~IJt.,....l,.II"""""""'~""':' .s"""'1 A Subsidiary of Kuwait Petroleum Corporation
STANDARDS PUBLICATION
KOC STANDARD FOR EXTERNAL CATHODIC PROTECTION
OF
UNDERGROUND STEEL PIPELINES
&
PIPING NETWORKS
DOC NO: KOC-L-015 (Revision 2)
STANDARDS TEAM
III
DOC. NO. KOC-L-015
II
Page 1 of 48
II
REV. 2
STANDARDS PUBLICATION
KOC STANDARD FOR
EXTERNAL CATHODIC PROTECTION
OF
UNDERGROUND STEEL PIPELINES
&
PIPING NETWORKS
DOC.NO. KOC-L-015
STANDARDS TEAM
II
II
DOC. NO. KOC-L-01S
Page 2 of 48
REV. 2
II
KOC STANDARD
FOR
EXTERNAL CATHODIC PROTECTION OF
UNDERGROUND STEEL PIPELINES
&
PIPING NETWORKS
DOC.NO. KOC-L-01S
ISSUING AUTHORITY:
STANDARDS TEAM 2
0710.12
Published as Final KOC CP Standard
TaskForce (TF-CP/02)
Rev.
Date
Description
Prepared by Tel. No. 65434
I~
l
I~~ ~ Snr. Engr. Standard€' Tel No. 61407
«,--Tearr
U W!Z V_
eader Standards , I. No~ 61896
DOC. NO. KOC-L-015
Pa e 3 of 48
REV. 2
Page No. FOREWORD
5
SUMMARY OF CHANGES
6
1.0
SCOPE
7
APPLICATION
7
3.0
TERMINOLOGY 3.1 Definitions 3.2 Abbreviations
7
7
10
4.0
REFERENCE STANDARDS, CODES AND SPECIFICATIONS 1 Conflicts List of Standards, Codes and Specifications
10
10
5.0
ENVIRONMENTAL CONDITIONS
12
6.0
HEALTH, SAFETY AND ENVIRONMENT
12
7.0
CATHODIC PROTECTION SYSTEM 7.1 Basic Design Requirements 7.2 Protection Criteria Current Requirements Density 7.4 Current Drainage
Bonding 7.6 Test Station 7.7 Line Current Measurement Station 7.8 Road 7.9 Overhead Power Transmission Lines 10 Pre-Design Survey 7.11 Electrical Continuityllsolation 7.12 Cable Connections 7.13 Anode Ground 7.14 Galvanic/ Sacrificial Anode System
12
21
8.0
CATHODIC PROTECTION DESIGNER & INSTALLER
21
9.0
MATERIALS AND EQUIPMENT REQUIREMENTS 9.1 Anodes
Cables
Transformer Rectifier Junction Boxes Carbon Surge
22
10
12
13
13
14
14
15
16
16
16
18
19
23
23
24
24
REV. 2
DOC. NO. KOC-L-015
9.7 9.9 10.0
11
Solid State Polarization Cell Coupon
INSTALLATION OF CP SYSTEM 10.1 General 10.2 Installation of Transformer Rectifier (T/R) 10.3 Installation of Anode Ground Bed 10.4 Installation Shallow Ground Bed 10.5 Installation Test Station and Junction Boxes 10.6 Installation of Solid Polarization Cell 1 Installation of Test Coupons 10.8 Cable Laying 10.9 Galvanic ISacrificial Anode Installations PRE-COMMISSIONING AND FINAL COMMISSIONING 11.1 General 11 Natural Potential 11.3 Preliminary Adjustment 11.4 Coating Conductance Test 11.5 Interference Testing 11 Potential Measurement 11 Final Commissioning 11 Post Commissioning Surveys
24 24 25 25
26 26 27
27 28 28
30
12.0
QUALITY ASSURANCE /QUALITY CONTROL
30
13.0
MARKING
30
14.0
DELIVERABLES 14.1 14.2 Calculations and Documentation
30
1
AS-BUILT DRAWINGS
16.0
APPENDICE S
Appendix-A: Appendix- B: Appendix- C: CP-003 Rev.O CP-004 Rev.O CP-006 Rev.O CP-LCTP-001 Rev.O
Typical Inspection and Cathodic Protection System Typical Check Lists Typical Drawings for Cathodic - Typ. - Typ. Typ. Typ. and
3346 for
l-J,.rort::.l"lr,ron
Deep Anode Ground General Arrangement Single & Double T/RU Compound Layout Cathodic Protection System for Piping I Pipelines Line Current Station Construction Details
ACKNOWLEDGEMENT
30 31
43
44
47-48
Pa e 5 of 48
DOC. NO. KOC-L-015
REV. 2
FOREWORD
This final document "KOC Standard for Cathodic Protection of Underground Pipelines & Piping Networks" (Rev.2) been approved by Standards Team in consultation with Standards Technical Committee (STC) for consistent use throughout for the corporate engineering and operational functions of Kuwait Oil Company (K. The purpose of this Standard
out to achieve the following objectives:
a)
To describe current technical practices in industry and general procedures to minimize and control corrosion establishing Cathodic Protection system with a external of underground steel pipelines and piping network.
b)
To establish general technical inputs and guidance for developing project specifications in order ensure quality, and reliability.
c)
provide general technical inputs and guidance for KOC User Teams and Contractors during the maintenance and upgrading programs of the existing Cathodic Protection
d)
To set out minimum requirements and guidance for monitoring compliance of materials and testing with a Contract.
e)
act as a tool for internal communication from which future safety, environmental and technological changes can be measured.
Feedback as well as any comments or suggestions from application of this Standard derived at any stage of design, construction, maintenance and field experiences are encouraged and should directed to: The Team Leader (Chairman, Standards Technical Committee) Box-9758, Ahmadi 61008 of Kuwait
Preparation of this KOC Standard has entrusted by the Standards Technical Committee (STC) of Task No (TF-CP/02) comprising of the following members: A. AI-Shamari Mohd. Hasan Jaragh
Insp.&Corr (N&WK) Insp. & Corr (S&EK) Insp. & (S&EK) Insp. & Corr (N&WK)
Specialist-I (Corr.) Snr SpeCialist (Insp) Specialist I (Corr.) Snr Corr. Engineer
TF Leader Te1,No.66394 Member Tel. No.63693 Member Tel. NO.65434 Member NO.65428
DOC. NO. KOC-L-01S
Page 6 of 48
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SUMMARY OF CHANGES 51. No. 1 2 3 4 5
Clause Nos. Title 7.5.1 7.5.2 7.8 7.9
6
7.10
7 8
7.11 7.15.2
9
7.16
10
7.16.7
11
9.2
12
11.1.3
13
11.1.4
Description of the Major Changes Revised "KOC Recommended Practice" as "KOC Standard" Added design current density for temporary CP system. Deleted "additional 30% drain current requirement" Reduced coupon test station interval to 1 Km Added Line Current Measurement Test Station. Revised Internal and External surfaces of casing pipe at road crossing locations to install uncoated pipes. Added more details on casing insulating spacers and end seals. Added "mitigation measures for AC voltage Included Pin-brazing. New addition: Close distributed shallow anode ground bed or continuous anode specified for plant piping . Included caution to avoid penetrating "Dammam formation layer" during deep anode GB drilling activities. Deleted detailed specification of Anode, since new material specification standard will be released soon. Specified method to check anode ground bed resistance. Added testing of insulation resistance of buried/installed CP main cables.
III
2
DOC. NO. KOC·L·015
1.0
SCOPE This Standard covers the minimum requirements for equipment, material, installation, inspection Itesting and commissioning of Protection systems for protection of buried underground pipeline! piping network or sections.
2.0 2.1
The equipment, , installation, I testing and commissIoning of Cathodic system for underground steel structures, to the requirements this Standard and pipelines, and piping networks shall standards I codes m&l.nTI,nn'::~rI herein.
2.2
Any or deviations from Standard, along with their merits and justifications, shall brought to the attention of KOC Controlling Team for their review, consideration and amendment by Standards (if required). with this KOC Standard does not of itself confer immunity from legal or
2.3
3.0 3.1
Definitions purposes of this Standard, the following definitions apply.
3.1.1 Anode cell at which oxidation occurs. 3.1 electrode of an electrochemical cell at which 3.1
occurs.
Cathodic Disbondment disturbance of adhesion between coating and pipe surface
3.1
to Cathodic
Polarization
charge of electrolyte potential in
passing across the electrolyte interface.
direction
by the current
3.1.5 Cathodic Protection A technique to or control the corrosion of a metal surface by making that surface the cathode of an electrochemical cell.
REV. 2
DOC. NO. KOC-L-015
3.1
Coating A liquid. liquefiable, or mastic composition that, converted into a solid protective, decorative, or functional
3.1
application to a surface, is film.
Coating Disbondment loss of
between the coating
the metal surface.
1.8 Corrosion The deterioration of a usually a metal. environment. It is an electrochemical
results from a reaction with its
3.1.9 Corrosion Rate The rate
which corrosion proceeds.
3.1.10 Current The
flowing to or from a
area of an electrode surface.
3.1.11 Electrical Isolation condition that a metal structure is structures or from the environment.
electrically separated from other metallic
3.1.12 Electrolyte An environment that to considered.
ions migrating in an
field. In
Standard, soil is
3.1.13 Foreign Structure Any metallic structure
is not intended as a part of the cathodic protection system.
3.1.14 Galvanic Anode A metal that is consumed to provide corrosion protection to another metal, when they are electrically connected in the environment I electrolyte. 3.1.15 Holiday Damage to the coating that exposes the
surface to
environment
3.1.16 Impressed Current current supplied to a . ."",...1',1',,:,1"'1 commercial AC,
system by an external power source such as transformer or electric power generators.
3.1.17
REV. 2
Pa e 9 of 48
DOC. NO. KOC-L-015
n1-ortoron
Any
disturbance on a
3.1.18
structure resulting from stray current.
Bond A metallic connection designed
interchange .,,'''u''''..... metallic
control electrical
3.1.19IR voltage across a
in accordance with Ohm's Law.
3.1.20 Mixed Potential A potential resulting simultaneously on one 3.1
from two or surface.
more
electrochemical
occurring
Pipe-to-Electrolyte potential between the pipe metallic surface and electrolyte, that is with reference to an electrode in with the electrolyte.
3.1.
Piping Networks Underground steel piping system constructed
facilities.
3.1 potential as a result of current across the electrode I
3.1
Electrode electrode, whose open-circuit for measuring measurement; and is
is constant under similar conditions relative potentials other electrode.
Sacrificial Refer to Galvanic 3.1
in clause
1.14
Standard.
Shielding Preventing or diverting the cathodic protection current from
1
Shorted Pipeline
A casing that is in
metallic
r-n"To:I,r"'T
with the carrier pipe.
intended path.
DOC. NO. KOC-L-015
2
Current
3.1
Current is through paths
than the intended path.
3,1,29 Stray-Current Corrosion Corrosion occurs resulting from flow current through paths other than the intended earth. circuit, e.g., by any extraneous current in
3.2
Abbreviations AJB
CP CTJB DCVG HMWPE
IF IFTJB ITP KOC MMO NJB PVDF T/R
Anode Junction Box
Bonding Junction Box
Interval Potential Protection Casing Junction tsO;l(es Direct Current Voltage Gradient High Molecular Weight Polyethylene Health Safety and Environment Impressed Current Cathodic Protection Insulating Flange Isolation Flange Junction Inspection and Test Plan Kuwait Oil Company (KS.C.) Line Current Measurement Station Mixed Metal International Negative Junction Poly Vinylidene Difluoride Transformer Rectifier Station
4.0 4.1
Conflicts event of conflicts this Standard and the / codes or other Contractual requirements, the most stringent requirement shall apply. In case further clarifications are required, the subject shall brought to attention KOC Controlling
4.2 The latest edition of the following standards, codes and specifications shall apply: 4.2.1
National/International Standards and Codes G57
Method for Field Measurement Wenner Method
Soil Resistivity using
DOC. NO. KOC-l-015
2
Pa e 11 of 48
NACE RP 01
Use of Coupons Applications
NACE
Control of External Corrosion on Underground or Submerged Metallic Piping Systems
0169
SP 01
NACE
0200
NACE SP 0286
Mitigation of Alternating Current and Lightning Metallic Structures and Corrosion Control .....,,''' •..,'.11
0572
on
Steel-Cased Pipeline Practices The Electrical Isolation
SP 0502 NACE
Cathodic Protection Monitoring
Cathodically Protected Pipelines
External Corrosion
Assessment Methodology
Design, Installation, Operation and Maintenance of Current Ground
4.2.2 KOC Standards and Recornmended
Parts 1 to 6
KOC Recommended Practice for Selection, Installation and Maintenance of Electrical Equipment in Hazardous Areas.
KOC-E-008
KOC Recommended for Selection and Installation of Cables, Cable Systems and Wiring
KOC-E-023
KOC
KOC-E-024
KOC Recommended Practice for Earthing and Bonding
KOC-G-004
KOC Standard
KOC-G-007
KOC Standard for
KOC-L-002
KOC Recommended for the Protection of KOC Services: Clearance Requirements for Pipelines & Piping, Cables, Underground Structures, Buildings and Housing Projects
KOC-L-012
KOC Standard for Cathodic Protection Material SpeCification
KOC-P-001
KOC Standard for Painting/Coating of
KOC-P-004 Part-4
KOC Recommended Practice for External Coating of Part Layer Fusion Bonded Epoxy Coating
KOC-P-004 Part-6
KOC Standard for External Coating of Pipes Using Three Layers Extruded Polyethylene I Polypropylene "'-\lcr",rn
KOC-P-004
KOC Standard for External Coating of Field Girth Welds, Fittings and Flanges
for
Power Cables and Wiring
Packing, Marking and Documentation Design Data
Metal Surfaces
REV. 2
DOC. NO. KOC-L-015
for External Coating of Underground Piping I Build Epoxy Coating
KOC-P-004 Part-8 KOC-P-004 Part-9
KOC for External Coating Pipelines High Build Polyurethane
KOC-P-004 Part-10
KOC Standard for Polyurethane Insulation and Outer Casing of Polyethylene for Underground Pre-Insulated KOC
for Internal Coating of Pipelines
KOC
Drawing
4.2.3 KOC Standard Drawing
5.0 5.1
Corn pound
ENVIRONMENTAL CONDITIONS environrnent of Kuwait is severe, and rnust procurernent of plant and equipment.
considered carefully for sel'eCllon and
h""t·I'\"'''''
5.2
in Kuwait, refer to KOC-G-007 "KOC Standard for Basic Data", which provides detailed design information regarding the environmental, utility supply conditions prevailing throughout KOC facilities.
6.0
HEALTH. SAFETY AND ENVIRONMENT
6.1
Designer I Contractor shall assure the compliance of necessary design requirements to minimize consequences and impacts of hazards on surrounding and adjoining facilities. Cathodic Protection conditions.
....:"C"t.on",
shall be installed and continuously
under safe
7.0 7.1 7.1.1 Impressed Current Cathodic Protection (ICCP) systems shall be to protect the underground pipelines/piping network or sections. The minimum design life of the permanent Cathodic System shall 35 years. 7.1
Sacrificial anode may be such as underground of the piping at road crossing locations. This has to Proposal to use sacrificial anode systems 1
1
Temporary CP protected from operational.
protection for some short portions ground flow lines of normally identified by the CP systern. require prior KOC
shall be installed to ensure that all buried structures are time of their installation until the permanent CP facilities are anode terminated in a Junction Box.
REV. 2
The minimum design life the Temporary CP system shall be the longer period of either at least two (2) years, or the maximum period when the permanent CP are installed and operational. 7.1.4 The Contractor shall ensure that the integrity of the existing impressed current cathodic protection (CP) system for the pipelines and other buried metallic assets is intact after the installation of works. 7.1.5
provided with a minimum of one (1) pipeline, flow lines and piping run shall cathode (negative) connection point. actual number of connection points current flow and to provide protection by uniform shall be considered to control potentials over the cathode facility.
7.1.6 Junction box I boxes shall current flow control.
utilized for cable connection, anodes distribution, and
7.2 1
structure-to-soil potential shall measured by using high impedance Multimeter and duly Calibrated Copper/Copper Sulphate (CU/CUS04) saturated electrode. The negative polarized potential of at least 850 mV relative to a saturated (CU/CUS04) saturated electrode as per NACE 0169.
7.2.3
maximum negative potential value permissible (IR corrected, instant OFF) shall not exceed -1.2 V (CU/CUS04)
7.2.4
maximum "ON" negative value permissible shall be - 2.5 V (CU/CUS04). If any special circumstances exist where an "ON" potential of more than V (CU/CUS04) is required to be applied, then it shall be brought forward for company approval with proper justification supported by pipeline coating Manufacturer's recommendations. A minimum negative cathodic polarization of 100 mV method may be applied for pipelines only as an alternative acceptance criterion in specific, irregular instances and at the sole discretion of KOC. However, the criterion stated in the above sub-clauses is the preferred minimum negative acceptance value.
7.3 1 For design purposes,
minimum protective current density shall be:
a) 0.5 mA/m2 for buried piping I pipelines where high quality coating (e.g. fusion bonded epoxy, high build epoxy, high build polyurethane, or three layers extruded polyethylene) are applied as per the appropriate KOC Standard{s) such as KOC-P-004 Part 4, KOC-P-004 Part 6, KOC-P-004 Part KOC-P-004 Part 8, KOC-P-004 Part 9 or KOC-P-004 Part-10.
DOC. NO. KOC-L-015
b) c)
7.4
REV. 2
3.0 mA/m 2 for buried piping I pipelines, where coal tar enamel or tape wraps coating are applied. 15 IJ A/m2 for temporary system for buried piping I pipelines.
Current Drainage
1 The following can drain current from the included:
system and a current allowance shall be
Earth grid
Steel in reinforced concrete
Cables Armours
Pipe rack footings
Module bases
7.4.2
design earth conductors.
7.5
Bonding
the minimum
shall be 40 mAlm 2 for buried copper
7.5.1 The Contractor shall supply and install bonding stations the new pipeline as a provision for interference mitigation. Bonding Junction box (BJB) shall be installed as a minimum the following locations a) Where the new pipeline runs parallel to the existing pipelines, start and of parallelism and at every five (5) km intervals. As a minimum, all existing parallel pipelines within a distance of 10m shall be provided with bonding provision. Where pipeline crosses or intersects the existing buried pipelines or buried section of pipelines I Piping. shall have provision terminate 16 mm 2 bonding and a 10 mm 2 potential monitoring cables connected to each foreign pipelines as well as new pipelines. BJB shunts and resistors for each circuit. shall be provided with appropriately 7.5.3 If the new pipeline crosses redundant line, the Contractor shall consider using sacrificial anodes connected to the new pipeline in above ground junction box. 7.5.4 Bonding stations shall limit drain current from the existing T/R unit to be not more than 10% of T IR rated output current. 7.6
Test Station
1 Test Station with Coupons shall be provided at both ends of pipeline and at maximum interval 1 km (1000 m) along the pipeline length. If the pipeline length is less than 1 (1000 m), three (3) test stations shall be provided as minimum. 7.6.2 For the underground piping system inside the plants, appropriate and representative number of Stations shall installed with minimum of 1 station every 50 m
DOC. NO. KOC-L-015
interval.
REV. 2
Pa e 15 of 48
number and location of the Test
The Test Station shall measurement, while RP 04.
,,,:;,ronn
shall be subject
KOC approval.
provided with dual coupons. One shall be for IR other shall for native potential measurement as
potential NACE
7.6.4 The Test shall include a magnetic reed switch between the polarized coupon and the pipe connections to interruption of coupon. The Station shall 2 by using thermit weld or have double 10 mm copper cables connected to the pin brazing. 7.6.5 Additional
Stations shall
installed at the following locations:
a)
Insulating
b)
At both sides of the valve station.
c)
On
d)
At the galvanic I sacrificial
e)
At the stray current areas
f)
At a location that a
g)
At hot spot area
h)
At the drain
i)
At Overhead power transmission line crossing or parallelism
j)
Subkha area
locations
sides of cased road croSSing
"'(,:">TIl'"
installation
in the pipe
thickness or
occurs
7.6.6 If bonding stations as mentioned in clauses 7.8.5 & are , then such facility shall be upgraded to coupon available at one (1) km stations specified in clause 7.8.1. e.g., station the requirement of coupon Insulation Test station provided at the start point shall provided with coupons, instead of installing another coupon test station the same location.
7.7 7.7.1 Line Current Test Station every five km (5 km 15000 m). 7.7.2
be provided
points and
the pipelines at
Current Test ..... "::IT.rln shall be constructed as per KOC DWG. No. CP-LCTP-001.
7.7.3 Current carrying cables on LCTS shall be 10 mm 2 , whereas measurement cable shall 6 mm 2 .
DOC. NO. KOC-L-015
7.8
II
Page 16 of 48
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Road Crossings Pipelines and piping systems provided with road crossing casing pipe shall meet the following requirements:
7.8.1 Casing pipe (sleeve) shall be bare (uncoated) metallic type. 7.8.2 Casing pipe (sleeve) shall be electrically isolated from the pipe, using Polypropylene or HOPE spacers. The distance between two consecutive spacers shall not be more than 2m. In addition, double spacers shall be installed on carrier pipe at both ends of the casing. 7.8.3 Casing pipe (sleeve) shall be sealed at each end to prevent ingress of soil 1 water. Only pull-on type end seals shall be used for new pipelines. Retrofitting or wrap around type end seals shall only be used for existing pipelines with split casing installations. The end seal shall be designed such that the end seal material by itself shall form water tight fit on caSing as well as carrier pipe. Additional Metallic binding straps shall be provided for mechanical protection. 7.8.4 The sleeve isolators and end seals material shall be selected as per clause 7.4 of NACE SP 0286. 7.8.7 Road crossing shall be designed as per NACE SP 0200 and NACE SP 0286 section 5. 7.9
Overhead Power Transmission Lines Testing shall be carried out in accordance with NACE SP 0177 to evaluate the effects of induced AC current and voltage on the cathodic protection system, pipeline and the effect on safety of personnel during pipeline construction. Remedial measures shall be implemented in accordance with NACE SP 0177. In addition, any AC voltage indicating a current density of 20 mAlm 2 or above (assuming 1 cm 2 sized area of holiday 1 defect) shall be mitigated using a solid state DC de-coupling device and sacrificial anodes.
7.10 Pre-Design Survey 7.10.1 Pre-design cathodic protection site survey shall be carried out along the route of pipeline and survey report shall be submitted to KOC for review and approval. Site survey findings I results shall be offered for site verification to KOC representatives prior to submission of reports. Site survey report shall include detailed layout drawings of pipeline I facilities, reflecting aI/ foreign pipeline I Overhead power transmission lines crossings & parallelism, existing CP facilities (such as transformer rectifiers, anode ground beds, test facilities etc.), soil resistivity survey locations, road crossing locations, etc. The following surveys shall be carried out as a minimum along the pipeline route.
il
DOC. NO. KOC-L-015
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REV. 2
7.10.2 Soil Resistivity Survey a)
The
procedure take into and planned finished grade
the surface soil conditions, at the Site.
b)
carried out for subject area and survey results which shall optimum and calculations for the CP system.
c)
Soil I conductivity measurements for deep anode are recommended, but not mandatory before borehole is . In any final borehole depth and anode placement be approved by KOC during construction, [)a~~ea on measurements drill stem resistance and anode resistance, taken during drilling the anode borehole.
d)
Soil data in CP design calculations seasonal weather conditions whereby the most onerous Soil resistivity
shall be
include the is
of
out at following locations as a minimum:
(i) Along the pipeline route at every one (1) km interval, temporary sacrificial anode
locations, road crossing locations and over head power transmission 1m, 2m and 3m depths, utilizing Wenner's 4-pin method as per ASTM by Electromagnetic method (ii)
resistivity shall be out at shallow anode ground bed locations plant areas. Soil resistivity survey shall be carried out at 1m, 2m, 3m, 5m and every 2m interval up to the depth of anode, using Wenner 4 pin as per G57. survey shall carried out minimum four (4) locations each CP system
7.10.3 Stray Current Interference a) Site
shall be conducted to identify
possible source
DC Stray
b)
Survey shall identify the existing anode ground bed and locations in the locations vicinity of route. list of foreign ground bed I including rating and operating of ground I CPTR shall included in the report.
c)
Foreign crossings and parallelism along the identified. survey report include entire list pipelines along pipeline
7.10.4 HVAC
route shall be details of
Crossings and Parallelism
survey shall carried out along the pipeline to identify the HVAC locations and/or HVAC line parallelisms. Site survey report shall include a list which includes the HVAC line rating in KV, distance of HVAC line I tower footings from and length of parallelism. Survey shall include AC potential measurements of existing pipelines in the same corridor.
Pa e18of48
DOC. NO. KOC-L-015
REV. 2
7.11 7.11.1 pipeline I piping shall electrically continuous over the total length but excluding is provided, a controllable connections to other pipelines. Where an insulating bonding connection with variable resistors and current shunts shall be provided across the insulating device. 7.11.2 Electrical isolation of all newly constructed pipelines I piping shall made via insulating which shall be properly selected to comply with the pipe design parameter. 11.3 Electrical isolation
shall
installed at
following location(s):
a}
Connection points of new pipe with eXisting pipelines.
b)
Connection pOints of new pipe with gathering pump stations, and metering
c)
When connecting the pipe to a device, that requires
d)
Connecting pipes made of dissimilar metals.
7.11.4 Electrical isolation may require with an insulating flange kit, required, pipe spool shall be Contractor shall assess the provision. Internally coated pipe spools flow across the insulated flange.
booster stations, manifolds,
grounding.
pipe spool in conjunction on conductivity fluid within the pipe. If with epoxy as per KOC Standard KOC-P-005. for such arrangement make appropriate shall be of sufficient length to prevent current
7.11 Additional insulating kits, insulating glands and similar equipment shall installed, as necessary, to prevent shorting of electrical isolation by instrumentation, electrical, and civil requirements. Such isolation points shall provisions shorting with bond boxes I cables during commissioning and operations. 7.11 Insulating devices shall not 7.11
installed in any buried section of a pipeline or piping.
insulating flange shall be fitted with an appropriate device to provide electrical DC voltages and currents, but provide a path for safe of AC isolation of fault and lightning currents.
7.11.8 The isolating device shall be 7.11 All steel in electrically isolated from
as per NACE SP 0286. electrical grounding system, shall piping I pipeline to be protected under this Standard.
e 19 of 48
DOC. NO. KOC-L-015
REV. 2
7.12 Cable Connections
7.12.1 Aboveground Cable Connections a) Aboveground cable to pipeline I piping and structures shall means of bolted cable lug connections to steel plates structure. Only highly pure brass and, bolts nuts shall be used. b)
by the
plate and weld method shall be compatible with the structure plate coating be removed to facilitate the bolted cable connection. coating I touch up as per KOC Standard KOC-P-001 shall be on the steel completion of connection.
7.12.2 Underground Cable Connection a)
Underground cable connections to piping and pipelines shall Brazing. thermit welding or by
means of
b) A section of the pipe coating required for connections shall be removed to the minimum area, not more than 100 mm x 100 mm from the top of pipe. c)
Suitable tools and method shall be for cutting and peeling back coating to avoid any damage metal and coating (percussion tools or grinders, shall not for this purpose).
d) This pipe area be thoroughly (NACE 2) surface preparation.
to a near white metal finish
Sa2~,
weld shall be no more 15 grams, and cable cores shall be not larger than 16 mm 2 If heavier to be attached, the core shall be 2 separated into strands of than 16 mm each and welded separately.
f)
Upon completion the applicable
g) A holiday have no holidays. h)
7.1
All
the weld, the pipe Specification I shall be used
shall be for pipe coating
in accordance with
verify that the applied coating and wrapping
laid in single runs. No underground cable-to-cable splicing made.
The connection be tested for strength and continuity (Contact resistance between the pipe and cable shall not exceed 0.01 Ohm).
DOC. NO. KOC-l-015
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2
7.13 7.13.1 Only deep ground
7.1
shall be used to cathodically protect pipelines outside plant
Close distributed type shallow anode ground bed and lor deep ground beds shall be to protect piping and piping networks inside plant facilities.
structures and cathodic 7.13.3 In case of plant piping where area is congested due or distributed shallow vertical protection of subject pipeline by remote anode is not practical, continuous type anode may be along the pipeline better current distribution. 7.1
Deep anode ground shall located cathode structure as well as any foreign structures is not within the anode voltage gradient. A minimum of 100 m shall be maintained between new ground bed and cathode I foreign structure.
7.1
Where new pipelines I piping run within calculated voltage gradient of an existing current mitigation shall be provided. Either a bonding station shall anode ground bed, provided between pipeline the ground transformer-rectifier (T/R) unit negative connection or sacrificial anodes may used at "hot spots". Use of sacrificial ~nr'f"IQ shall be subjected to approval. Bonding stations should limit drain current from the existing unit to not more than 10% of the rated output current.
7.13.6 All anode groundbeds shall have ground bed marker posts with the groundbed number and depth on a stainless plate. Coated metallic pipe or non-metallic IJIQ·;:'Uv ground casing, alternatively, metallic non-metallic, plastic with adequate
tag
be utilized for inactive length of pipe inactive length shall cased with strength.
7.13.8 The Contractor shall provide GPS Coordinates for the proposed deep ground bed location to KOC prior to Drilling activities for approval. 7.13.9 The Maximum depth of the anode ground bed shall 70 for South, "Dammam formation shall whereas 130 metres for North, West Kuwait. In any not be penetrated during drilling operations. The Drilling Contractor shall stop drilling Dammam formation or upon activities and inform KOC representatives upon reaching discovering Hard rock during drilling. 7.13.10The anode material for ICCP system shall be mixed metal oxide coated Titanium. All anodes shall be of tubular configuration. 13.11 (Canister) MMO Standard shall used for shallow
with carbonaceous backfill as
ground
distributed type
DOC. NO. KOC-L-015
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Page 21 of 48
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REV. 2
7.13.12The Vendor shall submit the calculation of quantity of backfill material required, which shall include quantity up to the top of the anode (active length) and spare quantity above the active column. Coke breeze quantity shall be estimated for specified design life considering consumption rate of coke breeze 1.0 kg per amp year. The maximum discharge current density at the active section of casing pipe to earth interface (or canister 2 to earth interface in case of canister anodes) shall not exceed 1.61 Amp/m . Spare amount of backfill shall be five metres (5 m) above the active column. 7.13.13 Deep vertical anode ground beds shall be in accordance with NACE SP-0572 and Drawing No. CP-003. 7.14 Galvanic I Sacrificial Anode System 7.14.1 The use of a galvanic I sacrificial anode system shall be subject to KOC approval, and may be considered for the following cases: a) Localized "hot-spot" protection to supplement ICCP systems. b) Temporary CP systems during construction periods. c) Underground road-crossing areas of above ground pipelines. d) Stray current areas. e) Overhead power transmission line crossing or parallelism f)
Short section of buried burn pit lines where bonding with the nearest ICCP system is not viable.
g) Short buried sections of flow lines.
7.14.2 Prior to the selection of cathodic protection by sacrificial anodes, soil resistivity shall be measured to determine, if the resistivity is sufficiently low to allow successful application of sacrificial anodes; and to calculate the required weight of the sacrificial anodes. 7.14.3 Sacrificial anodes shall be used and supplied in low resistivity chemical backfill package. 8.0
CATHODIC PROTECTION DESIGNER & INSTALLER
8.1
The design and installation of the CP system shall be carried out by a Cathodic Protection Specialized Contractor, subject to KOC approval.
8.2
The design and commissioning of cathodic protection systems shall be carried out by a Cathodic Protection Specialist Engineer (NACE certified as CP-Specialist or equivalent).
8.3
A NACE certified Technician of Level II or equivalent shall present at all time at site to supervise the installation of all the parts of the cathodic protection system.
III
9.0
MATERIALS AND EQUIPMENT REQUIREMENTS All protection materials shall Protection Material Specification".
9.1
REV. 2
e 22 of 48
DOC. NO. KOC-L-01S
as per "',"-,,'-"-,1....-\..112 "KOC Standard for Cathodic
Anodes
1.1 The anode material be catalyzed Titanium anode coated with highly conductive Mixed Metal Oxide (MMO). 9.1.2
installed as a number of two (2) with of the ground bed.
strings, each comprising a maximum junction box to
9.2 9.2.1 Cables shall Standards
9.
specified, supplied and installed in accordance with the appropriate KOC 12, KOC-E-008 & of I HMWPE (KYNAR® I FLUORO chlorine. All other cables shall be of XLPE/PVC.
tails/string HMWPE) suitable to
the rating and voltage drop be determined to However, the following cable types with minimum sizes
9.2.3
a)
Anode main
b)
Anode tail / string cables
c)
Cathode main
d)
Bonding cables Test
f)
Sacrificial anode cable anode
g) h)
Pipe
i)
10 for AC mitigation
for AC mitigation Current
L ii. 9.2.4
+
and negative cables be of of different color. cable shall
and BLACK color respectively.
2
DOC. NO. KOC-L-015
9.2.5 All cables shall be clearly identified and numbered. Tagging shall be provided clearly identifying their purpose or point of origin and termination. 9.2.6 The cable and all their shall considered as critical. Complete electrical isolation shall be essential between the cable I connection and the environment. Water ingress or soil contact must not occur. All cables shall
laid in single runs. No cable to cable splicing shall be permitted.
9.3 9.3.1 Transformer
shall
in
with KOC Standard KOC-L-012.
9.3.2 The T/R unit output ratings for external requirements:
9.4
systems shall satisfy
following
a)
AlC Input
440V +/-6%, 4 wire,
50 2.5%.
b)
Minimum Output Voltage
50V DC, or as specified by design if higher is required.
c)
Minimum Output Current Rating
50A DC, or as specified by design if higher is required.
Junction Boxes
9.4.1 Junction boxes shall be certified for 'd', II B T3 Zone 1& 2 use in classified areas with minimum degree of protection as IP Junction boxes for non-classified area shall be constructed with SS 6L material with minimum of protection as IP 9.4.2 The system design shall have the following types of Junction boxes: a) AJB
Anode junction boxes
b) NJB
Negative junction boxes
c)
Test station
d) IFTS
Insulation Flange
e)
Casing Test Junction
f) BJB
Bonding Junction Box
g) LCTS
Line current
h) HTX
Overhead Power
Station
Station crossing or Parallelism junction box
DOC. NO. KOC-L-015
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of 48
IFTS, CTJB, B~IB, and HTX layout drawing(s) with a cover shall be to show the arrangement and cable connection of foreign pipelines, anodes, coupons, permanent insulation flanges, cables and all associated installations.
9.5
Carbon Backfill Carbonaceous backfill shall be suitable for use with cathodic protection anodes, comprising hard round grain carbon to No. 16; and shall dust free, with appropriate carbon lubricant added to bulk density around 70 Ibs/fe. recommended backfill is Loresco or approved equivalent.
9.6
Surge Diverter diverters installed at isolation and shall be such that the breakdown voltage of the electrodes is lower than that of the isolating flange capable of across which they are mounted. In addition the surge diverter shall discharging the lightning currents without sustaining damage.
9.7
Solid State PolariZation Cell Solid state polarization mitigating locations. life.
polarization
as a DC decoupling shall be suitably rated
at the AC specified
9.8 Coupon material shall conform to construction and installation shall be as L-012 & NACE RP 0104.
same grade of to KOC
10.0 10.1 10.1.1
to installations, all including transformers rectifiers, cables, are in good condition. and junction boxes shall be inspected to ensure that
10.1.2 All
olo.,...t..."·,,.
connections shall
10.1.3 The Cathodic Protection in of flare 10.1
backfill,
safe and as TR, junction
etc. shall not
installed
pit area.
The of cable connections shall be ensured prior to energisation of CP by suitable to ensure positive cable from and negative cable from NJB are connected to positive and negative terminals of Transformer
10.1.5 For I piping installed following modifications shall be
areas with existing as below:
grounding
the
REV. 2
Pa e 25 of 48
DOC. NO. KOC-L-015
a) The buried copper shall be insulated minimum pipeline) crossing location. b) Copper conductors parallel
new pipe
side of
10.0 m to
a distance of 3.0 m shall be insulated.
c) Relocate grounding rods to be 10.0 m away from the piping. 1 1.6 Samples of installation lists are attached in Appendix B of this Standard. Contractor shall make suitable additions or changes for the particular job. 10.1 Any damages caused existing Cathodic Protection equipment during construction by coordinating with KOCI activities new pipeline shall rectified on urgent owner representatives.
10.2 Installation of Transformer Rectifier (T/R) 10.2.1
area as per
transformer rectifier shall installed in secured, fenced and appendix-C (KOC Dwg. No. KOC-CP-004 and Drwg. No. 55-02-49).
10.2.2 All units shall installed outside the main Booster stations, manifolds, 10.2.3
AC cut-off switch shall
of plant
provided near the TR unit and within the
10.2.4 transformer / rectifier Appendix-C (CP-004) and
fence shall
GC's,
such
fence.
grounded in accordance with
10.3 10.3.1 Holiday shall conducted for anode tail prior installation. If any insulation damages found during holiday testing the whole anode assembly shall be rejected. 1
shall installed with in low resistivity carbonaceous backfill in such a way that the anode is in the center of the bore hole. Two (2) Nos. of centralizers shall be used for anodes of length 1.0 m and more.
10.3.3 A perforated vent geo-textile woven
shall be installed alongside the string(s) and covered by a to avoid backfill blocking the perforations.
10.3.4 The backfill shall be specially formulated to facilitate pumping bottom with to improve the minimum risk of air entrapment. Settling and compaction can be ground bed performance and life. The desirable properties for the backfill material shall as per NACE 0572.
10.4 Installation of Shallow Ground Bed 10.4.1 Close Distributed type Shallow Vertical or Shallow Horizontal Anode Installation. a)
The location of the anodes shall be marked
DOC. NO. KOC-L-015
10.5
1
REV. 2
b)
Anode tail cable shall holiday tested prior to lower the anode. If any holiday is anode '=>",<>o.m shall be
c)
depth and diameter of anode bore hole or shall be as the approved Upon completion of anode bore hole or trench, anode anode lowering care should be shall be lowered to the design depth. During taken that there is no damage the cable connection.
d)
shall be Quantity of for each CP design. After the completion of anode installation a trench and terminated in anode junction
e)
All the tail cable be terminated using suitable variable resistor and shunt inside the anode junction box. Anode cable shall properly tagged identification.
as per approved tail cables shall be laid in
Installation of Test Station and Junction Boxes
1 Test Station I Junction box shall
10.5.2 The
entry pipe
installed on a suitable concrete foundation.
the Test Station/junction box shall
cable shall be terminated inside identification.
10.
properly sealed.
junction box with proper tagging for
10.6 Installation of Solid State Polarization Cell
10.6.1 Solid locations.
polarization Cells be installed inside a suitable junction box at AC mitigation
tail cable, bonding and mounted with suitable support
1
cable shall be terminated inside the and foundation.
10.7
1
coupon shall be constructed and installed according to NACE RP 0104.
1
10.7.2 Coupon cable shall be terminated inside the be between pipeline one coupon.
A magnetic
switch shall
10.8
shall laid at
1 10.8.2 The
with
1
mm
and as
Standard
laying shall include provision of identification sand, provision of cable tile and warning tape.
Aboveground markers cable Cable route
in Arabic shall be provided
backfilling of
REV, 2
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DOC. NO. KOC-L-015
point. 10.9 10.9. 'I Prior to installation, the waterproof container shall be removed and the anode package shall inspected to confirm its good condition. 10.9.2
anode lead wire shall anode.
connected to the
inspected to ensure that it is
10.9.3 Prior to backfilling, it shall be confirmed package.
the
is centered in
backfill
10.9.4 anode shall connected to the cathode structure through test station / junction boxes, installed aboveground. 11.0 PRE-COMMISSIONING AND FINAL COMMISSIONING
11.1 General 11.1.1
ing
be carried out by CP Engineer to ensure high quality
performance. 11 1.2 All terminations inside the junction 11.1 Individual anode/ anode string measured using 3 - Pin method.
UVi',<;;;;:>.
test
and T/R shall be and total anode
CnE!CKf~O
resistance shall be
11.1.4 All buried cathodic protection main shall be tested for insulation damages prior to and / or during commissioning. The insulation resistance shall be measured between cable conductor and a temporary grounding by applying a test voltage of 500 Vdc and minimum acceptable insulation resistance value shall be 100 M Ohm. 11.1.5 Pipe shall be protected by temporary CP system immediately within two (2) weeks with sacrificial anodes and where installation of the burial in soil. For temporary are delayed, pipe and sacrificial anode cables may be allowed to junction I test temporarily connected by crimping both in order to provide protection system be monitored and maintained on immediately. In addition, temporary monthly basis until permanent system is commissioned. monthly report shall be submitted to KOC for review and approval. 11.1 Impressed current CP System commisSioning shall be procedure.
out as per the approved
11,2 11
1 Prior performing the natural potential survey, contractor shall confirm the subjected pipeline is disconnected from all the sacrificial anodes and pipelines I structures.
I
DOC. NO. KOC-L-015
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11.2.2 The subjected pipeline shall be disconnected for minimum 72 hours for depolarization. 11.2.3 Natural potentials shall be measured and verified at the Test Stations and Junction Boxes. If higher or lower natural potentials are observed then the location shall be investigated. 11 .2.4 The natural structure to soil potential shall be measured and recorded at all the measuring points on the pipeline, both sides of insulating joints, foreign structures, road crossing casing, test coupons, etc.. 11 .2.5 The survey results shall be witnessed and approved by KOC representatives.
11.3 Preliminary Adjustment 11.3.1 The T/R output shall be kept at 10% of design current output. After 48 hours, potential shall be measured and the transformer I rectifier output shall be increased or decreased, if required, in order to meet the protection criteria indicated in clause 7.4 of this Standard .
11.4 Coating Conductance Test 11.4.1 Line current measurement shall be carried out at all current measurement test stations. Line current measurement shall be carried out using calibrated digital millivolt meter. Prior bonding the new pipeline with foreign pipelines or structures, coating conductance test shall be performed by injecting a test current.
11.5 Interference Testing 11 .5.1 The Contractor shall perform all AC & DC interference testing; and shall be responsible to contact all relevant authorities and arrange for their presence at all the required tests. 11.5.2 DC Interference survey shall be carried out at insulation flange locations, the locations of foreign pipeline crossings , in the vicinity of foreign anode bed, where the new pipeline diverge or converge with existing pipelines and run parallel with existing pipelines. Other interference prone areas shall also be selected for the survey. 11.5.3 The DC interference survey shall be carried out as per the approved procedures. The DC interference survey shall be carried out by interrupting the new and existing TR(s) independently. 11 .5.4 Should any DC interference test results show a positive change in the potential of new I foreign installation or structure, the Contractor shall take remedial action to eliminate the interaction. 11.5.5 Mitigations shall be carried out based on the survey results and with consultation with new pipeline and foreign pipeline Owner. 11 .5.6 Post mitigation survey shall be carried out to ensure that DC interference is mitigated.
e 29 of 48
DOC. NO. KOC-L-015
REV. 2
11.5.7 Preferably, DC interference should be overcome by the use of adjustable resistors and alOCJes installed a bond station junction box, between bonding cable from the the foreign structure. 11
AC survey shall be carried out as per approved procedure. AC potentials and AC Current density shall the locations where HVAC overhead transmission than 11 kV) crossing, parallel to the pipeline and locations where converges I diverges. Continuous AC potential data logging shall carried for 24 hours locations where AC voltage indicates personnel hazards or AC corrosion.
11
If induced AC potential found above the limit mitigation measures to carried out the NACE 177. measured AC current density shall investigated loss due AC induction and mitigation measures shall be taken accordingly.
11
10Post mitigation survey shall be mitigated.
out to ensure that interference due to AC is
11.6
11
1 Following the adjustment of CP station outputs to the structure to soil potentials and after allowing time for structure polarization, a complete set of ON/OFF potentials shall recorded at all the measuring pOints and other positions measured During the ON/OFF all the connected and affecting the structure interrupted with GPS synchronized interrupters.
11.6.2 Should be more negative than their natural potential potential of metallic previously or if any potential swing occur on caSing potentials during ON/OFF survey, then Contractor shall investigate the reason the low and pipe. 11.7 Final Commissioning
Final commissioning shall consist of
following:
a)
Measuring structure to soil potentials and as specified in clause11.4.1.
b)
Measuring total current output from each CP where current measurements are
c)
Measuring
d)
Measuring current and resistance, if remedial bond fitted.
otTlln,..,c
of
all measuring points by an approved method
sources: transformer /
Calibrating all current measurement points.
f)
and
Measurement of AC potentials at test stations.
current in
direction
DOC. NO. KOC-L-015
I
Page 30 of 48
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11.8 Post Commissioning Surveys 11.8.1 Close interval potential survey (CIPS) and direct current voltage gradient (DCVG) surveys shall be carried out, as per NACE SP 0502 "Pipeline External Corrosion Direct Assessment Methodology", after all adjustments to the CP system are made. 11 .8.2 Prior to any DCVG and CIPS surveys, the Contractor shall develop a Survey Plan and Procedures and submit the same for KOC approval. 11 .8.3 The results of CIPS and DCVG surveys shall be analyzed, and the Contractor's proposal for proper remedial actions shall be recommended and carried out after KOC approval. 11 .8.4 Any coating defects identified during DCVG survey shall be investigated and further exposed for direct examination. Defects shall be repaired or rectified with approved procedures.
12.0 QUALITY ASSURANCE I QUALITY CONTROL 12.1 The Manufacturer / Contractor shall operate a quality system to ensure that the requirements of this Standard are achieved. The quality system shall be preferably based on ISO 9000 series of standards; and the Manufacturer / Contractor shall demonstrate compliance by providing a copy of the accredited certificate or the Manufacture's / Contractor's quality manual. 12.2 Verification of the Manufacturer's / Contractor's quality system is normally part of the pre qualification procedure, and it is therefore not detailed in the core text of this Standard. 12.3 The Contractor shall submit their Quality System Manual & Quality Assurance Plan that includes all the activities in chronological order with responsibilities. Inspection & Test Plan (ITP) for CP system design, procurement, installation and commissioning shall be submitted for KOC approval. KOC Standard project quality assurance / quality control requirements shall be adhered to. 12.4 A typical ITP is attached in Appendix A of this Standard . The Contractor shall make suitable additions or changes for the particular job work.
13.0 MARKING For all relevant requirements on Marking / Packing, refer to KOC Standard KOC-G-004 .
14.0 DELIVERABLES
14.1 General 14.1.1 All correspondence, drawings, instructions, data sheets, design calculations, or any other written information shall be in English Language. In the case of dual languages, one language shall be English .
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REV. 2
14.1 .2 All dimensions, units or measurements, physical constant, etc. shall be in SI units, unless otherwise specified. 14.2
Calculations and Documentation
14.2.1 The following documentation, drawings, inspection and test plans and check lists shall be submitted for KOC review and approval: a) b) c) d) e) f) g) h) i) j)
k) I) m)
n) 0) p) q) r) s) t) u) v) w) x) y)
Design Calculations; Schematic drawings of the entire structure and the CP systems; Anode ground bed detail drawings; T/R unit electrical schematic diagrams; T/R unit general arrangement and mounting detail drawings; Ground bed layout drawing; Anode material; CP cable schedule & layout drawing reflecting, type, size, colour, origin & destination; Test facility detail drawings; Junction boxes and support stands construction drawings; Junction boxes termination drawings; Piping cable connection detail drawings; A detailed area layout drawing reflecting the GIS Co-ordinates and locations of following: (i) Complete pipeline and piping with connections to other pipelines, manifold, plants, etc. including location of all insulation flanges / joints and cased road crossing locations. (ii) Installation of all CP equipment's such as Transformer Rectifier, anode ground beds, test & Junction boxes, etc. (iii) Cathodic Protection cable routing including start, end and turning points. (iv) Overhead / Underground AC power lines. (v) Foreign metallic structures close to the piping/ pipeline, including all crossing and parallel foreign pipelines Piping interactions survey report and remedial measures required; CP electrical installation specification; Installation procedure; Pre-commissioning and Final Commissioning procedures; Operation and maintenance procedures; CP material data sheet List of foreign pipeline CP system and anode ground beds in the pipeline vicinity List of Cased crossings Technical data sheet for all major CP equipment's AC & DC Interference survey & mitigation Procedures and Reports OAPIITP for material procurement OAP IITP for CP installation activities
III
DOC. NO. KOC-L-015
1
2
CP calculations shall include: a) b) d) f) g) h) i) j)
k) I)
Protected structure surface area; Anode ground resistance, output current, mass and number; Protected structure CP current demand; Foreign structure CP drain current; voltage including both the and cathode circuit; CP T/R TIR unit current resistivity calculations. current Station calibration factor Coating conductance Anode Remoteness calculation calculation cross country pipelines potential rise calculation for optimum distribution of close distributed anodes
15.0 AS-BUILT DRAWINGS 15.1 Construction I design drawings shall be updated to design, showing the as-built cathodic protection system.
field modifications to the original
15.2 The as-built drawings shall establish coordinate in "WGS 84 UTM (Geographic Information Systemlocations of the following: a)
38N"
route.
b)
c)
f) g) h) i) j)
1
Stations.
Electrical bonding. Interference locations.
Electrical isolation locations.
Cables.
Junction boxes.
Ground beds.
Transformer I Rectifiers.
Overhead lunderground AC power lines.
The Contractor also update the existing CP drawings of the particular facility I area incorporating the new system.
DOC. NO. KOC-L-015
Page 33 of 48
Il
REV. 2
16.0 APPENDICES. Appendix - A
Typical Inspection and Test Plan for Cathodic Protection System
Appendix - B
Typical Check Lists for 1. Pipe to Cable Con. by Thermite Welding or Pin Brazing 2. Deep Ground Bed Protection System 3. Road Crossing Cathodic Protection System
Boxes (JB and Test Box)
4. TR I Rectifier 5. Pre-commissioning Checklist for Impressed Current
Cathodic Protection System (Pipelines)
Appendix - C
Typical Drawings for Cathodic Protection
CP-003 Rev.O
CP-004 Rev.O
Typical Deep Anode Ground Bed General Arrangement Typ. Single & Double T.R Unit Compound Earthing Layout Typ. Cathodic Protection System for piping I Pipelines Typ. Line Current Test Station Construction and Cable Details
CP-006 Rev.O
CP-007 Rev.O
III
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II
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REV. 2
I
III
APPENDIX A: TYPICAL INSPECTION AND TEST PLAN FOR CP SYSTEM Inspection Status No.
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17. 18 19 20 21 22
Activity Description
Reference Document
Acceptance Criteria
Inspection Record
Sub Contractor
Contractor
KOC
Design and drawing
R
Pre-inspection Meeting
w
Material Purchasing
R
Material Inspection
w
Drilling of Ground Bed Casing Preparation, Welding and installation Anode Support pipe welding of bottom plate, centralizer and anode support shoe Installation of Anode, Cable and Vent pipe Preparation of Coke Breeze Backfill and backfilling the active area Backfilling of non-active area with Gravel Installation of shallow anode ground beds Anode Junction Box Installation
S
Negative cable installation Negative Junction Box Installation Pipe to Cable Connection and encapsulation Installation of test boxes, line current test boxes, and bond boxes. Underground cable installation Installation and testing of Insulation Flanges and Surge Diverters Electrical isolation test of casingl carrier at road crossing installation. Installation of pre-packaged sacrificial anodes Installation of DC-decoupling devices IPolarization Cells and associated grounding cells Installation of Temporary CP installation and monthly monitoring
S
w w S
S
w w w w w w w w w w w w
23
Installation of Polarisation coupon and permanent refrence electrodes
w
24
T/R Installation
w
25
Pre-commissioning
26
Natural Potential Survey Testing and energisation of Transformer Rectifier
w w
27
w
28
Protective potential survey
w
29
ACI DC interference Survey and mitigation
w
30
Line Current measurements
w
31 32
Commissioning
w
Review of Completeness
R
R:
s: W:
Review Su rvei Ilance Witness
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of 48
REV. 2
APPENDIX B:
1. 2. 3. 4. 5. 6.
Pipe
Cable Connection by Thermite Welding or Pin Ground Bed Protection System Road Crossing Cathodic Protection System Boxes (J.8 and Test Box) I Rectifier Pre-commissioning Checklist for Impressed Current Cathodic Protection System (Pipelines).
DOC. NO. KOC-L-015
2
APPENDIX B (contd.l) :
1.0 PIPE TO CABLE CONNECTION: TYPICAL CHECK LIST Test I Junction Box no.:
Date:
No of connections & cable conductor sizes'
Activity Description SI.
Results Acc.! Rej.! NA
Inspection Sub-
Contractor
No. Contractor
1
Location as Per approved Drawing I procedure
2
Connection areas cleaned to bright metal Pipe to Cable connection acceptable
3
4
5
(Pin Brazing I Thermite Welding} Cable conductor size and distance between connection points as per approved drawing I procedure. Graphite weld mold size and condition
6
Pin brazing equlpm
7
Mechanical Integrity (pull test)
8
Electrical continuity (less than 0.01 Ohm)
9
Coating Encapsulation and holiday tested.
10
Cable ends tagged
Comments:
S,·h.
KOC
Name
"'H'"'''''''' Date
may added by KOC at any stage of by the Contractor.
Abbreviations Acc. : ACCeIDtf!!Cl
NA : Not Applicable
work and
KOC
REV. 2
DOC. NO. KOC-L-015
2.0
Date:
Deep Ground Bed No.: lSI.
I
I
1
3
Activity -~ .~, ."
Results Acc./ Rej./ NA
101
Sub·Contractor
If"''' "",,·tinn Contractor
KOC
Location of De~p Ground Bed Sufficient distance maintained from nearest foreign structure, structure & other GBs ' foreign structure (M) Distance
~"m ("m ,,,ted,, ,,,",,"co (M) •
I
5 6
Depth Borehole to the required length (M)
7
Drill stem resistal interval
8
Drilling stopped at I before "Dammam formation'
9
I ,
ance from other anode GB (M)
I
..
--. •
measurement at every 10m
_\fIIeldin!j of Cai>ing and Installation
10
Casing Length (M)
11
Metallic Casing at Active Length eM)
12
Non-metallic Casing at Inactive length eM)
13
Welding of Support Pipe Plate,Ce"uaHL""" and Anodes Support Shoe
14
Support Pipe Length ( M )
15
Attach Anode 10 Support ",Ipe andinstaliation
-
I
16
Anode Quantity ( EA )
17.
Anode Spacing ( M )
18
Vent Pipe Length ( M )
19
Coke Breeze Backfill Quantity (Kg)
20
Rough Sand or Gravel Backfill
21
Anode Bed sealed as per aI"" v.,,'" drawing
22
Resistance Measurement
23
Anode Bed Resistance Measurement
I
-'_._
I
•
KOC
Su" Name
rNote -
Date
Additional items may be added by KOC implemented by the Contractor.
any
Abbreviations Acc. : Accepted; Rej.: Rejected; NA : Not Applicable
of the work and shall
REV. 2
DOC. NO. KOC-L-015
APPENDIX B (contd./) :
3.0 ROAD CROSSING CATHODIC PROTECTION SYSTEM: TYPICAL CHECK LIST
Road Crossing No.:
SI.
!
Date:
Activity Description
!
Results
1 Acc'! Rej.! NA
Inspection Sub-
Contractor
KOC
No. Contractor 1
12
Location of Road CrOSSing as per drawing Check the Nos. of Insulation Spacers
~ d'''mrt'""'~ be[we,c
Pipe during and after insertion
e""" P,,", .cd eM'C,
k discontinuily between carrie~i::~~ and Casing works Pipe after completion of carrier pipe
5
Check discontinuity between Carrier Pipe and Casing Pipe after backfilling
6
Check Installation of End Sea!
Sub-C,
KOC
Name Date
Note -
Additional items may be added by KOC at any implemented by Contractor.
Abbreviations Acc. : Accepted;
. Rejected; NA : Not Applicable
of the work and shall be
I
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APPENDIX B (contd./) :
4.0 BOXES (J.B AND TEST BOX) : TYPICAL CHECK LIST
Junction box I Test Station Date:
& Identification Number: SI.
Results Acc.! Rejl NA
Description
Sub-
Inspection Contractor
KOC
No. Contractor Location as per Drawing 2
Support as per detail drawings
3
Foundation Location and Details correct
4
Installation as per detailed drawing
5
Cable connections as per Tennination Diagram
6
Cables installed & Termination complete.
7
Schematic diagram provided inside the JB
8
All Cables clearly identified with tags
9
JB tagged according to approved drawing I procedure Comments:
Sub-Contractor
Contractor
KOC
Name Signature Date
Note -
Additional items may be added by KOC at any stage of the work and shall be implemented by the Contractor.
Abbreviations Ace . : Accepted; Rej.: Rejected; NA : Not Applicable
Page 40 of 48
DOC. NO. KOC-L-015
REV. 2
II
III
APPENDIX 8 (contd./) :
5.0 TR I RECTIFIER: TYPICAL CHECK LIST TR I Rectifier No.:
Date:
TR I Rectifier Capacity Type
0
Tap
o
Manual
AC Input :
Automatic
Volts
Phase
Coar se
Medium
Description
SI.
DC Output:
Volts
Amps
Fine Results Acc.! Rej.! NA
Sub-
Inspection Contractor
No. Contractor
Equipment Undamaged 2
Orientation and Alignment Correct
3
Accessories Installed I Sun Shade
4
Earth as per detail drawing
5
T/R Foundation
6
Insulation resistance :
6.1
Primary Winding - Earth
6.2
Secondary Wind ing Earth
6.3
I
Primary Winding - Secondary winding
7
Oil filling complete and no leakage
8
Condition of Silica Gel
9
AC Supply
10
AC setting
11
MCB operation for input
12
MCB operation for output
13
DC output voltage
14
DC output current
15
Negative cable connection
16
Positive cable connection
17
External AC isolator provided
18
Schematic & operating manual inside TlR
19
T/R Fence
Comments:
Sub-Contractor
Contractor
KOC
Name Signature Date
Note -
Additional items may be added by KOC at any stage of the work and shall be implemented by the Contractor.
Abbreviations Acc. : Accepted; Rej. : Rejected; NA
Not Appl icable
KOC
III
DOC. NO. KOC-L-01S
II
Page 41 of 48
II
REV. 2
APPENDIX 8 (contd./): TYPICAL INSPECTION AND TEST SHEET
PRE-COMMISSIONING CHECKLIST FOR IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM (PIPELINES)
No. 1.0
o o
o o o o
o o
o o o o
o o
o 2.0
o o o o o
o o
Inspector
Description
Date
Remarks
Pre-Commissioning Check if number and location of the anode are as per drawing Check if all anodes cable are terminated and labeled with schematic drawings in the anode Junction Box (AJB). Check if the negative cable (from structure) is terminated in a junction box with appropriate cable tagging and schematic drawinQ inside the JIB. Check if all JIBs and Test Stations are marked and labeled inside and outside with schematic drawinas. Check if all JIBs shunt and resistor ratinQ as per specification Check if all T/Rs capacity, location, labeling, oil level, silica gel are as per specification. Check if the T/R positive cable is connected to anode JIB and neQative cable is connected to Structure JIB . Check if all coupons are installed as per drawinQs. Verify that no short circuit exists between the casing and carrier pipe at road crossing locations Check if the isolation flange (IF) are installed and there is no short circuit Check If all bonding cables to foreign pipelines are not connected . Check If all temporary cathodic protection system is disconnected. Witness potential natural reading for all Test Stations before enerQizing the T/Rs. Witness Calibration of pipeline at line current Test Station Cable insulation resistance test of buried main CP cables by "MeQQer" After energizing the T/Rs. Verify if T/Rs meters are functioninQ. Conduct Coating Conductance test Witness if potential "On/Off readings are meeting the protection criterion for all Test Stations, JIB & IF. After bonding cables to foreign pipelines are connected, Mg anode is connected to the casing and Zn anode is connected to the carrier pipe, witness if potential "On/Off readings are meeting the protection criterion for all Test Station JIB & IF. Check for any interference. Interference MitiQation CIPS & DCVG Survey
I Notes: I Reviewed By..............................................
I Approved
By ...............................
I (Snr.
Engr.)
Note - Additional items may be added by KOC at any stage of the work and shall be implemented by the Contractor.
DOC. NO. KOC-L-01S
Page 42 of 48
II
REV. 2
APPENDIX C: TYPICAL DRAWINGS FOR CATHODIC PROTECTION
CP-003 Rev.O
Typical Deep Anode Ground Bed General Arrangement
CP-004 Rev.O
Typical Single and Double T. R. Unit Compound Earthing Layout
CP-006 Rev.O
Typ . Cathodic Protection System for Piping I Pipelines
LCTP-001 Rev.O :
Typ. Line Current Test Station Construction and Cable Details
II
o
;>
DEEP ANODE GROUNDBED (TYPICAL)
Q)
a::
DE SCRIPTION S 1 POSITM JUNCTION BOX (PJBI 2 PosnVE CABLE TO TRU 3iANODE STRlIIG CABLES 4 SEALED CABLE ENTRYCONDUIT
(COATED CASING PIPE)
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10 IMCTM ZOIIE (NOH METALLIC PIPEI 11 LAST ANODE STRING CABLE 12 VENT PIPE 13 ~cnVE ZONE (UIICOATED CASING PIPE) 14 ~NODE SUPPORT PIPE 15 CARBONACEOUS BACKFILL 16 ~MO ANODE 17 FIRST AlIODE STRJIIG CABLE 18 CE/ITRALIZER 19 1I1IODE SUPPORT PLATE 20 NYlON TIE 21 HODE CABLES TIED AROUND
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1. THE WELL CASING SHALL BE CARBON STHL PIPE
300mm & 4mm THICK IN WELDED SECTIONS. THE INACTIVE SECTIONS SHALL BE NON METALLIC PIPE. 2. WELL CASING CABLE PENETRATION APERTURE 150mm X150mm AT 600mm BELOW GRADE LEVEl.
3. VENT PIPE SHALL BE NOtI METALLIC PIPE.
4. ANODE STRltlG CABLES SHALL BE 25Sqmm
COPPER STRArlDED KYIlAR INSULATED I XLPE
SHEATHED WITH TWO ANODES PER STRING.
5. THE CARBONACEOUS BACKFILL SHALL BE PRE· MIXED IN SOKg BATCHES IN 24LITERS TO lOllTERS OF PORTABLE WATER THE SLURRY SHALL BE COIHlUOUSLY AGITATED DURlNG PUMPING OPERATIONS. THE BACKFILL SHALL BE 51<1 ABOVE ACTIVE ZONE. THE BACKFILL SHALL BE COMPACTED. 6. GRAVEL SHALL COMPLETE THE FILL ABOVE THE CARBONACEOUS BACKFILL UPTO 1000mm BELOW THE TOP OF THE VEtil PIPE. 7. THE DRAWING SHOWS A GENERAL ARRANGEMENT FOR A DEEP GROUND AJjQDE BED. THE A/lODE QUANTITY AND WELL DEPTH SHALL BE CALCULATED TO SUIl THE CA THOOIe PROTECTIOtI SYSTEM REQUIREMENTS.
SUPPORT PIPE WITH NYlON TIES 22 ~'JELL HOLE 23155 PIPE 316L
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NOTES:
SECT1(JN "AA-M"
APPROVALS O£PARmEHT I SIGNATURf
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DRAWING NO. : CP " 003
Page 44 of 48
DOC. NO. KOC-L-015
REV. 2
APPENDIX - C (contd.l) : Typical Single and Double T.R. Unit Compound Earthing Layout. (CP-004 Rev.O) 8
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FOR BURIED PIPES
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APPROVALS {Jt.PARIUlNT
EdiTST \ 1]0 \
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DRAWING NO. : CP-LCfP-OOl
OAfE
2
Pa e 47 of 48
DOC. NO. KOC-L-015
ACKNOWLEDGEMENT
by the Standards Technical Committee
This Standard comprising of the following: Mr. Mr. Mr. Mr. Mr. Mr. Mr. Mr. Mr. Mr. Mr. Mr. Mr.
Hamzah Ahmad Mohd. Emam S. Kumar Unnikrishnan Daniel Pin a Abdul R. AI-Shamari Haithem Aboughaith Gopal Murti Mohd. Aslam Imadi G. Unnikrishnan Fahad AI-Qattan Abdulla AI-Yousef Richard Arthur
Chairman Deputy Chairman Secretary/Member Member Member Member Member Member Member Member Member Member Member
Standards Team Insp. & Carr. Team (S&E)
for review and the
The draft of this Standard had been responses were received from PROJECTSSUPP.SVCS.GROUP
Team Leader Tech. Expertise
Insp. Carr. (S&EK)
Team Leader Quality &
Insp. Carr. (N&WK)
MAJOR PROJECTS. GROLIP (I) Team Leader Major Proj. IV
Team
Support
CORP. PRO ..IECTS GROLIP Team Leader Corp. Projects - I
Team Leader Utilities
GAS OPNS. GROUP Leader Gas Opns. (S&EK)
(Gas)
Team Leader MSR
SECURITY & FIRE GROUP
Team Leader Opns. Tech.
(S&EK)
Team Leader Drlg.&W/O Svcs.Tech. Svcs.-I MSR (NK)
Team Leader Drlg.&W/O Svcs.Tech.
I
III
DOC. NO. KOC-L-01S
Il
Page 48 of 48
REV. 2
II
III
SUPPORT SVCS. GROUP (S&EK)
EXPORT OPNS. & MARINE OPNS. GROUP
Team Leader HSE (S&EK)
Team Leader Export Tech. Svcs
OPNS. GROUP (WK)
SUPP. SVCS. GROUP (WK)
Team Leader Opns . Tech. Svcs.
Team Leader HSE (WK)
Team Leader MSR (WK) HEALTH, SAFETY & ENVIRONMENT GROUP Team Leader Safety Team Leader H&E Team Leader HSE System
Task Force Responsible for this Standard
121
The revision of this Standard (Rev.2) has been entrusted by the Standards Technical Committee (STC) to the Task Force No. (TF-CP/02) comprising of the following members:
51. No. 1
2 3 4
Task Force Members
KOCTeams
Status
Tel. No.
Mr. Abdul R. AI-Shamari Mr. Mohd. Emam Mr. Hasan Sabri Mr. Amer Jaragh
Insp. & Corr Team.(N&WK) Insp. & Corr Team.(S&EK) Insp. & Corr Team.(S&EK) Insp. & Corr Team.(N&WK)
TF Leader Member Member Member
66394 63693 65434 65428
