/02/2009

6. DESIGN

6.1. Site Surveys

Field data are required prior, to proceed with design studies following
the survey requirements.

6.1.1. Surveys

The survey method to be used for this project shall consist in rapid or
spot testing of soil resistivity at typical points along the structure. The
environmental conditions, size, physical layout, economics and need
for design information will determine which variables require field
measurement.

6.1.2. Data accumulation

Proper data recording in the field is mandatory. In additions to


electrical measurement, recorded data shall include dates, weather
conditions, soil conditions, names of survey personnel, telephone
numbers and addresses of foreign contacts, terrain description, entry
roads, potential sources of electric power, locations suitable for
sacrificial anodes an 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 on such structures.

Detailed location measurements, such as for possible cathodic


protection locations, shall be properly references by a triangulation
system to property lines, kilometres posts, and/or established survey
stations.

6.1.3. Testing facilities

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 protection facilities
are given below:

6.1.3.1. Location

The temporary ground bed shall be located at the site selected for the
proposed permanent facility.

EACH REVISION SUPERSEDES PREVIOUS ISSUE, CHANGES ARE INDICATED IN MARGIN BY THE REVISION NUMBER OR A VERTICAL LINE.
This drawing embodies proprietary information of the Consortium. This drawing or the material described thereon may not be copied or disclosed in any form or medium to third parties, or used for other than
the purpose for which it has been provided, in whole or in part, in any manner except as espressly permitted by Consortium
clientfilename: 00-FELE-SP-0024
El Palito Refinery Expansion Project

Document Title Cathodic Protection

Document No. 00-FELE-SP-0024 Page 14 of 38


FWI Revision: C01
FWI Document No. BD0382A-78A4 Date: 03/02/2009

6.1.3.2. 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 amperages of required magnitudes for the
particular test duration.

6.1.3.3. Temporary ground beds

Temporary ground beds may consist of buried junk pipe, abandoned


buried metallic structures, aluminum foil in burrow ditch water, etc.
which may be utilized to provide sufficient electrical ground contact to
allow stimulation of the proposed ground beds. Temporary wiring used
for connecting the ground bed shall have sufficient insulation to
prevent uncontrolled circuits and to provide personnel safety.

6.1.3.4. Current measurement

After the system has stabilized at the required protective levels,


measurements shall be made of current drainage at all current source
including control bonds.

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.

6.1.3.5. Soil to pipeline potential measurement

Soil to pipeline potentials shall be obtained at all test leads; both sides
of insulating flanges or unions, foreign pipeline or other buried metallic
structure crossings, or like 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 system and to
assure against induced stray current corrosion on structures not to be
included into the cathodic protection scheme.

All potential readings shall be recorded to the nearest millivolt using


suitable precision instruments and standard copper–copper sulphate
(Cu/CuO4) half cell reference electrodes, or silver–silver clorure
(Ag/Ag Cl) half shell reference electrodes.

EACH REVISION SUPERSEDES PREVIOUS ISSUE, CHANGES ARE INDICATED IN MARGIN BY THE REVISION NUMBER OR A VERTICAL LINE.
This drawing embodies proprietary information of the Consortium. This drawing or the material described thereon may not be copied or disclosed in any form or medium to third parties, or used for other than
the purpose for which it has been provided, in whole or in part, in any manner except as espressly permitted by Consortium
clientfilename: 00-FELE-SP-0024
El Palito Refinery Expansion Project

Document Title Cathodic Protection

Document No. 00-FELE-SP-0024 Page 15 of 38


FWI Revision: C01
FWI Document No. BD0382A-78A4 Date: 03/02/2009

Potential readings shall be taken at sufficient intervals to prevent over


looking a non–protected or corroding portion of the buried structure to
be protected.

Readings shall also be obtained to ascertain that the cathodic


protection system being designed will not create noncontrollable
interference problems upon other buried structures. In locations
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.

6.1.3.6. Measurements 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 as described in NACE RP–
01–69, Section 6, “Criteria for Cathodic Protection”. Choice of criteria
shall be governed by economics, coating condition, environment and
type of buried structure to be protected.

Minimum protective level – 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.

6.1.3.7. Soil resistivity survey

Soil resistivity survey measurements shall be obtained using the four–


electrode method.

Pipeline Route – Where resistivity measurements are required along


the pipeline, they shall be made at maximum intervals of 1 km (or less
when the soil conditions change) using electrode spacing equivalent to
pipe depth.

EACH REVISION SUPERSEDES PREVIOUS ISSUE, CHANGES ARE INDICATED IN MARGIN BY THE REVISION NUMBER OR A VERTICAL LINE.
This drawing embodies proprietary information of the Consortium. This drawing or the material described thereon may not be copied or disclosed in any form or medium to third parties, or used for other than
the purpose for which it has been provided, in whole or in part, in any manner except as espressly permitted by Consortium
clientfilename: 00-FELE-SP-0024
El Palito Refinery Expansion Project

Document Title Cathodic Protection

Document No. 00-FELE-SP-0024 Page 16 of 38


FWI Revision: C01
FWI Document No. BD0382A-78A4 Date: 03/02/2009

Ground Bed Sites – Resistivity readings at proposed ground bed


locations shall be taken to allow complete resistivity contouring at each
alternate proposed ground bed site.

Anode Sites – Resistivity readings at proposed galvanic anode sites


shall be taken along the pipe at suitable intervals using potential
electrode spacing as required.
Resistivity readings shall be corrected to consider the worst resistivity
conditions, that is, summer conditions.

Soil Samples – Suitable soil sample shall be obtained when necessary


to determine additional soil characteristics such as soluble salts,
moisture content, ph, etc. The content of sulphate shall be determined
to detect the presence of sulphate–reductor bacteria’s.

The single pin method will be acceptable only when the four-pin
method cannot be used because of space or other limitations.

6.1.3.8. Locating 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.

6.2. 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 flanges, and monitoring points.
- Proposal information above mentioned must be approved by the
Consortium/ Company’s engineer

EACH REVISION SUPERSEDES PREVIOUS ISSUE, CHANGES ARE INDICATED IN MARGIN BY THE REVISION NUMBER OR A VERTICAL LINE.
This drawing embodies proprietary information of the Consortium. This drawing or the material described thereon may not be copied or disclosed in any form or medium to third parties, or used for other than
the purpose for which it has been provided, in whole or in part, in any manner except as espressly permitted by Consortium
clientfilename: 00-FELE-SP-0024
El Palito Refinery Expansion Project

Document Title Cathodic Protection

Document No. 00-FELE-SP-0024 Page 17 of 38


FWI Revision: C01
FWI Document No. BD0382A-78A4 Date: 03/02/2009

7. CATHODIC PROTECTION UNITS

7.1. General

7.1.1. These facilities include such devices as engine driven generator, alternators,
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
when choosing and sizing cathodic protection equipment.

7.1.2. Rectifiers will usually provide the lowest cost protection current where AC
power is available and where the current demand will exceed that
economically obtained from galvanic anodes.

7.1.3. Surface ground beds will normally provide maximum long–term economies.

7.1.4. 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.

7.1.5. Galvanic anodes provide specific economic and operational advantage in high
interference areas such as offshore environments and when used with ”hot
spot” high–dielectric coatings such as “X–thru–coat” and thin film Epoxy.
Galvanic anodes are the economic cathodic protection choice for short
pipeline systems.

7.2. Location of Units

7.2.1. Location shall be governed by the following factors:

- Near an existing economic power source such as a government station


- DC power source adjacent to the ground bed
- Non–explosive area
- Sheltered and adequately ventilated
- Access roads nearby
- Low resistance well watered soil
7.3. Spacing of Units
7.3.1. Spacing shall be governed by the following factors:

- Rectifier and ground bed capacity


- Stray current effect
- Allowable potentials on coating
- Protective coatings insulating and dielectric qualities
- Economics
- Soil conditions

EACH REVISION SUPERSEDES PREVIOUS ISSUE, CHANGES ARE INDICATED IN MARGIN BY THE REVISION NUMBER OR A VERTICAL LINE.
This drawing embodies proprietary information of the Consortium. This drawing or the material described thereon may not be copied or disclosed in any form or medium to third parties, or used for other than
the purpose for which it has been provided, in whole or in part, in any manner except as espressly permitted by Consortium
clientfilename: 00-FELE-SP-0024
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Document Title Cathodic Protection

Document No. 00-FELE-SP-0024 Page 18 of 38


FWI Revision: C01
FWI Document No. BD0382A-78A4 Date: 03/02/2009

7.4. Type of Units

7.4.1. Off–the–shelf or catalogue units manufactured in accordance with appropriate


standards are preferred. Type selection is determined by the following:

- Air-cooled single-phase units shall be used for normal requirements.


- Oil–immersed units shall be used in locations where high humidity
conditions, high ambient temperatures, harmful corrosive vapors,
excessive dust conditions, hazardous explosive vapors, or similar
conditions may be encountered.
- Three–phase units may be used when such electrical power is available.
- Base mounted units shall be used in instances where appearance and/or
weight are controlling factors. Foundations for such units shall be made in
accordance with Project Civil Design Specifications.
- Rectification Element. Generally, Selenium full wave stacks shall be used.
Where high current requirements or system economics demand the use
of Silicon elements, the elements shall be fully protected with adequate,
specially designed surge protectors and lightning arresting device.

7.5. Specialized Units

7.5.1. Rare design problems will require the use of special cathodic protection
devices such as the constant potential or constant current unit. Problems like
variable ground bed resistance, high voltage direct current interference, and
exposure to other severe direct current interference problems, will generally
require automatic regulation of cathodic protection current output for complete
and economic protection. Special cathodic protection units such as engine–
driven generators or alternators shall be selected from manufacturers’
standard equipment.

EACH REVISION SUPERSEDES PREVIOUS ISSUE, CHANGES ARE INDICATED IN MARGIN BY THE REVISION NUMBER OR A VERTICAL LINE.
This drawing embodies proprietary information of the Consortium. This drawing or the material described thereon may not be copied or disclosed in any form or medium to third parties, or used for other than
the purpose for which it has been provided, in whole or in part, in any manner except as espressly permitted by Consortium
clientfilename: 00-FELE-SP-0024
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Document Title Cathodic Protection

Document No. 00-FELE-SP-0024 Page 19 of 38


FWI Revision: C01
FWI Document No. BD0382A-78A4 Date: 03/02/2009

8. IMPRESSED CURRENT GROUND BEDS

8.1. Location

8.1.1. Selection of ground bed sites shall be based on:

Current Utilization – Ground beds shall be located for the maximum utilization of
protective currents with a minimum flow of interfering currents in the soil circuits.

Accessibility – The design should strive minimize right–of–way procurement problems


while providing maximum, accessibility for installation, inspection and maintenance.

Soil – Soils having the best combination of low electrical resistivity, high chemical
concentration and maximum moisture content are preferred for the ground bed site.

Soil to Structure Potential – The ground shall be located so that the potential between
the coated structure and the soil contacting it shall not exceed the following levels as
measured to a copper–copper sulphate electrode located directly over the pipe:

CONDITION MAXIMUM POTENTIAL


High resistance Soil, high bond strength coating 3.0 volts
High resistance Soil, low bond strength coating 2.5 volts
Low resistance Soil 2.0 volts
Sea water 1.3 volts
Bare Pipe Lines As limited by interference
conditions

8.2. Type

8.2.1. 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.

8.3. Anode Selection

8.3.1. Generally, passive type (graphite, cast iron, lead silver) rather than sacrificial
type anodes shall be used. Such anodes shall be surrounded with tamped
soft coal or calcinated petroleum coke breeze when practical in order to
increase effective anode size.
8.3.2. Ferro–Silicon anodes shall be used for deep well beds and are preferred for
surface beds.

EACH REVISION SUPERSEDES PREVIOUS ISSUE, CHANGES ARE INDICATED IN MARGIN BY THE REVISION NUMBER OR A VERTICAL LINE.
This drawing embodies proprietary information of the Consortium. This drawing or the material described thereon may not be copied or disclosed in any form or medium to third parties, or used for other than
the purpose for which it has been provided, in whole or in part, in any manner except as espressly permitted by Consortium
clientfilename: 00-FELE-SP-0024
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Document Title Cathodic Protection

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FWI Revision: C01
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8.4. Anode Placement

8.4.1. Where feasible, anode placement shall be designed to allow discharge of


nearly equal currents from all anodes in the ground bed.

8.4.2. Surface ground bed anodes shall normally be installed in the preferred
vertical position, but where rock or other obstructions are encountered the
anodes may be installed horizontally to take advantage of soil conditions at
the particular installation.

8.5. Deep Well Ground Beds

8.5.1. 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.

8.5.2. Other design criteria include:

- Low current drain (3–4 amps per anode) to minimize gassing and
promote longevity
- Anode spacing to take advantage of favorable strata, 1524 mm (60 in.)
minimum
- Adequate means for gas venting
- Anode centralizers
- Coke slurry injection from bottom
- Inert or non–corrosive structural materials so that anodes alone
determine effective life, including plastic vent pipe, nylon support rope,
stainless steel clamps and centralizers, plastic casing to top of coke fill,
etc.

8.6. Current Density

8.6.1. Maximum design current for graphite anodes shall be 3 amperes for 76 mm x
1524 mm (3 in. x 60 in.) anodes and 4 amperes for 102 mm x 2032 mm (4 in.
x 80 in.) anodes.

8.7. Ground Bed Design Aids

8.7.1. 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.

EACH REVISION SUPERSEDES PREVIOUS ISSUE, CHANGES ARE INDICATED IN MARGIN BY THE REVISION NUMBER OR A VERTICAL LINE.
This drawing embodies proprietary information of the Consortium. This drawing or the material described thereon may not be copied or disclosed in any form or medium to third parties, or used for other than
the purpose for which it has been provided, in whole or in part, in any manner except as espressly permitted by Consortium
clientfilename: 00-FELE-SP-0024
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Document Title Cathodic Protection

Document No. 00-FELE-SP-0024 Page 21 of 38


FWI Revision: C01
FWI Document No. BD0382A-78A4 Date: 03/02/2009

8.7.2. “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 utilizing 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.

8.7.3. 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.

9. GALVANIC ANODES

9.1. Application

9.1.1. In general, galvanic anodes may be advantageously installed on sections of


buried structure where control of interfering currents is difficult, particularly in
congested and urban areas.

9.1.2. They may serve for installations remote from electric power or for protection
of small-insulated sections in a large unprotected system.

9.1.3. Magnesium anodes are frequently the economic cathodic protection choice
for long or complex piping systems coated with long–life, high dielectric
coatings such as extruded plastic and the fusion bonded thin film epoxies.

9.2. Location

9.2.1. 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.

9.2.2. 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 3048 mm
(120 in.).

9.3. Type

9.3.1. Galvanic anode selection shall be restricted to commercially available


magnesium or high purity zinc anodes.

9.3.2. Zinc anodes shall be used only in low resistance soils and where low current
outputs and resultant low solution potentials are tolerable.

EACH REVISION SUPERSEDES PREVIOUS ISSUE, CHANGES ARE INDICATED IN MARGIN BY THE REVISION NUMBER OR A VERTICAL LINE.
This drawing embodies proprietary information of the Consortium. This drawing or the material described thereon may not be copied or disclosed in any form or medium to third parties, or used for other than
the purpose for which it has been provided, in whole or in part, in any manner except as espressly permitted by Consortium
clientfilename: 00-FELE-SP-0024
El Palito Refinery Expansion Project

Document Title Cathodic Protection

Document No. 00-FELE-SP-0024 Page 22 of 38


FWI Revision: C01
FWI Document No. BD0382A-78A4 Date: 03/02/2009

9.3.3. Anode size, shape, weight, purity and backfill shall be governed by the
requirements of the particular installation in accordance with materials
specified herein.

10. TEST POINTS

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
minimize the possibility of overlooking a non–protected, corroding
portion of the buried metallic structure.

10.1. Potential Measurement

10.1.1. Location

At readily accessible locations convenient to public roads and/or


waterways (See Table C - LOCATION OF ELECTRICAL TEST
POINTS FOR POTENTIAL MEASUREMENT)

10.1.2. Typical test point design

Test points for potential measurement 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 buried structure insulation,
prevent contact damage to decorative coatings, and eliminate notch
penetrations into the metallic structure by repeated base metal
contacts.

10.1.3. Other data

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.
EACH REVISION SUPERSEDES PREVIOUS ISSUE, CHANGES ARE INDICATED IN MARGIN BY THE REVISION NUMBER OR A VERTICAL LINE.
This drawing embodies proprietary information of the Consortium. This drawing or the material described thereon may not be copied or disclosed in any form or medium to third parties, or used for other than
the purpose for which it has been provided, in whole or in part, in any manner except as espressly permitted by Consortium
clientfilename: 00-FELE-SP-0024
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Document Title Cathodic Protection

Document No. 00-FELE-SP-0024 Page 23 of 38


FWI Revision: C01
FWI Document No. BD0382A-78A4 Date: 03/02/2009

10.2. Current Measurement

10.2.1. Location

Refer to Table D - LOCATION OF ELECTRICAL TEST POINTS FOR CURRENT


MEASUREMENT for location of electrical test points for current measurement

10.2.2. Typical test point design

Test points for measurement of electrical current shall generally consist of calibrated
shunt type measuring facilities, which allow measurement of current without breaking
the cathodic protection circuit.

10.2.3. Other data

Standard one millivolt per one ampere (0.001 ohm) suitable capacity shunts shall be
used when possible. For galvanic anode installations and low current rectifiers the ten
millivolt one ampere (0.01 ohm) shunt may be used. The shunts shall be contained in
proper housings.

Where sacrifice anode systems are used, potential measurements shall be made
remote from the anodes and the number of potential measurements to be made shall
be reviewed with the owner’s engineer.

11. 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 either side of
the insulation shall be brought above ground for current measurement and control. O
offshore insulated unions or other “hard–to–reach” insulators, spare leads shall be
installed during construction.

Insulating fittings shall be provided at sufficient intervals along the metallic cathodic
protection circuit to result in adequate circuit control. These insulations shall generally
be installed in already proposed flanges, such as at line block valves, to minimize
cost of line electrical insulation.

Selection and design of the insulation fitting (flange or union) to be used shall be
governed by the requirements of the particular application. Material shall be selected
from standard manufacture items.

EACH REVISION SUPERSEDES PREVIOUS ISSUE, CHANGES ARE INDICATED IN MARGIN BY THE REVISION NUMBER OR A VERTICAL LINE.
This drawing embodies proprietary information of the Consortium. This drawing or the material described thereon may not be copied or disclosed in any form or medium to third parties, or used for other than
the purpose for which it has been provided, in whole or in part, in any manner except as espressly permitted by Consortium
clientfilename: 00-FELE-SP-0024
El Palito Refinery Expansion Project

Document Title Cathodic Protection

Document No. 00-FELE-SP-0024 Page 24 of 38


FWI Revision: C01
FWI Document No. BD0382A-78A4 Date: 03/02/2009

11.1. Pipeline Insulating Locations

11.1.1. Main lines

Shall be insulated from station and terminal structure, river crossings,


and injection connections.

11.1.2. Storage tanks

Shall be insulated from connected buried metallic structure, and


production tankage shall be insulated from government’s system.

11.1.3. Foreign line connections

Shall be insulated from government’s line.

11.1.4. Flow lines

Shall be insulated from wells.

11.1.5. Coated selection

Coated pipelines shall be insulated from adjacent uncoated pipeline


sections.

11.1.6. Buried flanges and above ground flanges

These shall be provided with sufficient insulation to insulate fully each


bolt from both flanges.

11.2. Special Insulating Points

Typical locations that require special insulating provisions are as


follows:

11.2.1. Valves in valve pits

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.

11.2.2. Pier supports

Shall be isolated from pipelines by multiple layers of glass wrapper


saturated with coating material, or sheet insulating material.

EACH REVISION SUPERSEDES PREVIOUS ISSUE, CHANGES ARE INDICATED IN MARGIN BY THE REVISION NUMBER OR A VERTICAL LINE.
This drawing embodies proprietary information of the Consortium. This drawing or the material described thereon may not be copied or disclosed in any form or medium to third parties, or used for other than
the purpose for which it has been provided, in whole or in part, in any manner except as espressly permitted by Consortium
clientfilename: 00-FELE-SP-0024
El Palito Refinery Expansion Project

Document Title Cathodic Protection

Document No. 00-FELE-SP-0024 Page 25 of 38


FWI Revision: C01
FWI Document No. BD0382A-78A4 Date: 03/02/2009

11.2.3. Cross lines and parallel lines

A minimum space of 305 mm (12 in.) shall be provided between cross


lines for insulating purposes. When this spacing cannot be obtained,
insulation assurance can be obtained by using sheer insulating
material such as miscast. Thickness of insulating sheet will be
governed by distance between lines, but should not be less than 6.35
mm (1/4 in.). When practical the space between parallel lines 6” and
larger should be a minimum of 2–1/2 times the diameter of the largest
line.

11.2.4. Electrical ground connections and conduit

Shall be isolated from coated pipeline sections. Bare copper ground


cables shall be spaced at least 305 mm (12 in.) from other buried
dissimilar metallic structures.

11.2.5. Public utility lines

Sewer, gas and electricity lines shall be insulated from government’s


buried metallic structures.

11.2.6. Buried dissimilar metallic structures

Shall be insulated from each other.

12. PROTECTION FROM STRAY ELECTRIC CURRENTS

Corrosion prevention design of all buried metallic structures shall


minimize the probability of stray electric currents flowing between
existing and/or proposed facilities. Adequate coatings and/or insulation
shall be provided at anticipated trouble points to minimize the flow of
stray currents. Design shall normally incorporate appropriate bond
circuits between buried metallic structures to prevent the corrosive
effect of stray electric currents.

12.1. Typical Bond Application

12.1.1. Cathodic protection currents

Shall be controlled to prevent stray 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.

EACH REVISION SUPERSEDES PREVIOUS ISSUE, CHANGES ARE INDICATED IN MARGIN BY THE REVISION NUMBER OR A VERTICAL LINE.
This drawing embodies proprietary information of the Consortium. This drawing or the material described thereon may not be copied or disclosed in any form or medium to third parties, or used for other than
the purpose for which it has been provided, in whole or in part, in any manner except as espressly permitted by Consortium
clientfilename: 00-FELE-SP-0024
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Document Title Cathodic Protection

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FWI Revision: C01
FWI Document No. BD0382A-78A4 Date: 03/02/2009

12.1.2. Alternating currents

Where stray 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, especially 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.

12.1.3. Lead sheath cable currents

Bonds shall be provided at each end of conduit runs to insure non–


demanding flow of cathodic protection currents. Lead, aluminum and
zinc, if exposed to a severe alkaline environment, will corrode rapidly,
even if cathodically protected. Thus, these metals must be maintained
at a potential below 1.2 volts to copper sulphate to prevent build–up of
cathodic protection caused by alkaline products. In cases where higher
potentials, occur, specially designed resistance bonds are required.

12.2. Typical Bond Circuits

12.2.1. Soil bond

A solid low resistance metallic circuit that electrically connects the


offending and offended structures

12.2.2. Resistance bond

Similar to solid bond except that a resistor is placed in the circuit to


restrict the operating bonds current.

12.2.3. Electrolytic bond

Similar to resistance bond except 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 electrolytic resistance.

12.2.4. Surge gap bond

Similar to resistance bond except that an air gap resistance is used in


place of the resistor.

EACH REVISION SUPERSEDES PREVIOUS ISSUE, CHANGES ARE INDICATED IN MARGIN BY THE REVISION NUMBER OR A VERTICAL LINE.
This drawing embodies proprietary information of the Consortium. This drawing or the material described thereon may not be copied or disclosed in any form or medium to third parties, or used for other than
the purpose for which it has been provided, in whole or in part, in any manner except as espressly permitted by Consortium
clientfilename: 00-FELE-SP-0024
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Document Title Cathodic Protection

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FWI Revision: C01
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12.2.5. 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.

12.2.6. Rectifier bond

Independent cathodic protection rectifiers connected to a common


ground bed.

13. INSULATING FITTINGS PROTECTION SYSTEMS

13.1. Insulating Flange Electrical Surge Gap

Where application requirements allow, flange insulation may be


protected by the installation of an electrical surge gap within the
flange’s bolting system at the time of flange assembly. An electrolytic
bond such as pre–fabricated zinc anode grounding cell may be used to
protect the flange insulation.

13.2. Lighting Arrestor Assembly

Where electrical surge gap or electrolytic bond assemblies are


impractical on flanges and on all insulated unions, a lightning arrestor
assembly shall be connected as a shunt across the insulated flange.
The arrestor shall be housed in a protective junction box at an
accessible above ground location that is readily available for
maintenance checks.

13.3. Alternating Currents

Electrolytic bonds, such as a prefabricated zinc anode-grounding cell,


shall be provided across insulating flanges where it is desirable to
insulate the direct current only.

EACH REVISION SUPERSEDES PREVIOUS ISSUE, CHANGES ARE INDICATED IN MARGIN BY THE REVISION NUMBER OR A VERTICAL LINE.
This drawing embodies proprietary information of the Consortium. This drawing or the material described thereon may not be copied or disclosed in any form or medium to third parties, or used for other than
the purpose for which it has been provided, in whole or in part, in any manner except as espressly permitted by Consortium
clientfilename: 00-FELE-SP-0024
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Document Title Cathodic Protection

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FWI Revision: C01
FWI Document No. BD0382A-78A4 Date: 03/02/2009

14. GALVANIC COUPLES

Dissimilar metals 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 service. Metals having the least potential
differences shall be selected when galvanic coupling becomes
necessary.

14.1. Protection Methods

Where contact between dissimilar metals can occur as with galvanized


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.

14.2. Corrosion Rate

The magnitude and direction of current flow between dissimilar


materials in a conducting solution determine the corrosion rate on a
coupling member.

EACH REVISION SUPERSEDES PREVIOUS ISSUE, CHANGES ARE INDICATED IN MARGIN BY THE REVISION NUMBER OR A VERTICAL LINE.
This drawing embodies proprietary information of the Consortium. This drawing or the material described thereon may not be copied or disclosed in any form or medium to third parties, or used for other than
the purpose for which it has been provided, in whole or in part, in any manner except as espressly permitted by Consortium
clientfilename: 00-FELE-SP-0024
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Document Title Cathodic Protection

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FWI Revision: C01
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15. MATERIAL AND EQUIPMENT STANDARDS

15.1. General

This section will provide the basic criteria, including quality control and
acceptance testing, for material and equipment required for cathodic
protection facilities associated with the handling of crude oil, crude oil
products, water and other materials transported by pipeline or
associated facility. Unless otherwise specified, only the latest editions
of referenced standards shall be used. Materials used shall comply
with all applicable local regulatory requirements.

15.2. Rectifiers

Shall conform to NEMA Standard MR 20 for semi–conductor rectifiers


– cathodic protection units.

15.2.1. Case (or Housing)

Adequately sized cases shall be small arms proof and tamper


resistant. They will be properly galvanized or coated to resist
atmospheric corrosion. Oil immersed cases shall be pressure tested
for leaks, and air cooled units shall be screened to prevent insect
entry. If located outdoor, the enclosure housing shall be NEMA 4X.

15.2.2. Interior frame

Component parts shall be mounted so that all connections are


accessible. Oil immersed rectifiers shall contain a removable frame
upon which immersed parts are mounted. In general, galvanized steel
or other atmospheric corrosion prevention coatings shall be used for
the interior frame and bolts in air–cooled rectifiers.

15.2.3. Transformers

There shall be a separate transformer for each electrical phase used in


the rectifier.

15.2.4. Rectifying assemblies

All rectifiers shall contain full–Wave Bridge connected rectifying


assemblies mounted to minimize heat transfer to the rectifying
elements.

EACH REVISION SUPERSEDES PREVIOUS ISSUE, CHANGES ARE INDICATED IN MARGIN BY THE REVISION NUMBER OR A VERTICAL LINE.
This drawing embodies proprietary information of the Consortium. This drawing or the material described thereon may not be copied or disclosed in any form or medium to third parties, or used for other than
the purpose for which it has been provided, in whole or in part, in any manner except as espressly permitted by Consortium
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15.2.5. 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. Solid copper bars shall be used to prevent oil
siphoning on wires.

15.2.6. Instruments

Rectifiers shall have readily accessible direct current voltmeters and


external shunt type ammeters.

In areas with a high frequency of lightning strikes, knife switches will


be added to the meter circuits allowing meter isolation when not in use.

15.2.7. Ratings

Unless otherwise specified, all units shall be rated for maximum 45°
(113 °F) ambient temperature.

15.2.8. Circuit diagram and parts list

Circuit diagrams parts lists shall be furnished with each rectifier by


vendor.

15.2.9. Protective devices

Manually operated circuit breakers or magnetic starters with properly


sized instantaneous and time delay trips shall be used for controlling
the rectifiers.

15.2.10. Transformer oil

Non–detergent, non–inhibited transformer oil is required for rectifier


use because transformer oil detergents and inhibitors attack Selenium,
the major component in most cathodic protection rectifiers.

15.2.11. Special auxiliary futures

Remotely located units require a DC system failure detector consisting


of a visible light driven by a DC magnetic relay.

Special input frequencies, silver–plates connections, lightning


protection, constant current transformation, etc. shall be specified
where required by design.

EACH REVISION SUPERSEDES PREVIOUS ISSUE, CHANGES ARE INDICATED IN MARGIN BY THE REVISION NUMBER OR A VERTICAL LINE.
This drawing embodies proprietary information of the Consortium. This drawing or the material described thereon may not be copied or disclosed in any form or medium to third parties, or used for other than
the purpose for which it has been provided, in whole or in part, in any manner except as espressly permitted by Consortium
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Document Title Cathodic Protection

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FWI Revision: C01
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15.2.12. Foundations for base mounted units

Shall conform to the requirements of civil design specifications.

15.3. Impressed Current Ground Beds

15.3.1. 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 other
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,
each anode shall be encased with well-compacted soft coal or
calcinated petroleum coke breeze screened to proper particle size
requirements.

15.3.2. 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 #1/0 or #1/0 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


juncture. 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.

15.3.3. Shunts and shunt boxes

Current measuring shunts – 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 from the soil.

EACH REVISION SUPERSEDES PREVIOUS ISSUE, CHANGES ARE INDICATED IN MARGIN BY THE REVISION NUMBER OR A VERTICAL LINE.
This drawing embodies proprietary information of the Consortium. This drawing or the material described thereon may not be copied or disclosed in any form or medium to third parties, or used for other than
the purpose for which it has been provided, in whole or in part, in any manner except as espressly permitted by Consortium
clientfilename: 00-FELE-SP-0024
El Palito Refinery Expansion Project

Document Title Cathodic Protection

Document No. 00-FELE-SP-0024 Page 32 of 38


FWI Revision: C01
FWI Document No. BD0382A-78A4 Date: 03/02/2009

15.3.4. Cable splicing materials

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 splice. Typical materials
are:

- Appropriately sized copper solder lug.


- 50% tin – 50% lead solder with non–corrosive flux
- Pressure sleeve connectors

15.3.5. 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.
- Individualized epoxy insulating compound kits.
- Two component cold cured epoxy.

15.3.6. Other

Canvas based phenolic such as Miscast, Bakelite or Synthane type


insulating board material shall be used for special insulating problems
such as positioning bolted connections in above ground junction
boxes.

15.3.6.1. 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.

15.3.6.2. Concrete

Material requirements for concrete and its contents are given in related
Job Specification, N° 00-FSTC-SP-0005.

EACH REVISION SUPERSEDES PREVIOUS ISSUE, CHANGES ARE INDICATED IN MARGIN BY THE REVISION NUMBER OR A VERTICAL LINE.
This drawing embodies proprietary information of the Consortium. This drawing or the material described thereon may not be copied or disclosed in any form or medium to third parties, or used for other than
the purpose for which it has been provided, in whole or in part, in any manner except as espressly permitted by Consortium
clientfilename: 00-FELE-SP-0024
El Palito Refinery Expansion Project

Document Title Cathodic Protection

Document No. 00-FELE-SP-0024 Page 33 of 38


FWI Revision: C01
FWI Document No. BD0382A-78A4 Date: 03/02/2009

15.4. Galvanic Anodes

15.4.1. Anode material

In low resistance soils (less than 1,500 ohm–centimetre) zinc or


standard magnesium anodes shall be used in series with a suitable
resistor.

15.4.2. Anode Backfill

All galvanic anodes used for soil applications require proper low
resistance drilling mud type backfill material with moisture retention
characteristics to insure dependable anode output.

15.4.3. Anode weight and shape

Anode weight, size and shape shall be chosen from standard


commercially available materials according to individual installation
requirements.

15.4.4. Shunts

Calibrated shunts shall be used to allow evaluation of galvanic anode


maintenance. Where small current outputs are expected, ten millivolt
for 1-ampere (0.01 ohm) shunt should be used. If possible these
shunts should be housed in above ground-galvanized cabinets.

EACH REVISION SUPERSEDES PREVIOUS ISSUE, CHANGES ARE INDICATED IN MARGIN BY THE REVISION NUMBER OR A VERTICAL LINE.
This drawing embodies proprietary information of the Consortium. This drawing or the material described thereon may not be copied or disclosed in any form or medium to third parties, or used for other than
the purpose for which it has been provided, in whole or in part, in any manner except as espressly permitted by Consortium
clientfilename: 00-FELE-SP-0024
El Palito Refinery Expansion Project

Document Title Cathodic Protection

Document No. 00-FELE-SP-0024 Page 34 of 38


FWI Revision: C01
FWI Document No. BD0382A-78A4 Date: 03/02/2009

15.5. Electrical Test Points

15.5.1. 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 cable with polyethylene
insulation suitable for soil burial. Above ground where repeated
readings are required, stub–type terminals made of copper or
aluminum (in sulphur contaminated atmospheres) provide the most
effective, long lasting contact mechanisms.

Test leads shall be brought into adequately sized above ground


galvanized terminal boxes via standard weight rigid galvanized
conduit. In severe atmospheric corrosion areas, plastic conduit and
junction boxes shall be used. Size and number of conductors as
shown in Table C - LOCATION OF ELECTRICAL TEST POINTS FOR
POTENTIAL MEASUREMENT in the National Electrical Code shall
govern conduit size.

15.5.2. Test lead terminal connection

The test lead may be connected to the metallic structure where it is to


serve by either arc-welding, termite welding, brazing, soldering or
bolting. Termite weld connections shall not use powder charges larger
than Cadweld’s No. 15 cartridge or its 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.

15.6. Electrical Insulating Devices and Materials

Standard manufactured insulating devices and materials are required


to insulate coated or cathodically protect structure from adjacent bare,
non–protect metallic structure.

15.6.1. Insulated flanges

Material for gaskets, sleeves and insulating washers shall be Grade C,


or better, canvas based phenolic. Extreme caution shall be exercised
to ensure that any substitute materials are not subject to cold flow,
cracking under extreme temperatures and similar problems.

EACH REVISION SUPERSEDES PREVIOUS ISSUE, CHANGES ARE INDICATED IN MARGIN BY THE REVISION NUMBER OR A VERTICAL LINE.
This drawing embodies proprietary information of the Consortium. This drawing or the material described thereon may not be copied or disclosed in any form or medium to third parties, or used for other than
the purpose for which it has been provided, in whole or in part, in any manner except as espressly permitted by Consortium
clientfilename: 00-FELE-SP-0024
El Palito Refinery Expansion Project

Document Title Cathodic Protection

Document No. 00-FELE-SP-0024 Page 35 of 38


FWI Revision: C01
FWI Document No. BD0382A-78A4 Date: 03/02/2009

All gaskets shall be Maloney Type E (Full Face) or approved


equivalent. Type F (Inside Bolt Circle) may be required where flange
misalignment occurs. All bolts shall have double insulation. In high
lightning strike areas surge gap material may be inserted between the
bolt’s insulating washers.

Gaskets for 20 in. flanges and above shall be faced with neoprene or
have pressure sealing inserts.

15.6.2. Pipeline insulating 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.

15.7. Casing Insulators

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:

15.7.1. Build-up abrasion pads

Pipelines coated with asphalt enamel, coal tar enamel and “Somatic”
materials 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.

15.7.2. Mechanical

Plastic or neoprene insulating devices shall be used for insulating


pipelines from support pads. The following material requirements apply
in their selection:

15.7.2.1. Pipe Sized Through 12–inch

Glass reinforced epoxy or polyester molded insulators such as


Maloney No. 57 or Plastic Products, Inc. non–conductive casing
insulator or equivalent shall be used.
Non–reinforced material or other plastics should not be used because
of undesirable “cold flow” characteristics.

EACH REVISION SUPERSEDES PREVIOUS ISSUE, CHANGES ARE INDICATED IN MARGIN BY THE REVISION NUMBER OR A VERTICAL LINE.
This drawing embodies proprietary information of the Consortium. This drawing or the material described thereon may not be copied or disclosed in any form or medium to third parties, or used for other than
the purpose for which it has been provided, in whole or in part, in any manner except as espressly permitted by Consortium
clientfilename: 00-FELE-SP-0024
El Palito Refinery Expansion Project

Document Title Cathodic Protection

Document No. 00-FELE-SP-0024 Page 36 of 38


FWI Revision: C01
FWI Document No. BD0382A-78A4 Date: 03/02/2009

15.7.2.2. Pipe Sizes above 12–inch

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: (1) glass reinforced
epoxy or polyester such as Maloney Type PF or (2) canvas based
phenolic such as SP1 A8 and A12 or Maloney 63 and 59. Minimum
width of insulator shall be 203 mm (8 min.) with the more durable 305
mm (12 in.) 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. Equivalent insulation
material is acceptable.

15.7.3. 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 wrap around
seal will serve depending upon characteristics of the pipeline system
involved.

15.8. Galvanic Couples

Dissimilar metallic components assembled according to


manufacturer’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.

EACH REVISION SUPERSEDES PREVIOUS ISSUE, CHANGES ARE INDICATED IN MARGIN BY THE REVISION NUMBER OR A VERTICAL LINE.
This drawing embodies proprietary information of the Consortium. This drawing or the material described thereon may not be copied or disclosed in any form or medium to third parties, or used for other than
the purpose for which it has been provided, in whole or in part, in any manner except as espressly permitted by Consortium
clientfilename: 00-FELE-SP-0024
El Palito Refinery Expansion Project

Document Title Cathodic Protection

Document No. 00-FELE-SP-0024 Page 37 of 38


FWI Revision: C01
FWI Document No. BD0382A-78A4 Date: 03/02/2009

Table C - LOCATION OF ELECTRICAL TEST POINTS FOR POTENTIAL MEASUREMENT

LOCATION TEST REMARKS


POINTS
1.Coated pipeline, cased, at roads,
railways, canals:
Casings – less than 45.7 m (150’) in Measurement of pipe to soil and casing to
length 1 soil potentials.
Casing – 45.7 m (150’) and greater in
Measurement of pipe to soil and casing to
length 2 soil potentials at each end of casing
2.Coated pipeline, greater than 762 m Measurement of pipe to soil potential near
1
(2500’) between casings center
3.Long bare pipeline sections 1 km Measurement of pipe to soil potential
intervals
4.Long bare pipeline section being 0,5 km Measurement of pipe to soil potential
cathodically protected intervals
5.Pipeline near foreign owned rectifier Measurement of pipe to soil potential
2
ground bed where pipe enters and leaves anodic field
6.Pipeline opposite government owned Measurement of pipe to soil potential
rectifier ground bed within 305 m (1000’) 1
of line
7.Joint interference at crossing of foreign Requires prior approval of regulatory
1
line agency and foreign company
8.Insulated flanges or couplings 2 One on each side
9.Main line riser 1 Adjacent ground junction with riser
10.Buried structure opposite galvanic Measurement of structure to soil potential
1
anode battery
11.Dissimilar metal systems near ground Measurement of buried structure to soil
bed potential on affected metal as galvanized
1
conduit, iron sewer lines, copper ground
cables, steel anchors, etc.

EACH REVISION SUPERSEDES PREVIOUS ISSUE, CHANGES ARE INDICATED IN MARGIN BY THE REVISION NUMBER OR A VERTICAL LINE.
This drawing embodies proprietary information of the Consortium. This drawing or the material described thereon may not be copied or disclosed in any form or medium to third parties, or used for other than
the purpose for which it has been provided, in whole or in part, in any manner except as espressly permitted by Consortium
clientfilename: 00-FELE-SP-0024
El Palito Refinery Expansion Project

Document Title Cathodic Protection

Document No. 00-FELE-SP-0024 Page 38 of 38


FWI Revision: C01
FWI Document No. BD0382A-78A4 Date: 03/02/2009

Table D - LOCATION OF ELECTRICAL TEST POINTS FOR CURRENT MEASUREMENT

LOCATION TEST POINTS REMARKS


1. Rectifiers and galvanic anode batteries 1 Measurement of total current output

2.Ground bed connected to rectifier Measurement of individual ground


1
bed
3. Power anode 1 Measurement of anode output
4. Buried metallic structure Measurement of return current from
1 each structure connected to negative
side of cathodic protection unit
5. Negative rectifier lead connected to Measurement of current magnitude
1
buried structure and direction flowing in the structure
6. Long coated pipeline sections Max 10 km Measurement of cathodic protection
intervals current flow
7. Insulated flanges Measurement of possible current
1
flow
8. Pipelines operated by other Measurement of current magnitude
At practical points and direction where ownership or
operational jurisdiction changes
9.Long inaccessible pipeline sections Measurement of currents entering
and leaving sections such as major
2
water crossings and congested
areas
10.Interfering and/or straying currents Measurement of current as required
As required
for specific instance

EACH REVISION SUPERSEDES PREVIOUS ISSUE, CHANGES ARE INDICATED IN MARGIN BY THE REVISION NUMBER OR A VERTICAL LINE.
This drawing embodies proprietary information of the Consortium. This drawing or the material described thereon may not be copied or disclosed in any form or medium to third parties, or used for other than
the purpose for which it has been provided, in whole or in part, in any manner except as espressly permitted by Consortium
clientfilename: 00-FELE-SP-0024

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