Plant :

Document No. :

Rev. A

Az-Zour North Phase 1 - IWPP

Title :

00-BXF-ELH-54287-DYC
VEN Doc. No : DYC-6065-110

(Total 15 pages including cover)

TECHNICAL SPECIFICATION FOR CATHODIC PROTECTION SYSTEM

A REV.

Nov. 27, 2013 DATE

ISSUE FOR APPROVAL DESCRIPTION

J.S.SONG BY

H.J.JOO CHK

S.M.HONG APP

Project :

Az-Zour North Phase 1 - IWPP

Project Co. :

Az-Zour Oula Power and Water Company K.S.C

Owners Engineer :

EPC Contractor :

Vendor :

DONGYANG CORROSION ENGINEERING CO.,LTD

Doc No : 00-BXF-ELH-54287-DYC

Technical Specification for CP REVISION LOG

Rev. No. A Revised Date Nov. 27, 2013

Rev No :

Revised Page Initial Issued

Description

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Doc No : 00-BXF-ELH-54287-DYC

Technical Specification for CP

Rev No :

Table of Contents

1. 2. 3. 4. 5.

General .......................................................................................................................................................... 4 Reference....................................................................................................................................................... 4 Configuration ................................................................................................................................................ 5 Criteria for Protection.................................................................................................................................... 6 Technical specifications ................................................................................................................................ 7

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Doc No : 00-BXF-ELH-54287-DYC

Technical Specification for CP 1. GENERAL

Rev No :

This document is prepared for the impressed current cathodic protection system of Az-Zour North IWPP in Kuwait.

2. REFERENCE
BU-E-27-001-002 (Rev. A) Technical Specification for Cathodic Protection System BS7361 British Standard Title : Cathodic Protection, Part 1, Code of Practice for Land and Marine Applications

SP0169 National Association of Corrosion Engineers Standards (N.A.C.E) Title : Control of External Corrosion on Underground or Sub-merged Metallic Piping systems

SP0177 National Association of Corrosion Engineers Standards (N.A.C.E) Title : Mitigation of Alternating Current and Lightning Effects on Metallic Structures and Corrosion Control Systems

RP0193 National Association of Corrosion Engineers Standards (N.A.C.E) Title : External Cathodic Protection of on-grade carbon steel tank bottoms

SP0388 National Association of Corrosion Engineers Standards (N.A.C.E) Title : Impressed Current CP of Internal Submerged Surfaces of Carbon Steel Water Storage Tanks

RP0286 National Association of Corrosion Engineers Standards (N.A.C.E)

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Doc No : 00-BXF-ELH-54287-DYC

Technical Specification for CP

Title : The Electrical Isolation of Cathodically Protected Pipelines

Rev No :

RP0572 National Association of Corrosion Engineers Standards (N.A.C.E) Title : Design, Installation, Operation and Maintenance of Impressed Current Deep Groundbeds

3. CONFIGURATION
The cathodic system is applied as following structure: - Seven (7) Tank Bottom External - Three (3) Water Tank Internal - Nine (9) Pump Internal - Thirteen (13) Pump External - Four (4) Bar Screen - Four (4) Band Screen - Twenty (20) Stop gate guide frame for Pump & Screen & Intake pipe - Eleven (11) Stop gate for Pump & Screen & Intake pipe - Thirty one(31) Stop gate guide frame for Seawater outfall - Twenty nine(29) Stop gate for Seawater outfall - A/G Pipeline Internal (1 Lot, 72m) - U/G Pipelining (1 Lot, 8,849m) - U/G Pipelining (1 Lot, 12,050m) - Two hundred ten (210) PIV & Outdoor Hydrant & Riser Pipe

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Doc No : 00-BXF-ELH-54287-DYC

Technical Specification for CP 4. CRITERIA FOR PROTECTION

Rev No :

Section 4.3 of NACE recommended practice RP0193-2001 " External cathodic protection of ongrade carbon steel storage tank bottoms " addresses several criteria for cathodic protection. Applicable excerpts of the criteria, which will be used to design this cathodic protection system, are as follows:
A negative (cathodic) potential of at least -850 mV with cathodic protection current applied. The potential shall be measured with respect to a saturated copper / copper sulfate reference electrode (CSE) contacting the electrolyte. Consideration must be given to voltage drops other than those across the structure-to-electrolyte boundary for valid interpretation of this measurement. A negative polarized potential of at least - 850 mV relative to a CSE. A minimum of 100 mV of cathodic polarization between the carbon steel surface of tank bottom and a stable reference electrode contacting the electrolyte. The formation or decay of polarization can be measured to satisfy this criterion. A negative polarized potential of at negative limit 2V relative to a CSE.

An -850 mV potential relative to a Cu/CuSO relates to -800 mV to a Ag/AgCl reference electrode and +250 mV to a zinc reference electrode.

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Doc No : 00-BXF-ELH-54287-DYC

Technical Specification for CP 5. TECHNICAL SPECIFICATIONS

Rev No :

The following sections include typical specifications for the majority of the cathodic protection equipment, which will be required for Jeddah South Power Plant Project.

5.1 Transformer / rectifier

5.1.1 General Requirements The transformer / rectifier units shall be designed for continuous operation in an onshore environment. The units will be suitable for outside installation.

5.1.2 DC Output Rating The units will be suitable for outside installation in non-electrical areas. General details on the transformer rectifier unit are as follows:
Input Power

: 415 VAC, 3 phase 4 wire, 50 Hz Voltage 10%, Frequency 5%

Cooling Rectification Control Method Cabinet Construction Protection Rating Panel Internal Cable

: Oil cooling (ONAN) - Outdoor type : Silicon stack : Auto & Manual control : Stainless steel 316L w/Painting : Outdoor - IP 55 (Weather proof), Indoor - IP 41 : 600V HKIV (600V Heat-Resistant PVC Insulated Flexible Wire)

- Control Cable Color : Yellow Size : Above 2.5sqmm

But, for electronic circuit board cable size : 1sqmm Power Cable Color : Black Size : Above 6sqmm

Painting Color (According to Doc. No. TB-T-32-001-001, Painting Specification)

The painting color and painting system shall be as follow; Indoor : RAL 6021 (Pale Green)
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Doc No : 00-BXF-ELH-54287-DYC

Technical Specification for CP

: Outdoor : : : Inside of Panel :
st

Rev No :

1 Coating : 60 ~ 80m, Epoxy Polyester or Hybrid Powder RAL 7032 (Pebble Gray) 1st Coating : 80 ~ 100m, Epoxy Zinc Powder 2nd Coating : 60 ~ 80m, Polyester Powder RAL 9001 (Cream)

5.1.3 Cooling The rectifiers shall be designed to operate continuously at the rated DC output voltage and current in ambient temperatures of 50 degrees C without damage to the transformer/rectifier components.

5.1.4 DC output rating The rectifiers shall be capable of operating continuously at the rated output current at any output voltage from zero to 100%, without damaging any rectifier components. The transformer / rectifier will have a DC output rating.

5.1.5 Electrical (1) Circuit Breakers The main circuit breaker shall be rated for at least 125% of the rated automatically controlled rectifier primary current rating. The circuit breaker shall be used in primary circuit of the automatically controlled rectifier. The circuit shall be mounted-case, thermal-magnetic of trip-free construction rated 600 volts, 50Hz, three-pole, manually reset and shall be compensated to operate for maximum ambient air temperature plus temperature rise due to other electrical components within the cabinet. The reset shall be accessible from panel.

(2) Fuses Fuses shall be mounted on the rear of the panel. The fuses are nonrenewable single element, fast acting type and rated at one standard size above unit rating assuring protection of the automatically controlled rectifier. (3) Transformer
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Doc No : 00-BXF-ELH-54287-DYC

Technical Specification for CP

Rev No :

Transformer shall be three (3) phase, two-winding, ONAN, insulated type with the primary winding capable of withstanding 2,200 volts, 50Hz between the primary winding and the core and the secondary winding capable of a withstand test as specified. The insulation of transformer will be class B or better.

(4) Silicon stacks Each automatically controlled rectifier shall use silicon type air-cooled cells of the high current density, non-aging type or equivalent type. Full rated DC output shall be obtainable with an input voltage variation 10 % of the rated AC voltage, and the cell shall operated without damage at a continuous input voltage 10 % above design AC voltage in an ambient temperature of 50C.

(5) Technical specification

Rectification

- Rectifying elements shall be diode for three-phase full wave rectification.

The efficiency

- More than 75% of the rated output current and voltage.

The power factor

- More than 80% of the rated output current and voltage

The insulating resistance

- More than 5M when measured by 500V Megger

The internal insulating voltage (except electron circuit)

- Withstand at A.C 2,200 volts, 50Hz, for 1 minute.

The rise temperature

(t ) shall be lower than the following (Ambient temperature 50C)

- Transformer and reactor : Lower than 60C - SCR : Lower than 80C

5.1.6 Enclosure The rectifier enclosure shall be constructed of mild steel. The enclosures will be provided with hinged
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Doc No : 00-BXF-ELH-54287-DYC

Technical Specification for CP

Rev No :

doors and circuit breakers, meters and switches will be mounted on an inside panel. The cabinet of rectifier is dustproof type and weatherproof type. The cabinet shall be welded construction and conform to IP 55 for outdoor. The rectifier will have a min. 25sqmm grounding lug and will be suitable for pad mounting. The sunshade per each panel outdoor use shall be provided by vendor. The enclosure shall be suitable for pad mounting and be equipped with the following:
Lifting lugs Oil sight gauge Grounding terminal Anchor bolts

5.1.7 Name Plate Each rectifier shall be fitted with an engrave phenolic plate bearing the following indications: Name of manufacturer Serial no. Gross weight IP rating AC input voltage Number of phases Frequency DC output voltage DC output current Ambient temperature Oil capacity Circuit diagram no Date

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Doc No : 00-BXF-ELH-54287-DYC

Technical Specification for CP

5.2 Anode
5.2.1 M.M.O Ribbon Anode (For Tank Bottom External)
Type Substrate material Construction Coating Dimension

Rev No :

: Titanium with a mixed metal oxide coating : Grade 1 or 2 Titanium to ASTM B 265 or equivalent : Ribbon : Electro catalytic mixed metal oxide : 0.25 (6.4mm) Width x 0.025 (0.6mm) Thickness

5.2.2 M.M.O Tubular Anode (For Tank Internal, Pump External, U/G Piping )
Type Substrate material Construction Coating Dimension

: Titanium with a mixed metal oxide coating : Grade 1 or 2 Titanium to ASTM B 338 or equivalent : Tube : Electro catalytic mixed metal oxide : 1 (25.4mm) Dia. x 500 / 1,000mm

5.2.3 M.M.O Rod Anode (For Pump Internal, Intake Facility and Pipe Internal)
Type Substrate material Construction Coating Dimension

: Titanium with a mixed metal oxide coating : Grade 1 or 2 Titanium to ASTM B 338 or equivalent : Rod : Electro catalytic mixed metal oxide : Dia.25.4mm x 120/ 150mm Length

5.2.4 Mg Anode (17Lb, Hydrant & Riser Pipe) Material : Magnesium Bare size Backfill size Backfill Material - Gypsum - Bentonite - Sodium sulphate : 85mm x 90mm x 637mm ,17 Lbs : 170mm x 1750mm : The backfill material for anodes shall consist of the following substances: : : : 75 % 20 % 5%
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Doc No : 00-BXF-ELH-54287-DYC

Technical Specification for CP

Open circuit potential : 1.55 V to Cu/CuSO4 electrode Capacity of anode alloy : 2,200 A.h/kg Anode current efficiency: 50% 5.2.5 Al Anode (For Stop Gate)

Rev No :

(Refer to NACE : CP 3- Cathodic protection Technologist course manual, 2.4.1.1 Aluminum Anodes)

Application Material

: : : : :

Sacrificial anode cathodic protection Aluminum Later -1.10 V to Cu/CuSO4 electrode 2,530 A.h/kg 85%

Size Open circuit potential Capacity of anode alloy Anode current efficiency :

Chemical Composition (%) Element Zn Si Hg In Cu Fe Al Alloy III 2.8~3.5% 0.08 0.2% Max. 0.01 0.02% <0.01% <0.12% remainder

5.3 Reference Electrode

The reference electrode shall be installed to provide a means of obtaining structure-to-soil or water potential measurement.. (1) Cu/CuSO4 Reference electrode(For Tank Bottom, Tank Internal, U/G Piping)
Model No. US50-CUG-SW (Manufacture : EDI) Model No. IR40-CUG-LW010 (Manufacture : EDI)

(2) Zinc Reference electrode ( For Pump, Intake Facility and Pipe Internal)
Type I Type II

: Pure Zinc rod with slotted PVC cover. : Pure Zinc cylinder with Mold :

Chemical Composition (%)

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Doc No : 00-BXF-ELH-54287-DYC

Technical Specification for CP

Composition Zinc Fe Pb Cd
Construction Dimension

Rev No :

% More than 99.995% Balance

: :

Rod Type I - 30mm Dia. x 30 / 50mm Length

Type II - 50mm Dia. x 25mm Length

5.4 Boxes
5.4.1 Positive and Anode Junction Box Each CP system will have a positive & anode junction box (PJB, AJB) which will serve as a splice box to connect the anode strings to the common positive feeder cable. These boxes will be centrally located between the tr/rectifier and anode. The enclosures shall be constructed of Stainless Steel 316L and have a bolt type or lid fastener type cover and be suitable for post mounting type. The class of protection shall be for IP55.
Painting Color

The painting color and painting system shall be as follow; Indoor : : Outdoor : : : Inside of Panel : RAL 6021 (Pale Green) 1st Coating : 60 ~ 80m, Epoxy Polyester or Hybrid Powder RAL 7032 (Pebble Gray) 1st Coating : 80 ~ 100m, Epoxy Zinc Powder 2nd Coating : 60 ~ 80m, Polyester Powder RAL 9001 (Cream)

5.4.2 Test Box A test box shall be installed on each side of the structure and at specific intervals along the piping to allow future testing of the cathodic protection system. The enclosures shall be constructed of Stainless Steel 316L and have a bolt type or lid fastener type cover and be suitable for post mounting type. The class of protection shall be for IP55.
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Technical Specification for CP

Rev No :

The test box shall be properly sized to accommodate the all terminals. All terminals, lugs, nuts, bolts, and washers shall be constructed of brass. Each test box shall be supplied with an external nameplate.
Painting Color

The painting color and painting system shall be as follow; Indoor : : Outdoor : : : Inside of Panel : RAL 6021 (Pale Green) 1st Coating : 60 ~ 80m, Epoxy Polyester or Hybrid Powder RAL 7032 (Pebble Gray) 1st Coating : 80 ~ 100m, Epoxy Zinc Powder 2nd Coating : 60 ~ 80m, Polyester Powder RAL 9001 (Cream)

5.4.3 Connection Box Each CP system will have a Connection box (CB) which will serve as a splice box to connect the anode strings to the common positive feeder cable and to pass reference electrode strings. These boxes will be centrally located between the tr/rectifier and CP structure. The enclosures shall be constructed of SUS316L and have a bolt type or lid fastener type cover and be suitable for post mounting type. The class of protection shall be for IP55.
Painting Color

The painting color and painting system shall be as follow; Indoor : : Outdoor : : : Inside of Panel : RAL 6021 (Pale Green) 1st Coating : 60 ~ 80m, Epoxy Polyester or Hybrid Powder RAL 7032 (Pebble Gray) 1st Coating : 80 ~ 100m, Epoxy Zinc Powder 2nd Coating : 60 ~ 80m, Polyester Powder RAL 9001 (Cream)

5.5 Cables
The cable shall be single core, stranded, copper with a HMWPE insulated, 600 / 1000 volt grade. Details on the cables are as follows:
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Doc No : 00-BXF-ELH-54287-DYC

Technical Specification for CP

Negative cable Positive cable Anode lead cable Test lead cable

Rev No :

: 0.6/1kv Cu/HMWPE 1C 35sqmm / 25sqmm : 0.6/1kv Cu/HMWPE 1C 35sqmm / 25sqmm : 0.6/1kv Cu/HMWPE 1C 16sqmm : 0.6/1kv Cu/HMWPE 1C 10sqmm

Reference electrode lead cable : 0.6/1kv Cu/HMWPE 1C 10sqmm

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