Impressed Current Cathodic Protection Section

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SECTION

OPENER Impressed Current

2

IMPRESSED CURRENT CATHODIC PROTECTION 2.0 CONTENTS 2.1 Silicon Iron Anodes 2.1.1 Silicon Iron Rod Anodes 2.1.2 Silicon Iron Tubular Anodes

2.2 Mixed Metal Oxide Anodes 2.2.1 Mixed Metal Oxide Tubular Anodes 2.2.2 Mixed Metal Oxide Ribbon Anodes 2.2.3 Mixed Metal Oxide Wire Anodes 2.2.4 Mixed Metal Oxide Mesh & Ribbon Mesh Anodes 2.2.5 Mixed Metal Oxide Anode Accessories 2.2.6 Mixed Metal Oxide Ribbon Mesh Canister Anodes 2.2.7 Mixed Metal Oxide Discrete Mesh Anodes

2.3 Other ICCP anodes 2.3.1 Magnetite Anodes 2.3.2 Graphite Anodes 2.3.3 Platinised Titanium Anodes

2.4 Transformer Rectifiers 2.4.1 Air Cooled / Oil Cooled TR's 2.4.2 Remote Monitoring For TR's

2.5 Junction Boxes 2.5.1 Positive / Negative / Bond Junction Boxes

2.6 ICCP Accessories 2.6.1 Wellhead Assemblies 2.6.2 Carbonaceous Backfill 2.6.3 Cable XLPE/PVC 2.6.4 Cable XLPE/PVC/SWA/PVC 2.6.5 Cable PVDF / HMWPE 2.6.6 Cable Halar / HMWPE 2.6.7 Cable HMWPE 2.6.8 Vent Pipe 2.6.9 Casing Pipe 2.6.10 Splice Kits 2.6.11 Solar Power Units

IMPRESSED CURRENT CATHODIC PROTECTION

DATASHEET 2.1.1

SILICON IRON ROD ANODES REVISION 1 APPLICATION Marine Structures, Seawater Intakes, Deepwell Groundbeds, Horizontal Groundbeds, Distributed Anodes, Tank Internals & Tank Bottoms. Suitable For Use In Soils, Mud, Carbonaceous & Petroleum Coke Backfill; Fresh, Brackish and Sea Water.

SILICON IRON ANODE DATA

CHEMICAL COMPOSITION Normal

Chrome

Silicon

14.50%

14.50%

Manganese

0.75%

0.75%

Carbon

0.85%

0.95%

Chromium

–

4.50%

Iron

Remainder

Remainder

CONSUMPTION RATES Typical Rates Normal Alloy

0.5 kg/Amp/year

Chrome Alloy

0.2 kg/Amp/year

CABLE CONNECTION With Heatshrink Cap

With Heatshrink Sleeve

Anode/Cable Connection : Connection less than 0.001 Ohm

Venture Way, Grantham, Lincs NG31 7XS UK. Tel: +44 (0)1476 590666 Fax: +44 (0)1476 570605 Email: [email protected] Website: www.cathodic.co.uk Registered Office: Minalloy House, Regent Street, Sheffield S1 3NJ, UK VAT No. 116 8408 71, Reg’d in England No. 478098

DATASHEET 2.1.1


DATASHEET 2.1.1

SILICON IRON ROD ANODES REVISION 1 CABLE TYPES Available cable types include : XLPE/PVC, HMWPE, PVDF(Kynar), XLPE/PVC/SWA/PVC, EPR/CSPE

STANDARD ANODE TYPES AND WEIGHTS Type 36/2.0

A

B

C

(in)

(in)

(in)

Surface Area (m2) (ft2)

Approx Wt (kg) (lbs)

36

2.0

3.0

0.16

1.70

14.50

32

2.1

22.30

49

36/2.5

36

2.5

3.5

0.20

36/3.0

36

3.0

4.0

0.23

2.50

31.40

69

48/2.0

48

2.0

3.0

0.20

2.20

19.10

42

48/2.5

48

2.5

3.5

0.25

2.70

28.60

63

48/3.0

48

3.0

4.0

0.30

3.30

40.90

90

60/2.0

60

2.0

3.0

0.25

2.70

22.70

50

60/2.5

60

2.5

3.5

0.32

3.40

35.90

79

60/3.0

60

3.0

4.0

0.38

4.0

50.00

110

60/4.5

60

4.5

4.5

0.55

5.90

99.10

218

CANISTERED ANODES

DATASHEET 2.1.1

Standard Sizes

Standard Gauges

150mmDia x 1500mm L

1.0mm 20bg

200mmDia x 2000mm L

1.2mm 18bg

250mmDia x 2000mm L

1.5mm 18bg

300mmDia x 2000mm L

2.0mm 14bg



DATASHEET 2.1.2

SILICON IRON TUBULAR ANODES REVISION 1 APPLICATION Marine Structures, Seawater Intakes, Deepwell Groundbeds, Horizontal Groundbeds, Distributed Anodes, Tank Internals & Tank Bottoms (not recommended for large diameter tanks). Suitable For Use In Soils, Mud, Carbonaceous & Pet Coke Backfill; Fresh, Brackish and Sea Water

SILICON IRON TUBULAR ANODE DATA

CHEMICAL COMPOSITION Silicon Iron ASTM A518 – 86 Grade 3 Silicon

14.20 – 14.75%

Manganese

1.50% Max

Carbon

0.75 – 1.15%

Chromium

3.25 – 5.00%

Copper

0.50% Max

Molybdenum

0.20%Max

Iron

Remainder

TECHNICAL DATA Tensile Strength (1/2”Dia bar)

15,000 psi

Compressive Strength

100,000 psi

Brinell Hardness

520 bhn

Density

7.0 gr/ml

Melting Point

2,300 ˚F

Consumption Rate

Typical rates – Chrome: 0.2kg/A/yr For CP design a current density of not more than 30A/m2 of anode surface is recommended

Anode/Cable Connection

Centre connection less than 0.001 Ohm resin encapsulated

Cable Types

XLPE/PVC, HMWPE, PVDF(Kynar); XLPE/PVC/SWA/PVC, EPR/CSPE


DATASHEET 2.1.2


DATASHEET 2.1.2

SILICON IRON TUBULAR ANODES REVISION 1 STANDARD ANODE TYPES, WEIGHTS, DIMENSIONS AND OUTPUTS Type

DATASHEET 2.1.2

Average Wt

Approx Area

Outside Dia

Inside Dia

Length

Nominal Discharge

lbs

kgs

ft2

m2

mm

in

mm

in

mm

in

Amps

MS-1

31

14.1

2.4

0.2

71

2.8

45.7

1.8

1067

42

1.5-2.0

MS-2

46

20.9

4.0

0.4

58

2.3

35.6

1.4

2134

84

3.0-4.0

MS-3

63

28.6

4.9

0.5

71

2.8

45.7

1.8

2134

84

3.5-5.0

MS-4

85

39.2

6.9

0.6

96

3.8

74.4

2.9

2134

84

6.0-7.0

MS-5

110

49.9

8.7

0.8

124

4.9

99.0

3.9

2134

84

6.0-8.5



DATASHEET 2.2.1

MIXED METAL OXIDE TUBULAR ANODES REVISION 1 APPLICATION Marine Structures, Seawater Intakes, Deepwell Groundbeds, Horizontal Groundbeds, Distributed Anodes, Tank Internals & Tank Bottoms Suitable For Use In Soils, Mud, Carbonaceous & Pet Coke Backfill; Fresh, Brackish and Sea Water

TUBULAR MMO ANODE DATA

Substrate

Titanium ASTM B338 Grade 1 or 2

Coating

IrO2/Ta2O5

Coating Method

Multi pass thermal decomposition of precious metal salts technique

Diameter

25.4mm

Wall Thickness

0.90mm

Consumption Rate

0.5 - 4.0 mg/A/yr depending upon CP application conditions

Utilisation Factor

Dimensionally Stable

Working Environment

Suitable for Cl2 & O2 or combination of both

Operating Characteristics

Environment

Max Current Density

Life

(A/m2)

(Years)

Carbonaceous Backfill

50

20

Calcined Petroleum Coke

100

20

Freshwater

100

20

Brackish Water

100-300

20

Seawater

600

20

Coating loading can be adjusted for specific lifetime/current density requirement

Cable Types

HMWPE/PVDF(Kynar); XLPE/PVC/SWA/PVC; EPR/CSPE

Maximum 1Cx50mm2

Anode/Cable Connection

Centre connection less than 0.001 Ohm, resin encapsulated & helium tested to prove effective seal


DATASHEET 2.2.1


DATASHEET 2.2.1

MIXED METAL OXIDE TUBULAR ANODES REVISION 1 STANDARD ANODE TYPES, DIMENSIONS AND OUTPUTS Type

OD

Length

Soil (with carbon backfill)

mm

inches

S-2.5/50

25

S-2.5/100

25

FW-2.5/50 FW-2.5/100

Current Output (Typical)

Current Output (Typical)

mm

inches

(Amps from 5-70˚C)

(Amps from 0-5˚C)

1

500

19.7

4

2

1

1000

39.4

8

4

25

1

500

19.7

4

2

25

1

1000

39.4

8

4

SW-2.5/50

25

1

500

19.7

25

5

SW-2.5/100

25

1

1000

39.4

50

10

M-2.5/50

25

1

500

19.7

2-4

1.5

M-2.5/100

25

1

1000

39.4

4-8

3

Fresh Water

Sea Water

Mud (*)

Brackish Water (**)

(Amps from 10-70˚C) (Amps from 0-10˚C)

BW-2.5/50

25

1

500

19.7

4÷12

2÷6

BW-2.5/100

25

1

1000

39.4

8÷24

4÷12

(*) Current outputs in mud depend on site conditions (sea mud or river mud, etc) (**) Current outputs in brackish water depend on site conditions & chloride concentrations.

NOTES • Coating loading may be adjusted to suit a particular current density or design life • Standard anodes are designed for 20 year life, however, design life of up to 50 years can be catered for. • Tubular MMO anode strings can be supplied to Clients specific requirements. • Other tube diameters are available on request,16mm dia & 32mm dia.

DATASHEET 2.2.1


Datasheet 2.2.2

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DATASHEET 2.2.2

MIXED METAL OXIDE RIBBON ANODES REVISION 1 APPLICATION Reinforced Concrete Structures & Tank Bottoms

STANDARD ANODE TYPES, DIMENSIONS AND OUTPUTS APPLICATION

Sand & Concrete

RIBBON MMO DATA

Substrate

Titanium ASTM B338 Grade 1

Coating

IrO2/Ta2O5

Coating Method

Multi pass thermal decomposition of precious metal salts technique

Width (Nom)

0.25” (6.35mm)

Thickness (Nom)

0.025” (0.635mm)

Standard Coil Length

250’ (76.22m)

Standard Coil Weight

2.5lbs (1.12kg)

Surface Area of Ribbon Consumption Rate

0.014m2/m 0.5 - 4.0 mg/A/yr depending upon CP application conditions

Utilisation Factor

Dimensionally Stable

Working Environment

Suitable for Cl2 & O2 or combination of both CURRENT OUTPUT IN FINE SAND 12.8mA/ft (42mA/m) when operating at a current density of 0.278A/ft2 (3A/m2). 50 year design life when operating at a current density of 0.278A/ft2 (3A/m2).

Operating Characteristics CURRENT OUTPUT IN CONCRETE 0.45mA/ft (1.5mA/m) when operating at a current density of 10.19mA/ft2 (110A/m2). 100 year design life when operating at a current density of 10.19mA/ft2 (110A/m2).

Titanium Conductor Bar

Width: 0.50” (12.7mm); Thickness: 0.035” (0.9mm) Coil length: 250’ (76.22m); Coil Weight: 8.5lbs (3.8kg)

Substrate

Titanium ASTM B 265 Grade 1


DATASHEET 2.2.2

Datasheet 2.2.3

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DATASHEET 2.2.3

MIXED METAL OXIDE WIRE ANODES REVISION 1 APPLICATION Tank Bottoms, Tank Internals, Pipeline Internals, Canistered Anodes, Continuous Horizontal Groundbeds, Discontinuous Horizontal Groundbeds, Shallow Vertical Groundbeds, Deep Anode Groundbeds.

STANDARD ANODE TYPES, DIMENSIONS AND OUTPUTS Available in two standard sizes, with two standard current ratings. Other sizes and rating are available upon request. MMO Wire Anode consists of solid titanium wire which meets ASTM B348 Grade 1 or 2 standards, that has been coated with Mixed Metal Oxide.

WIRE ANODES ELECTRICAL RESISTANCE 1.5mm diameter : 75,537 microhms/ft / 247,821 microhms/m 3.0mm diameter : 18,884 microhms/ft / 61,954 microhms/m Approximate electrical resistance @ 25ºC. Mechanical properties are based on typical room temperature.

PIGGYBACK WIRE ANODE SYSTEMS For use on pipelines, the product comprises Mixed Metal Oxide Wire Anode material “piggybacked” to a cable at predetermined intervals (to aid current distribution and attenuation). The wire and cable is contained within a cotton sock filled with calcined petroleum coke breeze backfill. The Piggyback Sock Anode is placed alongside the pipeline with suitable lengths of cable at each end of the loop allowed for termination into a junction box.

PIGGYBACK WIRE SOCK ANODE SYSTEMS For use on pipelines, the product comprises Mixed Metal Oxide Wire Anode material “piggybacked” to a cable at predetermined intervals (to aid current distribution and attenuation). The wire and cable is contained within a cotton sock filled with calcined petroleum coke breeze backfill. The Piggyback Sock Anode is placed alongside the pipeline with suitable lengths of cable at each end of the loop allowed for termination into a junction box.


DATASHEET 2.2.3

Datasheet 2.2.3

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DATASHEET 2.2.3

MIXED METAL OXIDE WIRE ANODES REVISION 1 TYPICAL CABLE TO WIRE SPLICED CONNECTION

TYPICAL WIRE SOCK ANODE ARRANGEMENT

TYPICAL CONCENTRIC PATTERN WIRE ANODE ARRANGEMENT

DATASHEET 2.2.3


Datasheet 2.2.4 85

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DATASHEET 2.2.4

MIXED METAL OXIDE ELGARD 85 RIBBON MESH REVISION 1 ELGARD™ Anode ribbon mesh is composed of a precious metal oxide catalyst sintered to an expanded Titanium mesh substrate. The Anode Ribbon Mesh is used as a key component in the Cathodic Protection of Reinforced Concrete Structures.

MATERIAL SPECIFICATIONS ANODE PERFORMANCE Current rating @ 110 mA/m2 (10 mA/ft2)

2.8 mA/m (0.85 mA/ft)

Expected life (NACE Standard TM02944-94)

75 Years

Catalyst

Iridium Based Mixed Metal Oxide

Maximum anode concrete interface current density FHWA limit

110 mA/m2 (10 mA/ft2)

Short-term limit

220 mA/m2 (20 mA/ft2)

NOMINAL DIMENSIONS Width

10 mm (0.4 ")

Coil length

76 m (250 ft)

Actual anode surface per unit length of anode

0.025 m2/m (0.082 ft2/ft)

Expanded thickness

1.30 mm (0.051 ")

Diamond dimensions

2.5 x 4.6 x 0.6 mm (0.10 " x 0.18 " x 0.025 ")

Shipping weight per coil

1.4 kg (3.1 lbs)

SUBSTRATE Composition

Titanium, Grade 1 per ASTM B265

Coefficient of thermal expansion

8.7 x 10-5/˚K (0.0000048/in/in/˚K)

Thermal conductivity @ 20˚C

15.6W/ m2 - ˚K (9.0BTU/hr/ft2/˚F/ft)

Electrical resistivity

0.000056 Ohm-cm (0.000022 Ohm-in)

Modulus of elasticity

105 GPa (14,900,000 PSI) minimum

Tensile strength

245 MPa (35,000 PSI) minimum

Yield strength


Elongation

24% minimum

CURRENT DISTRIBUTOR Width

12.70 mm (0.5 ")

Thickness

0.90 mm (0.035 ")

Coil length

76 m (250 ft)


3.9 kg (8.6 lbs)

ELECTRICAL PROPERTIES Anode ribbon mesh resistance lengthwise

0.49 Ohm/m (0.15 Ohm/ft)

Current distributor resistance lengthwise

0.049 Ohm/m (0.015 Ohm/ft)


DATASHEET 2.2.4

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DATASHEET 2.2.4



3.5 mA/m (1.05 mA/ft)


75 Years

Catalyst


Maximum anode concrete interface current density : FHWA limit

110 mA/m2 (10 mA/ft2)

Short-term limit

220 mA/m2 (20 mA/ft2)


13 mm (0.5 ")

Coil length

76 m (250 ft)


0.032 m2/m (0.105 ft2/ft)

Expanded thickness

1.30 mm (0.051 ")

Diamond dimensions

2.5 x 4.6 x 0.6 mm (0.10 " x 0.18 " x 0.025 ")


1.8 kg (4 lbs)




8.7 x 10-5/˚K (0.0000048/in/in/˚K)


15.6W/ m2 - ˚K (9.0BTU/hr/ft2/˚F/ft)


0.000056 Ohm-cm (0.000022 Ohm-in)



Tensile strength


Yield strength


Elongation

24% minimum


12.70 mm (0.5 ")

Thickness

0.90 mm (0.035 ")

Coil length

76 m (250 ft)


3.9 kg (8.6 lbs)


0.39 Ohm/m (0.12 Ohm/ft)


0.049 Ohm/m (0.015 Ohm/ft)


DATASHEET 2.2.4

Datasheet 2.2.4 150 RIBBON

5/3/08

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DATASHEET 2.2.4



5.28 mA/m (1.61 mA/ft)


75 Years

Catalyst



110 mA/m2 (10 mA/ft2)

Short-term limit

220 mA/m2 (20 mA/ft2)


19 mm (0.75 ")

Coil length

76m (250 ft)


0.048 m2/m (0.157 ft2/ft)

Expanded thickness

1.30 mm (0.051 ")

Diamond dimensions

2.5 x 4.6 x 0.6 mm (0.10 " x 0.18 " x 0.025 ")


2.7 kg (6 lbs)




8.7 x 10-5/˚K (0.0000048/in/in/˚K)


15.6W/ m2 - ˚K (9.0BTU/hr/ft2/˚F/ft)


0.000056 Ohm-cm (0.000022 Ohm-in)



Tensile strength


Yield strength


Elongation

24% minimum


12.70 mm (0.5 ")

Thickness

0.90 mm (0.035 ")

Coil length

76 m (250 ft)


3.9 kg (8.6 lbs)


0.26 Ohm/m (0.08 Ohm/ft)


0.049 Ohm/m (0.015 Ohm/ft)


DATASHEET 2.2.4


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DATASHEET 2.2.4



5.3 mA/m (1.62 mA/ft)


75 Years

Catalyst



110 mA/m2 (10 mA/ft2)

Short-term limit

220 mA/m2 (20 mA/ft2)


20 mm (0.8 ")

Coil length

76 m (250 ft)


0.05 m2/m (0.082 ft2/ft)

Expanded thickness

1.30 mm (0.051")

Diamond dimensions

2.5 x 4.6 x 0.6 mm (0.10 " x 0.18 " x 0.025 ")


2.9 kg (6.38 lbs)




8.7 x 10-5/˚K (0.0000048/in/in/˚K)


15.6W/ m2 - ˚K (9.0BTU/hr/ft2/˚F/ft)


0.000056 Ohm-cm (0.000022 Ohm-in)



Tensile strength


Yield strength


Elongation

24% minimum


12.70 mm (0.5 ")

Thickness

0.90 mm (0.035 ")

Coil length

76 m (250 ft)


3.9 kg (8.6 lbs)


0.25 Ohm/m (0.07 Ohm/ft)


0.049 Ohm/m (0.015 Ohm/ft)


DATASHEET 2.2.4


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DATASHEET 2.2.4



7.0 mA/m (2.13 mA/ft)


75 Years

Catalyst



110 mA/m2 (10 mA/ft2)

Short-term limit

220 mA/m2 (20 mA/ft2)


25 mm (0.8 ")

Coil length

76 m (250 ft)


0.062 m2/m (0.203 ft2/ft)

Expanded thickness

1.30 mm (0.051 ")

Diamond dimensions

2.5 x 4.6 x 0.6 mm (0.10 " x 0.18 " x 0.025 ")


3.6 kg (7.9 lbs)




8.7 x 10-5/˚K (0.0000048/in/in/˚K)


15.6W/ m2 - ˚K (9.0BTU/hr/ft2/˚F/ft)


0.000056 Ohm-cm (0.000022 Ohm-in)



Tensile strength


Yield strength


Elongation

24% minimum


12.70 mm (0.5 ")

Thickness

0.90 mm (0.035 ")

Coil length

76 m (250 ft)


3.9 kg (8.6 lbs)


0.20 Ohm/m (0.061 Ohm/ft)


0.049 Ohm/m (0.015 Ohm/ft)


DATASHEET 2.2.4

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DATASHEET 2.2.4

MIXED METAL OXIDE ELGARD 150 ANODE MESH REVISION 1 ELGARD™ Anode mesh is composed of a precious metal oxide catalyst sintered to an expanded Titanium mesh substrate. The Anode Mesh is used as a key component in the Cathodic Protection of Reinforced Concrete Structures.


18.8 mA/m2 (1.71 mA/ft2)


75 Years

Catalyst



110 mA/m2 (10 mA/ft2)

Short-term limit

220 mA/m2 (20 mA/ft2)

NOMINAL DIMENSIONS Width of roll

1.22 m (4ft)

Length of roll

76 m (250 ft)

Area per roll

92.9 m2 (1000 ft2)

Actual anode surface per unit area of concrete

0.17 m2/m2 (0.17 ft2/ft2)

Expanded thickness

1.415 mm (0.056")

Diamond dimensions

34 x 76 x 0.64 mm (1.33 " x 3.0 " x 0.025 ")


26 kg (56 lbs)




8.7 x 10-5/˚K (0.0000048/in/in/˚K)


15.6W/ m2 - ˚K (9.0BTU/hr/ft2/˚F/ft)


0.000056 Ohm-cm (0.000022 Ohm-in)



Tensile strength


Yield strength


Elongation

24% minimum

ELECTRICAL PROPERTIES Anode mesh resistance lengthwise

0.085 Ohm/m (0.026 Ohm/ft)


0.049 Ohm/m (0.015 Ohm/ft)

Resistance width wise c/w current distributor

0.023 Ohm/m (0.007 Ohm/ft)


DATASHEET 2.2.4

Datasheet 2.2.4 210

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DATASHEET 2.2.4



24.4 mA/m2 (2.22 mA/ft2)


75 Years

Catalyst



110 mA/m2 (10 mA/ft2)

Short-term limit

220 mA/m2 (20 mA/ft2)


1.22 m (4 ft)

Length of roll

76 m (250 ft)

Area per roll

92.9 m2 (1000 ft2)


0.22 m2/m2 (0.22 ft2/ft2)

Expanded thickness

1.981 mm (0.078")

Diamond dimensions

34 x 76 x 0.89 mm (1.33 " x 3.0 " x 0.035 ")


33kg (73 lbs)




8.7 x 10-5/˚K (0.0000048/in/in/˚K)


15.6W/ m2 - ˚K (9.0BTU/hr/ft2/˚F/ft)


0.000056 Ohm-cm (0.000022 Ohm-in)



Tensile strength


Yield strength


Elongation

24% minimum


0.046 Ohm/m (0.014 Ohm/ft)


0.049 Ohm/m (0.015 Ohm/ft)

Resistance widthwise c/w current distributor

0.016 Ohm/m (0.005 Ohm/ft)


DATASHEET 2.2.4

Datasheet 2.2.4 300

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DATASHEET 2.2.4



37.8 mA/m2 (3.44 mA/ft2)


75 Years

Catalyst



110 mA/m2 (10 mA/ft2)

Short-term limit

220 mA/m2 (20 mA/ft2)


1.22 m (4 ft)

Length of roll

76 m (250 ft)

Area per roll

92.9 m2 (1000 ft2)


0.34 m2/m2 (0.34 ft2/ft2)

Expanded thickness

1.981 mm (0.078 ")

Diamond dimensions

25 x 51 x 0.89 mm (0.923 " x 2.0 " x 0.035 ")


43 kg (95 lbs)




8.7 x 10-5/˚K (0.0000048/in/in/˚K)


15.6W/ m2 - ˚K (9.0BTU/hr/ft2/˚F/ft)


0.000056 Ohm-cm (0.000022 Ohm-in)



Tensile strength


Yield strength


Elongation

24% minimum


0.027 Ohm/m (0.008 Ohm/ft)


0.049 Ohm/m (0.015 Ohm/ft)

Resistance width wise c/w current distributor

0.013 Ohm/m (0.004 Ohm/ft)


DATASHEET 2.2.4

Datasheet 2.2.5

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Page 1


DATASHEET 2.2.5

MIXED METAL OXIDE ANODE ACCESSORIES REVISION 1

APPLICATION A range of accessories are available to assist with the successful installation of our Mixed Metal Oxide anode systems.

SPOT WELDERS FOR UNDER TANK SYSTEMS For connection of Titanium conductor bars to Mixed Metal Oxide Ribbon Anodes (see data sheet 2.2.2.)

ANODE CENTRALISERS For connection to tubular anode systems allowing them to centralise within the casing / borehole. Available in a range of sizes and materials to suit the application. When ordering please specify metallic or non metallic type and the size of borehole / casing the are being passed through.

CABLE TIES AND CLIPS A full range of cable ties and clips are available to secure multiple anodes chains in place for ease of installation. Please specify the required length, thickness and material when ordering.


DATASHEET 2.2.5

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Page 2


DATASHEET 2.2.5

MIXED METAL OXIDE ANODE ACCESSORIES REVISION 1

END WEIGHTS End weights are secured to bottom of an anode string / chain configuration to ensure cables remain straight during installation. Weights are calculated according to the anode cable and ground bed arrangement.

DATASHEET 2.2.5


Datasheet 2.2.6

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Page 1


DATASHEET 2.2.6

MIXED METAL OXIDE RIBBON MESH CANISTER ANODES REVISION 1

APPLICATION Horizontal Groundbeds, Shallow Vertical Groundbeds.

STANDARD ANODE TYPES, DIMENSIONS AND OUTPUTS MESH STRIP ANODES are manufactured using titanium expanded mesh substrate, which meets ASTM B265 Grade 1 or 2 standards

MESH STRIP ANODES are 1.25" wide x 48" long and are rated 5 Amps for a 20 year design life in calcined petroleum coke. The MESH STRIP ANODE can be packaged in a spiral wound, galvanized steel canister or a fabric sleeve. Anode size and rating is calculated as follows, • Max Operating current density of anode = 100A/m2 • Titanium Surface Area of 1.25” (32mm) Width x 48” (1220mm) Length Strip Mesh Anode = 0.05m2 • Titanium is coated with a proprietary MMO coating with a sufficient loading to last a minimum of 20 years at the specified current density. • Surface area of anode is 0.05m2 and at current density of 100mA/m2 gives output 5A for minimum 20 years (or equivalent of 100 Amp/years at max current density of 100A/m2)

CABLE TYPES & CONNECTIONS Anodes are factory assembled with a fully encapsulated cable connection. Method of Connection : A stud bolt is passed through the mesh onto which a suitably sized cable lug is placed and then tightened with nuts and steel washers to create an electrical connection between mesh anode and cable. Electrical resistance test performed : Maximum connection resistance of 0.001 Ohm Connection encapsulated with heat shrink sleeve


DATASHEET 2.2.6

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Page 2


DATASHEET 2.2.6

MIXED METAL OXIDE RIBBON MESH CANISTER ANODES REVISION 1 CABLE TYPES & CONNECTIONS Standard Cable types included HMWPE, XLPE/PVC, PVDF/HMWPE, When ordering please specify cable type, length and size (mm2)

CANNISTER TYPES AND DIMENSIONS

DATASHEET 2.2.6

Standard Sizes

Standard Gauges

150mmDia x 1500mm L

1.0mm 20bg

150mmDia x 2000mm L

1.2mm 18bg

200mmDia x 2000mm L

1.2mm 18bg

250mmDia x 2000mm L

1.5mm 18bg

300mmDia x 2000mm L

2.0mm 14bg


Datasheet 2.2.7

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Page 1


DATASHEET 2.2.7

MIXED METAL OXIDE DISCRETE MESH ANODES REVISION 1

APPLICATION The Elgard Discrete Mesh Anode compliments the existing line of Elgard anodes for Cathodic protection of reinforced concrete structures. The anode is composed of a precious metal oxide catalyst on an expanded titanium mesh substrate. The anodes are available in 100mm, 150mm, 200mm, 250mm, 300mm and 350mm lengths and can be combined to meet specific requirements.

MATERIAL SPECIFICATIONS DIMENSIONS Anode Diameter

25.4mm (1 in)

Installation Hole Diameter

31.75mm (1-1/4 in)

Lengths

Variable – See Table Below

Expanded Mesh Thickness

1.30mm (0.051 in)

Diamond Dimensions

2.5mm x 4.6mm (0.1 in x 0.18 in)

Strand Thickness

0.6mm (0.025 in) SUBSTRATE

Composition



8.7 x 10-5/˚K (0.0000048/in/in/˚K)


15.6W/ m2 - ˚K (9.0BTU/hr/ft2/˚F/ft)


0.000056 Ohm-cm (0.000022 Ohm-in)



Tensile strength


Yield strength


Elongation

24% minimum CURRENT DISTRIBUTOR

Width

6.35mm (1/4 in)

Thickness

0.63mm (0.025 in)

ANODE PERFORMANCE 216mA/m2 (20mA/ft2)

Maximum Current Density (CD) @ Anode Mesh Length, “L”, mm (ft)

100 (.325)

Anode Surface Area, m2 (ft2)

.020 (.215) .030 (.325) .040 (.430) .050 (.545) .061 (.660) .071 (.770)

150 (.492)

Current Rating @ Max CD, mA

4.6

6.8

200 (.658) 9.1

250 (.817) 11.4

300 (.983) 13.7

Expected Life

50 Years

Anode Coating

Iridium Oxide, Mixed Metal Oxide


350 (1.125 15.9

DATASHEET 2.2.7

Datasheet 2.2.7

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DATASHEET 2.2.7

MIXED METAL OXIDE DISCRETE MESH ANODES REVISION 1 OUTLINE DRAWING

ANODE WELDMENT ELTECH PART No. 0670EA03-1 0670EA03-2 0670EA03-3 0670EA03-4 0670EA03-5 0670EA03-6

DATASHEET 2.2.7

DIM. “L1”

DIM. “L2”

100 150 200 250 300 350

400 450 500 550 600 650


Datasheet 2.3.1

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DATASHEET 2.3.1

MAGNETITE ANODES REVISION 1 APPLICATION Magnetite is a natural mineral with a high corrosion resistance making it an excellent anode material. The anodes are cast cylindrical and hollow. Cables are centre connected to give a uniform dissipation of current from the anode surface. The anode to cable connection is electrically sealed with a dielectric compound and an anode cap. Suitable for use in Horizontal Groundbeds, Deep Well Groundbeds, Fresh Water Installations, Seawater Installation

MAGNETITE ANODE DATA

Specific gravity Brinell hardness (WB5/187.5/15) Bending strength Density Melting point Coefficient of linear expansion

4.7–4.8 344 5 4,71 1500 6.4x10-6

kg/dm3

Consumption rate Current density (1) Efficiency

0.02 0.70 90%

kg/A year mA/dm2

kN/cm2 g/cm3 °C 1/°C (0-100°C)

(1) depends on environment

CHEMICAL COMPOSITION

FeO

28 - 32%

Fe3O4

60 - 64%

Balance

4 - 12%


DATASHEET 2.3.1

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DATASHEET 2.3.1

MAGNETITE ANODES REVISION 1 EXPERIENCE Lifetime comparison - Basis: anode current load 5 A

CHLORINE CONTAINING SOIL

SEAWATER AND DEEP GROUNDBEDS

STANDARD ANODE TYPES WEIGHTS AND OUTPUTS TYPE MA-U

Surrounding electrolyte: neutral soil and water without chlorine and sulfate content

TYPE MA-CS

Applications: shallow groundbeds, deep groundbeds

Surrounding electrolyte: chlorine and/or sulfate containing soil or stagnant water

Applications: shallow groundbeds, deep groundbeds

Diameter

60

mm

Diameter

60

mm

Total length

720

mm

Total length

720

mm

Effective length

670

mm

Effective length

670

mm

Total weight

6.0

kg

Total weight

6.0

kg

Min. effective mass

4.7

kg

Min. effective mass

4.7

kg

Surface area

13.4

dm2

Surface area

13.4

dm2

Max. current load

3.0

A

Max. current load

6.0

A

DATASHEET 2.3.1


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DATASHEET 2.3.1

MAGNETITE ANODES REVISION 1 STANDARD ANODE TYPES WEIGHTS AND OUTPUTS TYPE MA-SEA

Surrounding electrolyte: flowing seawater or brackish water

TYPE MA-CHAIN

Applications: platforms, jetties, harbours

Surrounding electrolyte: chlorine containing soil or stagnant water

Applications: deep groundbeds open hole, deep groundbeds closed hole, water tank

Diameter

60

mm

Diameter

60

mm

Total length

760

mm

Total length

740

mm

Effective length

710

mm

Effective length

600

mm

Total weight

6.0

kg

Total weight

6.2

kg

Min. effective mass

4.7

kg

Min. effective mass

4.7

kg

Surface area

13.4

dm2

Surface area

11.3

dm2

Max. current load

16.0

A

Max. current load (groundbeds)

6.0

A

Max. current load (tanks)

16.0

A

CANISTER FOR MA-U & MA-CS

COKE BACKFILL Minimum carbon content

90%

Maximum moisture content

5%

Maximum resistivity Density

1Ωm 700-950 kg/m3

Particle size (dia.)

20 mm max.

Standard canister

Diameter (mm)

Length (mm)

Total weight (kg)

CAN 10

160

1000

22

CAN 15

300

1500

85

CAN 20

300

2000

110


DATASHEET 2.3.1

Datasheet 2.3.2

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DATASHEET 2.3.2

GRAPHITE ANODES REVISION 1 APPLICATION Plain graphite anodes are used in dry soil conditions installed in groundbeds containing compacted carbonaceous backfill. Linseed oil impregnated anodes can be used in moist saline soils, in fresh and brackish water, and for seawater applications. Graphite anodes can be installed as horizontal or deepwell groundbeds to protect buried pipelines or due to their lightweight nature they can be suspended into the electrolyte to protect water tank internal surfaces or marine structures.

GRAPHITE ANODE DATA

Cathodic Protection Co Ltd graphite anodes are manufactured in two standard sizes - 3” dia up to 60” long & 4” dia up to 80” long. There are two types of graphite anodes - plain & linseed oil impregnated. Plain graphite anodes are used for ordinary soil conditions and linseed oil impregnated anodes are usually used for saline soil or seawater environments.

CONSUMPTION RATES


DATASHEET 2.3.2

Datasheet 2.3.2

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DATASHEET 2.3.2

GRAPHITE ANODES REVISION 1 TYPICAL CHARACTERISTICS

ANODE TO CABLE CONNECTION Cable for Graphite Anodes is supplied according to customer requirements. We can offer the following insulation and sheathing types PVC. XLPE/PVC, HMWPE, KYNAR, HALAR, EPR/CSPE.

DATASHEET 2.3.2


Datasheet 2.3.3

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Page 1


DATASHEET 2.3.3

PLATINISED TITANIUM ANODES REVISION 1 APPLICATION • Underwater steel structures - Wharves, jetties, sheet pile walls and piers. Usually rod type anodes distributed throughout the structure to be protected to give a good overall protective current distribution. Anodes should be installed in areas not liable to cause Anode damage i.e. out of the way of berthing vessels, mooring ropes, chains etc. • Exterior protection of ships hulls - anodes in the shape of plates, discs or strips. Housed in chlorine resistant plastic as the anode operates at high current densities in seawater which produces chlorine. • Water tank internal protection - usually distributed rod anodes are used for this type of installation by suspending from the tank roof. • Internal protection of plant - large diameter water pipelines such as cooling water can be protected using rod or wire shaped anodes.

PLATINISED TITANIUM ANODE DATA Platinised Titanium anodes are manufactured from a commercially pure titanium substrate plated with a very thin coating of platinum. The titanium serves simply as the anode body and the conductor, the active anode element being the platinum coating. The usual thickness of the platinum coating is approximately 2.5 microns, however, this coating thickness should be increased to 5.0 microns for harsher environments. The base metal is available in a wide variety of standard shapes rods, tubes, mesh, etc - which can be fabricated into non-metallic mounts for attachment to the structure to be cathodically protected. The thickness of the platinum coating and the current density at which the anode is operated determine the useful life of the anode. The maximum voltage at the anode to electrolyte interface should not exceed 8 Volts in electrolytes containing chloride as voltages greater than this value could cause local corrosion on any unplatinised portions of the anode. Platinised titanium anodes should not be used in electrolytes containing fluoride as titanium oxide dissolves in fluoride. Anodic passivation does not protect the titanium substrate in such electrolytes. The advantage of platinised titanium anodes is that they can be operated at high current densities with very low consumption rates.


DATASHEET 2.3.3

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DATASHEET 2.3.3

PLATINISED TITANIUM ANODES REVISION 1 CURRENT DENSITY AND CONSUMPTION RATES

FEATURES • Anodes can work at high current densities without decomposition or dissolving. • Favourable strength to weight ratio. • Anodes can be smaller and more compact than comparable conventional anodes. • Can be manufactured in a wide variety of shapes and sizes. • Lightweight support tube installation for Pt Ti anode installation.

ANODE INSTALLATION EXAMPLES

DATASHEET 2.3.3


Datasheet 2.3.3

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Page 1


DATASHEET 2.3.3

PLATINISED TITANIUM ANODES REVISION 1 APPLICATION • Underwater steel structures - Wharves, jetties, sheet pile walls and piers. Usually rod type anodes distributed throughout the structure to be protected to give a good overall protective current distribution. Anodes should be installed in areas not liable to cause Anode damage i.e. out of the way of berthing vessels, mooring ropes, chains etc. • Exterior protection of ships hulls - anodes in the shape of plates, discs or strips. Housed in chlorine resistant plastic as the anode operates at high current densities in seawater which produces chlorine. • Water tank internal protection - usually distributed rod anodes are used for this type of installation by suspending from the tank roof. • Internal protection of plant - large diameter water pipelines such as cooling water can be protected using rod or wire shaped anodes.

PLATINISED TITANIUM ANODE DATA Platinised Titanium anodes are manufactured from a commercially pure titanium substrate plated with a very thin coating of platinum. The titanium serves simply as the anode body and the conductor, the active anode element being the platinum coating. The usual thickness of the platinum coating is approximately 2.5 microns, however, this coating thickness should be increased to 5.0 microns for harsher environments. The base metal is available in a wide variety of standard shapes rods, tubes, mesh, etc - which can be fabricated into non-metallic mounts for attachment to the structure to be cathodically protected. The thickness of the platinum coating and the current density at which the anode is operated determine the useful life of the anode. The maximum voltage at the anode to electrolyte interface should not exceed 8 Volts in electrolytes containing chloride as voltages greater than this value could cause local corrosion on any unplatinised portions of the anode. Platinised titanium anodes should not be used in electrolytes containing fluoride as titanium oxide dissolves in fluoride. Anodic passivation does not protect the titanium substrate in such electrolytes. The advantage of platinised titanium anodes is that they can be operated at high current densities with very low consumption rates.


DATASHEET 2.3.3

Datasheet 2.3.3

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Page 2


DATASHEET 2.3.3

PLATINISED TITANIUM ANODES REVISION 1 CURRENT DENSITY AND CONSUMPTION RATES

FEATURES • Anodes can work at high current densities without decomposition or dissolving. • Favourable strength to weight ratio. • Anodes can be smaller and more compact than comparable conventional anodes. • Can be manufactured in a wide variety of shapes and sizes. • Lightweight support tube installation for Pt Ti anode installation.

ANODE INSTALLATION EXAMPLES

DATASHEET 2.3.3


Datasheet 2.4.1

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13:27

Page 1


DATASHEET 2.4.1

TRANSFORMER RECTIFIERS REVISION 1 APPLICATION Onshore, Offshore and Marine applications. A wide and varied range of high quality transformer rectifiers are designed and manufactured at our Grantham works to meet the market requirement for all land and marine structures necessitating an Impressed Current Cathodic Protection system or a Marine Growth Anti Fouling system.

TRANSFORMER RECTIFIER UNIT DATA

The products have been developed to satisfy the most arduous environmental conditions, giving safe operational reliability with minimal maintenance at competitive price levels. Two main types of transformer rectifiers are available ie: Air Cooled and Oil Cooled, the selection of which may be specification derived or personal choice. The final selection invariably being the environmental conditions and relative to output rating, these will determine the physical size and cost of the unit. Our engineers are able to assist you with this selection. Input Power Supply 1 Phase and 3 Phase supplies to 660Volts, 50/60Hz are readily catered for within our standard arrangements Output Rating @ Voltages: 6 to 120Volts DC (British Standards state 50Volts DC output max) Ambient Temperatures - Currents: 5 to 800Amps (Multiples of transformer rectifiers should be 10 to 55˚C considered for greater than 12kWatt)


DATASHEET 2.4.1

Datasheet 2.4.1

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Page 2


DATASHEET 2.4.1

TRANSFORMER RECTIFIERS REVISION 1

OUTPUT CONTROL Manual Switched

Auto Transformer Electronic

Auto (Electronic)

Constant Current

Constant Potential

Enclosures

Switch Control via control panel facia switches to select transformer tappings, 15 and 63 step control available as standard Auto transformer (Variac) control indefinitely from 0 to 100%. Electronic thyristor control from panel facia mounted potentiometer giving indefinite variable adjustment from 3Volts to maximum rating.

All auto systems operate from 3Volts to maximum rating and are fitted with a manual override facility. Constant current maintains the output current at the preset value irrespective of supply and output circuit changes. A permanent reference electrode(s) controls the output current to maintain a constant potential at the surface of the protected structure subject to compensate for changes in electrolyte resistivity, coating efficiency, power supply voltage variation, tidal conditions etc. A wide range of standard and purpose built arrangements up to IP66 protection levels.

Material

Mild steel, Stainless Steel, Aluminium and Glass Reinforced Polyester are available.

Finishes

Epoxy/Polyurethane paint finishes on prepared shot blast, cleaned and zinc chromate primed/Zinga base as standard. Options include Zinc flame sprayed, natural bead blast finishes, etc.

Electrical/Electronic Components

Selected to meet the specification requirement with particular emphasis on high efficiency transformers and generously rated semi-conductors

DATASHEET 2.4.1


Datasheet 2.4.1

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DATASHEET 2.4.1

TRANSFORMER RECTIFIERS REVISION 1

FACILITY AVAILABLE

TESTS

Supply/Output Monitoring Limit and Alarm (high and low) Local/Remote indication facilities 4-20mA re-transmission signals RCCD/MCB and fuse protection Surge suppression Lightning Arrestors Metering “Instant Off” timers Synchronous timing All transformer rectifiers undergo works testing to include the following as a minimum: • Wiring connection integrity • Circuit continuity and compliance • Operation at full output current and voltage far a minimum of 12 hours • High voltage insulation resistance test In addition new designs are subjected to a 12-24 hour heat run test at full load to ensure that the temperature rises are within permitted limits for the materials used in construction.


DATASHEET 2.4.1

Datasheet 2.4.1

6/8/08

13:27

Page 4


DATASHEET 2.4.1

TRANSFORMER RECTIFIERS REVISION 1 TYPICAL TRANSFORMER RECTIFIER GENERAL ARRANGEMENT (Model Shown Oil Cooled 75V / 125A)

TYPICAL TRANSFORMER RECTIFIER / POSITIVE JUNCTION BOX SITE ARRANGEMENT

DATASHEET 2.4.1


Datasheet 2.4.2

11/8/08

16:17

Page 1


DATASHEET 2.4.2

REMOTE MONITORING FOR TR’S REVISION 1

Bullhorn i-series ICP Information American Innovations’ Bullhorn i-series ICP is a satellite based remote monitoring device that provides scheduled and by exception inbound reporting as well as two-way communication for on-demand reads and activating/deactivating ancillary equipment. The device can be field upgraded to include a MicroMax® GPS80 current interrupter enabling the collection of IR-free cathodic protection (CP) reads in the most efficient, economical way possible. The ICP uses the OrbComm satellite system and enables equipment monitoring and control in very remote locations. It is ideal for international use. ®

The ICP monitors many different kinds of equipment in the cathodic protection industry including rectifiers, test points and critical bonds. It is also ideal for monitoring equipment in a number of other industries. The ICP provides automatic notifications of alarm events via email, cell phone or pager. With secure access, data can be viewed on the internet from anywhere in the world, day or night.

The ICP unit is available in 2 and 4 analog channel versions. The 5th analog channel is used internally when a MicroMax is utilized and is not available for other purposes. Both versions have 6 digital inputs and 6 digital outputs. For CP applications, analog inputs are available with filtering and surge protection. The ICP is easy to install since all configuration of the device takes place via the satellite system, so there is no need for a laptop computer in the field. It accepts customer supplied AC or DC line power or DC solar power. In the event of power loss, an internal rechargeable battery provides backup power.

• Remote interruption by adding MicroMax GPS80 Interrupter • Easy to install • Configure via the web • Up to 4 analog channels for external inputs • Satellite for global coverage


DATASHEET 2.4.2

Datasheet 2.4.2

11/8/08

16:17

Page 2


DATASHEET 2.4.2

REMOTE MONITORING FOR TR’S REVISION 1 I - series ICP Product Information

Data Inputs

Up to 5 Analog channels Available input ranges: 0-100V 0-10V 0-100mV • Analog inputs are isolated • Inputs specified at time of order 1 digital input available Remaining digital inputs: Available for use with MicroMax GPS Current Interrupter

Outputs Config. Parameters Supporting Products

Power Supply

Available for use with MicroMax GPS current interrupter Configuration via web interface MicroMax GPS80 Interrupter, AC Present Sensor, Interruption Verification Sensor AC (Line Power Supplied by Customer) w/ Nominal Voltage of 110VAC. DC (line power supplied by customer) 15-36VDC. Backup battery has a Nominal Voltage of 12 VDC and 7AH Capacity. Solar Power Option Available for an additional fee.

Physical Description

Data Integrity

Data stored in non-volatile (EEPROM) memory

Environmental

Temp: -40 degrees C to +85 degrees C; Humidity: 0-95% non-condensing

Compliance

Software Interface

Communications

DATASHEET 2.4.2

Aluminum or Fiberglass enclosure available: Height- 13.5 inches, Width- 11.5 inches, Depth- 7.125 inches

UL/CUL General Classification (pending); FCC Part 15; Enclosure: NEMA 4 compliant for all Bullhorn types Bullhorn secure website. Standard web browsers. AI Network operations center Orbcomm satelite


Datasheet 2.5.1

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Page 1


DATASHEET 2.5.1

JUNCTION BOXES REVISION 1 APPLICATION Junction boxes for positive and negative current distribution and control , and for resistance bonding are available to meet exact client specifications. Suitable for onshore and marine environments in safe and hazardous areas. When specifying a CPC Junction Box assembly please clarify specific hardware and components required.

ENCLOSURES Stainless Steel 316L & 304, Painted Mild Steel Galvanised and Painted

Aluminium Plastic Cast Iron

Explosion Proof GRP Custom Finishes

Please also specify IP, NEMA or Hazardous area classification required.

ACCESSORIES Resistors Shunts Support Frames Copper Links

Metering Monitoring Transducers Terminals

Diodes Labelling Switches Security / Locking


DATASHEET 2.5.1

Datasheet 2.5.1

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Page 2


DATASHEET 2.5.1

JUNCTION BOXES REVISION 1 CABLE ENTRY Cable entry can be made by any type of proprietary cable gland, or by conduit and hub assemblies allowing the safe passage of multiple cables into the enclosure.

TYPICAL JUNCTION BOX ARRANGEMENT

TYPICAL INTERNAL LAYOUT OF ANODE JUNCTION BOX

TYPICAL JUNCTION BOX SUPPORT ARRANGEMENT

DATASHEET 2.5.1


Datasheet 2.6.1

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DATASHEET 2.6.1

WELLHEAD ASSEMBLIES REVISION 1 APPLICATION Suitable for onshore and marine environments in safe and hazardous areas. For the termination and support of anode cables at deep well ground bed locations and for the safe ventilation of gases produced by high chlorine environments.

Cathodic Protection Co Ltd can manufacture a custom range of well head assemblies to suit your exact requirement. We can provide well head structures manufactured from a range of materials including GRP, Steel and Concrete. The well head design will generally incorporate the support and termination of anode cables, sufficient ventilation of gases generated in deep well ground bed locations and security / ingress protection to prevent tampering and environmental damage.

TYPICAL LAYOUT OF WELLHEAD STRUCTURE


DATASHEET 2.6.1


DATASHEET 2.6.2

CARBONACEOUS BACKFILL REVISION 1 APPLICATION Impressed current cathodic protection groundbeds and packaged impressed current anodes.

CARBONACEOUS BACKFILL DATA

TYPICAL ANALYSIS Chemical Composition (%)

DBW

SP

Ash

0.2

12 max

Volatiles

0.3

1.5 max

Moisture

0.3

10

Fixed Carbon

99.2

86.5 min (dry basis)

Sulphur

1.0

1.5 max

Silicon

168 ppm

1.0

Iron

83 ppm

1.1

Size Grading

0.25 - 1mm

0 -10mm

Resistivity @ 150psi

0.1 0hm cm

0.5 0hm cm

Products supplied in 25kg multi walled paper bags, stacked on pallets and shrinkwrapped. Alternatively 1 tonne bulk bags on pallets and shrinkwrapped


DATASHEET 2.6.2

Datasheet 2.6.3

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Page 1


DATASHEET 2.6.3

CABLE XLPE/PVC REVISION 1 APPLICATION Surface wiring & buried if protected by clean sand. Suitable for use as anode cable tails, positive feed cable, negative return cable and test cable.

XLPE/PVC CABLE DATA

Single core XLPE insulated/PVC sheathed 600/1000V BS7889 6181XY Conductors: Plain annealed copper Insulation: XLPE (Cross linked Polyethylene) Sheath/Jacket: PVC (Polyvinyl-Chloride) Colours: Black/Black, Red/Red Voltage: 600/1000v Operating temperature: Maximum 90°C, minimum bending 0°C Standard: BS7889 & IEC60502 Minimum bending radius : Diameter up to 25mm, 4 x OD; Diameter over 25mm, 6 x OD

STANDARD CABLE SIZES DIMENSIONS AND WEIGHTS Dia over

RT of

Nominal

Weight

Insulation

Core

Sheath

Overall Dia

(Kg/km)

(mm)

(mm)

(mm)

(mm)

3.12

0.7

4.5

1.4

7.3

104

10

4.05

0.7

5.5

1.4

8.3

150

16

5.10

0.7

6.5

1.4

9.3

214

25

6.40

0.9

8.2

1.4

11.0

317

35

7.50

0.9

9.3

1.4

12.1

420

50

8.90

1.0

11.1

1.4

14.2

560

70

10.70

1.1

13.2

1.5

16.4

787

Size

Maximum Dia

RT of

(mm2)

Over Conductor

(mm) 6

95

12.60

1.1

15.0

1.5

18.3

1050

120

14.98

1.2

17.6

1.6

21.2

1450

150

15.96

1.4

19.0

1.7

22.8

1650

185

17.78

1.6

21.3

1.7

25.1

2030

240

20.52

1.7

24.3

1.9

28.4

2660


DATASHEET 2.6.3

Datasheet 2.6.4

6/8/08

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Page 1


DATASHEET 2.6.4

CABLE XLPE/PVC/SWA/PVC REVISION 1 APPLICATION Surface wiring & buried if protected by clean sand. Suitable for use as anode cable tails, positive feed cable, negative return cable and test cable.

XLPE/PVC/SWA/PVC CABLE DATA

Single Core BS5467 600/1000V Conductors: Plain annealed stranded copper Insulation: XLPE (Cross linked polyethylene) Core identification: Brown Bedding: PVC (Polyvinyl-Chloride) Armour/Protection: SWA (Galvanised steel wire armour) Sheath/Jacket: PVC (Polyvinyl-Chloride) Colour: Black Voltage: 600/1000v Operating temperature: Maximum 90°C, minimum bending 0°C Standard: BS5467 Minimum bending radius : 6 x Outside Diameter

STANDARD CABLE SIZES DIMENSIONS AND WEIGHTS Dia of

Approx Dia

Nominal

Weight

Overall Dia

Kg/km

Size

Maximum Dia

RT of

mm2

Over Conductor

Insulation

mm

mm

mm

mm

mm

10

4.05

0.7

0.9

10.4

13.5

495

16

5.10

0.7

0.9

10.8

14.2

535

25

6.40

0.9

0.9

11.4

15.2

585

35

7.50

0.9

0.9

12.0

16.3

640

50

8.90

1.0

0.9

12.9

17.7

730

70

10.70

1.1

1.25

14.9

20.4

980

95

12.60

1.1

1.25

16.6

22.3

1270

120

14.98

1.2

1.25

18.3

24.0

1540

Armour Wire under Armour


DATASHEET 2.6.4

Datasheet 2.6.5

6/8/08

13:31

Page 1


DATASHEET 2.6.5

CABLE PVDF/HMWPE REVISION 1 APPLICATION Surface wiring & buried if protected by clean sand. Suitable for open hole deep well groundbeds and anode cable tails where H2S and high levels of chloride ion species and where oxygen and/or chlorine gases may be evolved.

PVDF/HMWPE CABLE DATA

Single core PVDF insulated/HMWPE sheathed 600/1000V Conductors: Tinned annealed copper Insulation: PVDF Fluoropolymer (Radiation cross linked polyvinyldene fluoride) Sheath/Jacket: HMWPE (High Molecular Weight Polyolefin) to ASTM Spec D-1248 Colours: Clear/Black Voltage: 600/1000v Operating temperature: Maximum 150°C, minimum bending minus -15°C Minimum bending radius : 10m x OD of cable

STANDARD CABLE SIZES DIMENSIONS AND WEIGHTS

mm

RT of Insulation mm

Dia over Core mm

RT of sheath mm

Nominal Overall Dia mm

Weight Kg/km

3.12

1.0

5.12

1.65

8.42

96

10

4.05

1.0

6.05

1.65

9.35

135

16

5.10

1.0

7.10

1.65

10.40

197

25

6.40

1.2

8.80

1.65

12.10

312

35

7.50

1.2

9.90

1.65

13.20

398

50

8.90

1.4

11.70

1.65

15.00

541

Size mm2

Maximum Dia

6

of Conductor

NOTE: The Polyolefin sheath protects the PVDF insulation from damage during installation. The HMWPE sheath will deteriorate under aggressive environmental conditions leaving the PVDF to withstand the surrounding media.


DATASHEET 2.6.5

Datasheet 2.6.6

6/8/08

13:31

Page 1


DATASHEET 2.6.6

CABLE HALAR/HMWPE REVISION 1 APPLICATION HALAR/HMWPE cable is designed for anode lead wires in a wide range of environments. Due to its dual insulation construction, it can be installed directly in native soils or submerged in fresh, brackish, or salt waters. The cable is ideal for deep anode bed installations where chlorine and hydrogen gases are generated. The HALAR insulation will not embrittle at temperatures down to (-80F) and will maintain dimensional stability and dielectric strength at temperatures up to 250F. It is highly resistant to notch propagation.

HALAR/HMWPE CABLE DATA

One of the major causes of deep anode failures is the failure of cable insulation. This is especially evident in areas where brackish water is present in the ground. In this environment, anodes generate reactive gases such as chlorine and nacent oxygen. These gases cause rapid deterioration of conventional HMWPE insulation. Cathodic protection cable insulated with HALAR fluoropolymer, is especially suited for deep anode lead wires. HALAR fluoropolymer is inert to reactive compounds and has an outstanding ability to prevent the passage of gases. Laboratory and field evaluations indicate that HALAR fluoropolymer insulated lead wire can extend the life of deep anode installations. The cable is composed of stranded copper wire covered by two layers of insulation. The outer insulation layer is made from high molecular weight polyethylene (HMWPE). It exhibits superior dielectric and tensile strength, and provides mechanical protection to the cable. The material is also resistant to water intrusion and is not affected by most organic or inorganic substances. The inner or primary insulation is composed of HALAR, a fluoropolymer. This insulating material demonstrates exceptional chemical resistance. In the presence of chlorine, hydrochloric acid, sulfuric acid, or other strong oxidizing agents the material remains stable. Further, it will not deteriorate when exposed to petroleum hydrocarbons which are encountered in numerous cathodic protection applications. The dual extrusion HALAR cable is made specifically for cathodic protection applications. It can withstand considerable abuse during installation.

STANDARDS Conductor : Stranded bare copper conductor conforms to ASTM Specification B-3 and B-8. Insulation : A homogeneous wall of natural ECTFE fluoropolymer (HALAR) shall be extruded over the conductor. Jacket : Insulation is high molecular weight polyethylene conforming to ASTM-D-1248, Type 1, Class C, Category 5, Grades E5 & J1. Tensile Strengths Jl, J3. Available with high density polyethylene (Types II, III, IV) Class B and C (all colors). Surface printed. Custom printing available.


DATASHEET 2.6.6

Datasheet 2.6.6

6/8/08

13:31

Page 2


DATASHEET 2.6.6

CABLE HALAR/HMWPE REVISION 1 CABLE DATA Size

No. of Strands

Circular Mils

AWG Diameter Inches

HALAR Thickness Inches

HMWPE Thickness Inches

Nominal Diameter Inches

Weight Lbs per 1000 ft

DC Ohms per Mft at 20 C

#8

7

16,510

.142

.020

.065

.32

81

.652

#6

7

26,240

.179

.020

.065

.36

116

.411

#4

7

41,740

.225

.020

.065

.41

170

.258

#2

7

66,360

.283

.020

.065

.46

254

.162

Specifications for HALAR/HMWPE Cathodic Protection Cable This specification describes a special single conductor size 8 AWG-2 AWG, HALAR insulated, High Molecular Weight Polyethylene jacketed cable designed for use as a direct burial feeder in deep anode ground-bed cathodic protection systems. The cable is ideally suited for use in harsh chemical environments involving brackish water, sour gas, chlorine, acids, alkalis, and petroleum based solvents. The cable is suitable for use at voltages up to 600 volts ac or dc. Applicable Standards (The following standards form a part of this specification to the extent specified herein:) ASTM Specification B 3, latest edition, for Soft or Annealed Copper Wire ASTM Specification B 8, latest edition, for Concentric-Lay Stranded Copper Conductors ASTM Specification D 1248, latest edition, for Polyethylene Plastics Molding and Extrusion Materials. ICEA Standard S-61-402/NEMA Standard WC5 for Thermoplastics Insulated Wire and Cable Conductor The copper conductor shall be Class B stranded, compressed, annealed, uncoated cooper in accordance with ASTM B 3 and B 8 Insulation : The conductor shall be insulated with an extruded layer of natural HALAR ECTFE fluoropolymer as a primary insulation. The average thickness shall be 20 mils. The minimum thickness at any point shall be not less than 90% of the specified average thickness. The insulation shall be applied tightly to the conductor and shall be free-stripping. Jacket : A black High Molecular Weight Polyethylene jacket having both insulating and jacketing properties shall be extruded over the primary insulation. The jacket, before extrusion, shall comply with the physical and electrical requirements of ASTM Specification D 1248 for Type1, Class C, Category 5, Grade E-5 and J-1 material. The average jacket thickness shall be 65 mils. The minimum thickness shall be not less than 80% of the specified average thickness. Identification : The cable shall be surface ink printed with: "Conductor Size AWG, CU, Manufacturer, HALAR/HMWPE CATHODIC PROTECTION CABLE". Tests : The completed cable shall be tested in accordance with the requirements of ICEA S-61-402, Part 6.

DATASHEET 2.6.6


Datasheet 2.6.7

6/8/08

13:31

Page 1


DATASHEET 2.6.7

CABLE HMWPE REVISION 1 APPLICATION Surface wiring & buried if protected by clean sand. Suitable for use as anode cable tails, positive feed cable, negative return cable and test cable.

HMWPE CABLE DATA

The cable utilized in cathodic protection systems is a critical component of any cathodic protection system. The industry standard cable for direct burial is a stranded copper conductor covered with an insulation of high molecular weight polyethylene (HMWPE). The thick insulation provides both electric isolation and mechanical protection. During installation, this cable can withstand considerable mechanical abuse without compromising the conductor. The HMWPE insulation is chemically resistant and protects against most organic and inorganic substances.

STANDARDS Conductor : Stranded copper conductor conforms to ASTM Specification B-8. Insulation : Insulation is high molecular weight polyethylene conforming to ASTM D-1248, Type 1, Class A, Category 5, Grades E4 & E5. Tensile Strengths Jl, J3. Available with high density polyethylene (Types II, III, IV) Class B & C (all colors). Tests : The completed cable shall be tested in accordance with the requirements of ICEA Pub. No. S-61-402, Part 6.

STANDARD SIZE AND DATA

WIRE SIZE

INSULATION THICKNESS

NOMINAL O.D.

NUMBER OF STRANDS

NOMINAL OD

AWG

mm2

Inches

mm

No

Inches

mm

14 12 10 8 6 4 2 1 1/0 2/0 4/0

2.5 4 6 10 16 25 35 45 50 70 120

0.11 0.11 0.11 0.11 0.11 0.11 0.11 0.125 0.125 0.125 0.125

2.794 2.794 2.794 2.794 2.794 2.794 2.794 3.175 3.175 3.175 3.175

7 7 7 7 7 7 7 19 19 19 19

0.299 0.31 0.34 0.36 0.41 0.46 0.52 0.59 0.63 0.67 0.78

7.59 7.87 8.64 9.14 10.41 11.68 13.21 14.99 16 17.02 19.82


DATASHEET 2.6.7

Datasheet 2.6.8

6/8/08

13:32

Page 1


DATASHEET 2.6.8

VENT PIPE REVISION 1 APPLICATION Deep well groundbeds, undertank systems.

1" PVC SCHEDULE 80 PIPE Schedule 80 is available in grey and is for socket or threaded fittings. It has a wide variety of uses in the chemical field and resistance, also in industrial plants. PVC material is Type 1 according to the American Society for Testing Material D-1784. Pipe is round and smooth on the inside and out, resistant to cracking, and made from premium virgin PVC resin. Sch. 80 socket fitting ASTM D-2467. Pipe- ASTM D-1785.

SOLID PIPE Standard lengths: Wall thickness: Diameter ID: OD:

3m 4.5mm 24.0mm 33mm

PERFORATED PIPE Standard lengths: Wall thickness: Diameter ID: OD: Perforations: Screen:

3m 4.5mm 24.0mm 33mm 1mm slots x 32mm long, Slotted on alternate sides @ 40mm spacing Monofilament Braided

COUPLER/SOCKET 1” Plain socket for glued connection of pipes.

END CAP 1” End cap to seal bottom of vent pipe.


DATASHEET 2.6.8

Datasheet 2.6.9

7/8/08

13:47

Page 1


DATASHEET 2.6.9

CASING PIPE REVISION 1 APPLICATION These uPVC casings are ideal for the installation of open hole deep well groundbeds in areas where a static water level can be reached. This also allows for the retrieval and replacement of anodes strings at the end of their life. Casings are supplied with threaded joints for convenient on-site assembly

CASING PIPES DATA

CASING (SOLID) Casing Material : Notch Impact @ 200C : Elasticity Coefficient : Tensile Strength : Thread : Diameter : Wall Thickness : Pipe Length :

PVC DIN4925 4.5 + 0.5kJ/m2 2943 N/mm2 45-55N/mm2 DIN 4925 Part 2 Table 4, Trapezoidal Without ‘O’ Ring 225mm (246mm At Internally Threaded End) 13mm Overall Length 5775mm (+35 / -10mm Tolerance) Effective Length 5700mm (+35 / -10mm Tolerance)

SCREEN (SLOTTED) Material Spec as above Slot Width : Open Area : Slot Ends : Mesh :

3mm Width Slots 20% Of Slottable Outside Diameter Of Pipe. Rounded Woven Polyethylene Filter Mesh To 300 Micron Sieve Analysis Fitted Over Slotted Section Protected By Heavy Duty PE Outer PE Outer Mesh & Secured At Ends By Heat Shrink Tape.

ACCESSORIES • Wooden casing clamps • Sump Pipes • Centralisers • Lifting hoists • End Caps


DATASHEET 2.6.9

Datasheet 2.6.9

7/8/08

13:47

Page 2


DATASHEET 2.6.9

CASING PIPE REVISION 1 OUTLINE DRAWING OF CASING / SCREEN PIPES

DATASHEET 2.6.9


Datasheet 2.6.10

6/8/08

13:33

Page 1


DATASHEET 2.6.10

SPLICE KITS REVISION 1 APPLICATION Onshore and Marine

SPLICE KIT DATA Suitable for plastic or rubber insulated cables 600/1000 V (without armour).

FEATURES • Strong clear plastic mould body with Snaplock connection for tight seal. • Stepped cable entry cut-off points for all cable diameters. • Large mould shell enables crimp or split bolt / line tap connectors to be used. • Resin 2-year shelf life.

APPLICATIONS • Used on Cathodic Protection applications including pipelines, tanks and buried structures. • Ideal for single core unarmoured Tee or Branch jointing rated up to 1kV, above or below ground. To suit mains cable single core max size up to 95 sq mm. Branch single core up to 35 sq mm.

RESIN SEALING COMPOUND • Resin sealing compound is suitable for all climate conditions. • High quality resin sealing compound has a high resistance to moisture absorption, is mixed in a clear pack and stored in an aluminium protective bag. • The long-term electrical properties of resin sealing compound result in a more reliable connection without any associated maintenance costs.

MAJOR USERS • Specified by leading oil, gas and water companies and consulting engineers.

QUALITY • Designed to meet the requirements of BS 7888:1998.


DATASHEET 2.6.10

Datasheet 2.6.10

6/8/08

13:33

Page 2


DATASHEET 2.6.10

SPLICE KITS REVISION 1 RESIN PACK FEATURES • The pack has been specifically designed and fabricated to offer the user a quick, clean and efficient method of mixing and pouring. • The pack consists of a two part polyurethane resin correctly proportioned into pouches separated by a divider. The user simply breaks the divider, amalgamates the two components and pours. • Dual system of packaging ensures that the pack is sealed against the atmosphere. • The outer aluminium packaging provides added protection against the atmosphere to give a shelf life of 2 years. • The inner transparent plastic packaging provides a visible reference for the user when mixing. • During mixing the user does not come into contact with the resin but gloves are provided for extra safety. • Each pack has its own unique batch number and use by date to provide an easy reference for the user. • Full safety labelling. • Controlled curing temperature designed to be compatible with PVC, XLPE, EPR, polythene and PILC cables. • Odour free. • Detailed storage instructions. • No special labelling required for transportation by road, sea or air. • Designed to meet requirements of BS 7888-3:1998 and CENELEC HD623 S1

DATASHEET 2.6.10


Datasheet 2.6.10

6/8/08

13:33

Page 3


DATASHEET 2.6.10

SPLICE KITS REVISION 1 TECHNICAL PROPERTIES Resin Black

Colour Specific gravity (gm/cubic cm) Viscosity (poise) Gelation time Full cure Shelf life Peak exotherm Thermal conductivity Tensile strength Shore hardness Elongation Dialectric strength (solid) Operating temperature

Hardener Brown

Mixed Black

1.58 1.23 1.51 70-100 1-2 50-60 20-30 minutes 200 gram mass @ 21°C 24 hours @ 23°C / 1 hour @ 80°C 2 years (24 months) when stored between 10-25°C. Packaging must remain intact. 75.2°C based on 5 ltr placed in a container 200mm diameter conditioned at 21°C. Measurements taken at 5 minute intervals at the centre of the resin mass. 0.46 w/mk 47 Mpa 80 A 40% Greater than 5 MV/m Provided resin is mixed correctly based on a static environment with gradual rise and fall in temperature is -40°C to +110°C.

TYPE

USABLE VOLUME OF PACK

PC5581 PC5581 PC5581 PC5581 PC5581 PC5581 PC5581

200ml 450ml 500ml 1000ml 1200ml 1500ml 2000ml

HEALTH & SAFETY Each pack contains mixing instructions and carries health and safety warnings in accordance with BS 7888:1998.

MIXING DETAILS


DATASHEET 2.6.10

Datasheet 2.6.10

6/8/08

13:33

Page 4


DATASHEET 2.6.10

SPLICE KITS REVISION 1 CABLE CONNECTORS

DATASHEET 2.6.10


Datasheet 2.6.11

6/8/08

13:34

Page 1


DATASHEET 2.6.11

SOLAR POWER UNITS REVISION 1 APPLICATION Onshore pipelines and plant in safe and hazardous areas.

SOLAR GENERATING UNIT DATA In remote areas, providing AC power for impressed current cathodic protection systems can be a major constraint. Solar electricity is a solution to this problem. Solar generators provide a reliable and low maintenance source of power that can be used for cathodic protection. The control equipment is an integral part to the reliability and performance of the Solar generator. We use world leaders in the design, manufacture and supply of these controls to cover an extensive range of requirements. The CP controller utilises high-speed pulse width modulated switching technology to ensure the highest conversion efficiency fully maximising the power from the SGU. The controller which is a DC-DC converter is suitable for connection to 12, 24 or 48Volt DC systems with output current options of 25A and 50A. The controller is capable of controlling the power delivered to the load to a maximum of 1V below the input voltage.

CONTROLLER FEATURES Control - Operating parameters are set by multi-turn controls with LED and volt free contacts for indication of control mode • • • • • • •

Constant Output Voltage Mode Constant Output Current Mode Constant Reference Electrode Voltage Low Current Alarm LED and Volt-Free Contacts High Current Alarm LED and Volt-Free Contacts Crystal Controlled Interrupt Timer (1-999 seconds ON and 1-999 seconds OFF) Output Circuit Breaker to protect the unit and allow the user to isolate the output.

METERING & DISPLAY VIA LCD DISPLAY • • • • • • • •

Voltage Set Point Output Voltage Current Set Point Output Current Reference Electrode Set Point Reference Electrode Voltage Low Current Alarm Set Point High Current Alarm Set Point

TERMINATIONS • 2 Power Input Terminals (M8 Studs) • Positive and Negative Output Terminals (M8 Studs) • 2 Input Terminals to connect the Reference Electrode/Pipeline with an input impedance of 1MΩ

ENCLOSURE • Stainless Steel to IP66 as defined in BS EN 60529:1992 (alternatives available) • Dimensions: 600H x 400W x 200D (mm)

OUTPUT • Voltage to within 1Volt of the Battery Voltage • Current to the Maximum stated • Output Resistance ≥0.25Ω


DATASHEET 2.6.11

Datasheet 2.6.11

6/8/08

13:34

Page 2


DATASHEET 2.6.11

SOLAR POWER UNTIS REVISION 1 ENVIRONMENT The controller will operate in the following conditions: • 99% relative Humidity • -100 to +550C Ambient Temperature

REMOTE MONITORING & CONTROL • Optional Remote Monitoring • Optional Remote Control • Optional Radio Synchronisation of Interrupt Timer • Optional RS 232 Port

SOLAR ARRAYS SOLAR ARRAY FEATURES We offer a wide range of different solar array types to meet the specific application and site where they are intended to be used. Solar modules are usually the traditional monocrystalline cells but other high density cells are also available. The mono-crystalline solar cells deliver maximum power even under reduced light conditions. All modules are assembled into robust weatherproof sub-arrays including cabling. • Mono-crystalline solar cells deliver maximum power even under reduced light conditions • Dense packing of cells provides more power where space is a limitation and creates a uniform aesthetic • Tight electrical specifications guarantee industry leading energy yield performance • Highly transparent tempered glass delivers more power and ensures high impact resistance and protection against hail, snow, ice and storms • Long and reliable service life backed by a 25 year warranty.

BATTERIES MAIN CHARACTERISTICS The batteries we offer are Dryfit type which are sealed, maintenance free lead acid batteries. It is no longer necessary to refill with water. • Lead Acid System • Sealed Units • Rechargable • Maintenance Free • Pb-Ca-Sn Alloy • Immobilised Gel Electrolyte (preventing acid layer formation) • Extremely Economical and Efficient

DATASHEET 2.6.11


Impressed Current Cathodic Protection Section

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