PDVSA 00-FELE-SP-0024 - 2009 - Carhodic Protection
PDVSA 00-FELE-SP-0024 - 2009 - Carhodic Protection
PDVSA 00-FELE-SP-0024 - 2009 - Carhodic Protection
REVISION INDEX
Initial issue
X Entire specification reissued
Revised pages only attached
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TABLE OF CONTENTS
1. GENERAL .....................................................................................................................................6
5. REQUIREMENTS ........................................................................................................................10
6. DESIGN .......................................................................................................................................13
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TABLES INDEX
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ATTACHED DOCUMENTS
Job Specifications
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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.
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2.2.1. US Codes
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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”.
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The Cathodic Protection will be used for equipment, piping and structures protection
as hereafter indicated in the following table:
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
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
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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:
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 :
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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.
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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:
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
5.1.9. The Vendor shall provide “as built” drawings of the installation.
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6. DESIGN
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.
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.
6.1.3.1. Location
The temporary ground bed shall be located at the site selected for the
proposed permanent facility.
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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.
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The single pin method will be acceptable only when the four-pin
method cannot be used because of space or other limitations.
Proposals shall:
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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.
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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.
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8.1. Location
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.
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:
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.
8.3.1. 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.
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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.
8.5.1. 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.
- 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.
8.6.1. 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.
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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
9.1.2. 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
9.2.2. 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
9.3.2. Zinc anodes shall be used only in low resistance soils and where low current
outputs and resultant low solution potentials are tolerable.
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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.
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.
10.1.1. Location
10.2.1. Location
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.
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.
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.
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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
15.2.3. Transformers
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15.2.6. Instruments
15.2.7. Ratings
Unless otherwise specified, all units shall be rated for maximum 45°
(113 °F) ambient temperature.
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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.
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15.3.5. Insulation
- 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
15.3.6.1. Casing
15.3.6.2. Concrete
Material requirements for concrete and its contents are given in related
Job Specification, N° 00-FSTC-SP-0005.
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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.
15.4.4. Shunts
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15.5.1. General
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Gaskets for 20 in. flanges and above shall be faced with neoprene or
have pressure sealing inserts.
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
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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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El Palito Refinery Expansion Project
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
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
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