17-SAMSS-007

Materials System Specification 17-SAMSS-007

31 December 2011 2011

Impressed Current Anodes for Cathodic Protection Document Responsibility: Cathodic Protection Standards Committee

Saudi Aramco DeskTop Standards Table of Contents

1 Scope............................................................. 2 2

Conflicts and Deviations............... Deviations..... ................... .................. ......... 2

3 References..................................................... 2 4 General........................................................... 3 5

Manufacturer's Technical Qualifications......... Qualifications. ........ 5

6 Design............................................................ 6 7

Inspection and Factory Tests................. Tests....... .................. ........ 9

8

Packing and Shipping................... Shipping....... ....................... ............... .... 11

Previous Issue: 17 January 2007 Next Planned Update: 31 December 2016 Revised paragraphs are indicated in the right margin Primary contact: contact: Zubail, Saleh Abdullah Abdullah on +966-3-8809599 Copyright©Saudi Aramco 2011. All rights reserved.

Page 1 of 12

Document Responsibility: Cathodic Protection Standards Committee 17-SAMSS-007 Issue Date: 31 December 2011 Next Planned Update: 31 December 2016 Impressed Current Anodes for Cathodic Protection

1

Scope This specification together with the Purchase Order covers the minimum requirements for impressed current anodes (with or without cables) for cathodic protection. Applications include offshore, nearshore and onshore installations.

2

3

Conflicts and Deviations 2.1

Any conflicts between this specification and other applicable Saudi Aramco Materials System Specifications (SAMSSs), Engineering Standards (SAESs), Standard Drawings (SASDs), or industry standards, codes, and forms shall be resolved in writing by the Company or Buyer Representative through the Manager of the Consulting Services Department of Saudi Aramco, Dhahran.

2.2

Direct all requests to deviate from this specification in writing to the Company or Buyer Representative, who shall follow internal company procedure SAEP-302 and forward such requests to the Manager of the Consulting Services Department of Saudi Aramco, Dhahran.

References Materials or equipment supplied to this specification shall comply with the latest edition of the references listed below, unless otherwise noted. 3.1

Saudi Aramco References Saudi Aramco Engineering Procedure SAEP-302

Instructions for Obtaining a Waiver of a Mandatory Saudi Aramco Engineering Requirement

Saudi Aramco Materials System Specification 17-SAMSS-017

Impressed Current Cathodic Protection Cables

Commentary Note: If anodes are ordered with attached cables, 17-SAMSS-017 shall be attached to the Purchase Order.

Saudi Aramco Standard Drawings AB-036008

Offshore-Mixed Metal Oxide Anode for Pile Mounting

AA-036304

Offshore-Installation Details for Pile Mounted Anodes Page 2 of 12


Saudi Aramco Inspection Requirement 175-171400 3.2

Impressed Current Anodes

Industry Codes and Standards American Society for Testing and Materials ASTM B338

Seamless and Welded Titanium and titanium Alloy Tubes for Condensers and Heat Exchangers

Deutsches Institute for Normung e.V. DIN STD 17866

4

Welded Circular Titanium and Titanium Alloy Tubes

General 4.1

Terms and Definitions The following terms are used in this specification: Anode: Where used in this specification, the term “Anode” shall refer to a Impressed current anode. Lead Wire: Where used in this specification, the term “Lead Wire” shall refer to a cable directly connected to an anode. Buyer: Saudi Aramco Purchasing Department Representative. Buyer's Representative : The person or persons designated by the Purchasing Department to monitor/enforce the contact. CSD: Consulting Services Department. Manufacturer : The Company that manufactures the anode. Reference Electrodes : Standard silver/silver chloride (Ag/AgCl/0.6M Cl) reference cells. SME: Subject Mater Expert for Cathodic Protection Materials in CSD

4.2

Site Conditions 4.2.1

Onshore Temperature

0ºC to 80ºC

pH

1 to 8

Chloride Content

Up to 31,000 ppm Page 3 of 12


4.2.2

4.2.3

Offshore Temperature

10ºC to 80ºC

pH – No Chlorine Gas

6 to 8

pH – Chlorine Gas

1 to 8

Water Velocity

Up to 1.5 m per second

Special Applications Special applications such as inside storage tanks o r process equipment may present different or extreme operating conditions. If so, the expected conditions shall be specified in the purchase order.

4.3

Manufacturer Technical Document Submittals 4.3.1

The English language shall be used on all documents, drawings, labels, etc.

4.3.2

Technical Documents for Manufacturer Prequalification to Supply Material The Manufacturer shall submit the following documents to the Saudi Aramco Strategic Sourcing Division:

4.4

a)

Manufacturer's material specification.

b)

Manufacturer certified drawings showing all dimensions and details.

c)

Manufacturer certified test data for the electrochemical properties and chemical composition confirming compliance with Section 6 of this specification.

d)

Submit the specification of individual components of impressed current anode.

Ordering Information The following shall be included with the Purchase Order: ●

Type of anode material

●

Net anode material mass

●

4.5

Critical dimensions, e.g., length and diameter

Manufacturer Document Submittals The Manufacturer shall submit the following documents. Any proposed Page 4 of 12


alternative designs in addition to the require design shall be clearly described in these submittals. a)

Manufacturer's name.

b)

Nominal and maximum anode output current capacity.

c)

Anode material composition.

d)

Test data and certificate of compliance with Section 6.

e)

Certified drawings, fully dimensioned and scaled, showing details of anode assembly.

f)

Anode cable material specification and construction details.

g)

Anode cable connection procedures with scaled drawing, including details of assembly and tools required.

h)

Restrictions for use in adverse environments.

Submittal of the above documents will not be required on repeat orders. However, if any modifications are made to the previously supplied (approved) materials, then all relevant data shall be resubmitted to the Saudi Aramco Subject Matter Expert (SME). 4.6

Labeling Each anode shall be labeled with the following information on waterproof paper tag with waterproof ink or using white traffolyte with black letters: ●

Type of Anode

●

Anode Dimensions

●

Date of Manufacture and Heat Number

●

Purchase Order Number

●

Manufacturer (anode and cable)

●

5

Saudi Aramco Material Number

Manufacturer's Technical Qualifications Impressed current anodes shall be supplied only by the manufacturers technically prequalified by Saudi Aramco. To qualify, the manufacturer shall have done the following: a)

Assembled at least ten of the anodes of the type proposed.

b)

Tested at least one of the assembled anodes according to Sections 6.3 and 7, in the presence of a Saudi Aramco Inspector.

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c)

Submitted samples of the individual components of the impressed current anode.

d)

Submitted Test reports, certificates, and detailed fabrication drawings.

These documents shall have sufficient details to satisfy the Manager, Consulting Services Department of Saudi Aramco or his delegate, that the anode will perform as required.

6

Design 6.1

Anodes 6.1.1

Silicon Iron Anodes 6.1.1.1

6.1.2

Silicon iron anodes shall be of tubular construction, and shall be designed for center cable connection and shall have the following composition: Silicon

14.20 - 14.75%

Manganese

1.50% maximum

Carbon

0.75 - 1.15%

Chromium

3.25 - 5.0%

Copper

0.5% maximum

Molybdenum

0.2% maximum

Iron

Remainder

6.1.1.2

Prepackaged anodes shall have two lifting eyes or polypropylene rope handles installed at the cable end to allow for vertical installation.

6.1.1.3

Prepackaged anodes shall have a wooden end cap installed at the cable end.

6.1.1.4

Prepackaged anodes are to be compressed by the “Drop-Lift” method. Compression shall be sufficient to ensure no additional compression or fill shrinkage/settlement occurs during transportation.

Platinized Anodes 6.1.2.1

Platinized Anodes shall be rod types and have a platinum coating with a minimum thickness of 5.0 microns on one of the following substrates: ●

solid niobium

●

niobium clad over copper core Page 6 of 12


6.1.3

6.1.2.2

Platinum and substrate material thickness shall be certified in writing.

6.1.2.3

During anode construction the anode shall always be supported or held with a non-metallic attachment, which will not scratch or abrade the anode.

Mixed Metal Oxide Anodes 6.1.3.1

Mixed Metal Oxide Anodes shall be constructed of a titanium base and the external surface shall be covered with a layer of mixed metal oxides. The thickness of the MMO layer shall depend on the application environment.

6.1.3.2

For the tubular anode, seamless grade 1 titanium shall be used as the base material with a wall thickness range of 0.9 to 1.1 mm. Tubular anodes shall have an outside diameter of 25.4 mm.

6.1.3.3

The metal oxide layer shall be applied over the titanium substrate by thermal decomposition and shall be composed of oxides of metals from Group IV, V, VIII and IX or a combination of these groups of the periodic table of elements. But mainly IrO2 (Iriduim Oxide)/Ta2O5 (Titanium Oxide). Properties of the mixed metal oxide layer shall include the following:

6.1.3.4 6.2

a)

A crystalline structure with a density ranging between 6 and 12 grams per cubic cm.

b)

Electrical resistivity in the range of nine (9) to eleven (11) micro ohm-cm.

All bare titanium surfaces in possible contact with the electrolyte shall be coated with MMO.

Anode Cables Anode cables when ordered attached to silicon iron, platinized or mixed metal oxide anodes (described in paragraphs 6.1.1, 6.1.2 or 6.1.3) shall be specified in the Purchase Order and shall comply with the requirements of 17-SAMSS-017.

6.3

Anode-to-Cable Connections 6.3.1

The cable connection to the silicon iron anodes shall be designed to withstand a force strong enough to break the cable or withstand a minimum pulling force of 350 kg which ever happens first. Page 7 of 12


6.3.2

Silicon iron anode cables shall be attached to the anode connector by means of brazing or soldering. ●

If a compression connector is used, the connection shall be soldered after compressing.

●

If a Wedge-Lock (TM) connector is used, soldering or brazing is not required. The cable shall be dipped in a tinning pot, then immediately placed in its sleeve and crimped. The cable and the sleeve connections shall be crimped with a hydraulic tool that applies a constant 10 to 12 tons of force to each crimp.

●

A 2 meter long (maximum No.16 AWG) test wire shall be integrated into the connection of the anode cable to the anode to be used for testing the quality of the anode connection (see paragraph 7.2 of this specification).

6.3.3

The cable-to-anode encapsulation scheme shall incorporate a moisture seal designed to last the life of the anode operating at rated current output.

6.3.4

For silicon iron anodes, a minimum of 1 meter of black semi-flexible, radiation cross-linked, adhesive coated on the internal diameter, heat shrinkable polyolefin sleeve (1.5 mm wall thickness minimum – after shrinking) shall be installed over the anode cable at the end connected to the anode. A minimum of 13 cm of heat shrink tubing shall be encapsulated inside the anode. A heat shrinkable, mastic filled 'CAP' will then be installed over the tubing and the end of the anode.

6.3.5

For platinized anodes, the anode cable shall be connected to the end of the anode by brazing or soldering. The cable-to-anode connection shall be protected by a heat shrink sleeve and encapsulation. The sleeve and encapsulation must be resistant to chlorine gas. A heat shrinkable, mastic filled 'CAP' will then be installed over the tubing and the end of the anode.

6.3.6

The mixed metal oxide tubular anodes shall have the anode-to-cable connection per the manufacturers recommendation, and two sealing connections; one each end of the tube. The anode-to-cable connection shall be done without breaking the conductor, maintaining the electrical continuity of the conductor. There shall be no visible cracks in the titanium tube after this operation has been completed.

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7

6.3.7

For tubular MMO anode, a Teflon sleeve shall be installed between the mixed metal oxide tube seal and the cable insulation at each anode end. The Teflon sleeve shall extend to 25.4mm over the anode end and 300mm from the anode end over the cable.

6.3.8

Anode-to-cable resistance shall not exceed 0.001 ohms.

6.3.9

Requirements for pile mounting of mixed metal oxide tubular anodes shall be in accordance with Standard Drawing AB-036304.

6.3.10

For the PYRAMID anode, anode-to-cable connection shall be sealed by “O” rings, epoxy resin and a cable gland. Cable shall be anchored by a separate double-seal cable gland.

6.3.11

A heat shrink sleeve shall be installed on the anode cable and the sleeve should completely cover the cable gland.

Inspection and Factory Tests 7.1

Inspection The manufacturer shall implement and maintain a quality control program which shall include clearly defined and documented procedures for the relevant quality assurance functions. The quality control documents shall be made available to the Buyer Representative for review and inspection. The items manufactured to this Specification are also subject to verification by the Buyer's Inspector per Saudi Aramco Inspection Requirements Form 175-171400 attached to the Purchase Order.

7.2

Testing Anode-to-Cable Connections 7.2.1

The cable to anode resistance of each silicon iron anode shall be tested as follows: a)

Before the connection is potted and sealed, pass a DC current of approximately 40 amperes from the free end of the anode cable to the bottom end of the anode. Measure the voltage drop from the end of the test wire to the top (head) of the anode. Calculate the cable contact resistance by applying equation (1), shown below. At 40 amps, the measured voltage drop must be less than 40 millivolts. R (ohms)

Voltage Drop (V) 

AppliedCurrent (A)

(1)

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7.3

b)

The resistance of the cable connection shall not exceed 0.001 ohms. A connection resistance higher than 0.001 ohms shall constitute rejection.

c)

After the contact resistance measurement has been completed, cut the measurement wire at the head of the anode, and push it down inside so as not to interfere with the potting and sealing process.

7.2.2

The entire length of non-armored anode cable shall be 100% holiday free. Testing of the cable insulation shall be completed using a pulsetype holiday detector. Test voltage shall be set to 18,000 D.C. volts. Any flaws shall constitute rejection.

7.2.3

For the PYRAMID anodes only, the cable to anode connection resistance shall be tested as follows: a)

A millivolt meter with a resolution not in excess of 0.1 mV shall be connected between the anode and the anod e-end of the cable core.

b)

A current of 40 amperes D.C. shall be passed through the anodeto-cable connection from the free end of the cable.

c)

The voltage-drop across the anode-to-cable connection shall, for each anode, be measured and recorded. An anode-to-cable voltage drop in excess of 0.04 volts shall constitute a failure and the assembly shall be rejected.

Testing Metal Oxide Anodes 7.3.1

The manufacturer shall provide a “certificate of compliance” to ASTM B338 or DIN STD 17866 for the grade 1 titanium material, and for meeting the requirements of Section 6.1.3.3 for MMO material with each order of anodes.

7.3.2

The anode-to-cable seal for tubular MMO anodes shall be tested by the following procedure: a)

After the cable is cut to length but before the anode end is sealed, the annular space between the conductor and the primary insulation shall be pressurized to 200 kPa gage (2 atmospheres) with helium gas. The opposite end of the cable is then “sniffed” by means of a mass spectroscopy detector to insure that the helium is passing through the entire length of cable.

b)

After the anodes have been crimped onto the cable, the annular space between the conductor and the primary insulation shall Page 10 of 12


again be pressurized to 200 kPa with helium. Each anode-tocable seal shall be “sniffed” for helium with a mass spectroscopy detector. If any helium is detected, the assembly shall be rejected. 7.3.3

8

The anode-to-cable seal for PYRAMID anodes shall be tested by the following procedure: a)

The anode to spool connections shall be made up incorporating all the “O” rings seals and cable gland as detailed in the approved Drawing(s).

b)

The pneumatic test apparatus as detailed in the approved Manufacturer’s Drawing(s) shall be connected to the anode spool assembly.

c)

The pneumatic test apparatus shall be pressurized to 6 atmospheres.

d)

The anode/spool assembly shall be completely immersed in a water containment chamber, as detailed in the approved Manufacturer’s Drawing(s). Visual examination of the anode/spool assembly shall determine any evidence of the emission of air bubbles.

e)

Each anode-to-spool-to-cable seal shall be tested via water immersion procedure described above. If any evidence of emission of air bubbles is detected, the assembly shall be rejected.

f)

A certificate of compliance for each anode assembly tested shall be provided.

Packing and Shipping The anodes shall be packed on a shock absorbing material such as wood, polyurethane foam, etc. on a pallet or skid sized to accommodate the total anode size. The packing of anodes and attached cable shall be suitable for long term outdoor storage. All anode cables longer than three (3) meters shall be wound on disposable wooden or plastic reels with the reel securely attached to the pallet or skid. The length of the pallet or skid assembly shall exceed the anode length to allow sufficient room for the anode cables or cable reels. Anode cables or cable reels are to be at the end of each anode when shipping; they shall not be stored on top of the anode. Anodes and cables/cable reels shall be securely fastened to the pallet or skid to prevent movement during shipping.

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The final pallet or skid assembly shall allow for an individua l anode to be removed from the pallet or skid without effecting the remaining anodes or anode cables. Total net anode assembly mass per crate shall not exceed 1360 kg (3000 lb).

31 December 2011

Revision Summary Revised the Next Planned Update. Reaffirmed the contents of the document, and reissued with minor changes. Update this materials specification to be in line with the new RVL process requirement and correct the chemical composition properties of the mixed metal oxides layer. “

”

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17-SAMSS-007

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