7 rei} CARIGALL © @B Punj Lloyd GED PUNJ LLOYD — DIALOG — PETROSAB CONSORTIUM DOCUMENT NO.: SSGP-L-DC-2601-A4 ENGINEERING, PROCUREMENT, CONSTRUCTION AND COMMISSIONING FOR SABAH — SARAWAK GAS PIPELINE PROJECT CONTRACT NO. : CH2/C3/2007/DSL/048 MASTER METHOD STATEMENT FOR INITIAL TEMPORARY CATHODIC PROTECTION SYSTEM (KP 003+270 TO KP 004+347) APPROVED FOR CONSTRUCTION PCSB TRANSMITTAL NO:- | Approved For Construction RKGIPKC Issue for Approval (updating Anode Design calculation) RKGIPKC Issue for Approval RKGIPKC DESCRIPTION STATUS CODE: C- REJECTED (REVISE AND RESUBMIT) B— ACCEPTED WITH COMMENTS (MINOR COMMENTS, WORK MAY PROCEED) A- ACCEPTED INO COMMENTS, WORK MAY PROCEED) Tota or paral eproducton and/or wiizaton ofthis document are fortidden witout por writen auharteaton of UNJ LLOYD DIALOG. PETOSAB CONSORTIUMDocument Number METHOD STATEMENT FOR SSGP-L-DC-2601-A4 INITIAL TEMPORARY CATHODIC | Revision: | ctatus:arc PROTECTION SYSTEM Date: | 12 Aug 2009 Page 1 of 14 REVISION TABLE ATTACHMENTS. PAGE REVISIONS REMARKS | 477] paces REVISIONS REMARKS ofa[2]3 ofal2y3 1 [x I 2 |x[x 21x 0 2 [x 3__|[x|x OT 4 [xx 4 [x s [x 6 |x 7 [x a [x|x “Tis documents He prepery of OWNER, Kmust not bestowed, repreduced or declsed io others wihout witanauhorzaton fom the OWNER, Doc. No.: SSGP-L-DC-2601-A4Document Number METHOD STATEMENT FOR SSGP-L-DC-2601-A4 INITIAL TEMPORARY CATHODIC | PFevision: | status: arc 2 PROTECTION SYSTEM Date: | 12" Aug 2009 Page 2 of 14 TABLE OF CONTENTS SR. DESCRIPTION PAGE 1.0 PURPOSE. 3 2.0 SCOPE... 3 3.0 REFERENCE DOCUMENTS. 3 4.0 TERMS AND DEFINITIONS.. 3 5.0 RESPONSIBILITIES... 4 6.0 INSTALLATION. 5 7.0 TOOLS AND EQUIPMENT. 8 8.0 HEALTH, SAFETY & ENVIRONMENT. 8 9.0 ATTACHMENTS. 8 Attachment I - Inspection and Test Plan. 9 Attachment I - Inspection Formats. <1 Attachment III - Typical Drawing’ is ‘This documents the property af OWNER. Irmust net be stor, reproduzed or discloses to alers wihout writen authorization fom the OWNER. Doc. No.: SSGP-L-OC-2601-A4PROTECTION SYSTEM Document Number METHOD STATEMENT FOR SSGP-L-DC-2601-A4 INITIAL TEMPORARY CATHODIC | Revision: | status: arc 2 Date: | 12” Aug 2009 Page 3 of 14 1.0 PURPOSE The purpose of this procedure is to describe the methodology involved in the initial temporary cathodic protection System for( KP 003-+270 TO 004+347 )to detail out the steps to be taken to meet the requirements during the execution of Sabah - Sarawak Gas Pipeline Project as specified in the PCSB Contract - CH2/C3/2007/DSL/048. 2.0 SCOPE The scope of work the initial temporary cathodic protection system method statement sets out the outline requirements for the provision of an initial temporary CP SYSTEM for KP (003+270) TO KP (004+347) SSGP underground pipeline system. 3.0 REFERENCE DOCUMENTS Reference Title ‘SSGP-PL-(GEN)-12-04-(SP 018)-Rev.0 ‘Specification for CP System. PTS 30,10.73.31 PETRONAS-Technical Standards: Design Cathodic Protection PTS 30.10.73.10 PETRONAS- Technical Standards: Cathodic protection BS 7361 Cathodic protection part1. code of practice for land and marine Application NACE RP - 0169 Recommended Practice for the cathodic Protection for buried or Submerged structures. NACE RP ~ 0177 Mitigation of alternating current and lighting Effects on metallic Structures and Corrosion Control system. 4.0 TERMS AND DEFINITIONS OWNER PETRONAS Carigali Sdn Bhd (PCSB) CONTRACTOR | PUNJ LLOYD - DIALOG - PETROSAB CONSORTIUM (PDPC) ‘Sub-Contractor_| HMS CORPORATION SDN.BHD. Vendor ‘Any CONTRACTOR's and/or Sub-Contractor’s supplier(s) of CONTRACTOR item(s). Quality Control | ‘cGuirements. Part of quality management focused on fulfilling quality PPE Personnel Protective Equipment, “This document isthe property of OWNER. Rmust nol be stored, reproduced or declosed to ihers without writen sihaization fom the OWNER, Dos. No.: SSGP-L-DC-2601-A4Document Number METHOD STATEMENT FOR SSGP-L-DC-2601-A4 INITIAL TEMPORARY CATHODIC | Revision: | status: AFC PROTECTION SYSTEM 2 Date : 12" Aug 2009 Page 4 of 14 5.0 RESPONSIBILITIES Project Director Responsible for providing adequate resources, giving specific instructions and guidelines during exigencies and emergent situations, which may pose constraints in project for implementation of this quality control procedure. Resident Project Manager Shall report to the Project Director and shall be overall (RPM) responsible for the Quality, Safety and Environment Management System of the Project. Project Coordinator Shall report to Resident Project manager. He shall be responsible for obtaining appropriate approvals and permits for the works. He Shall coordinate with RPM, RCM and Local as well as Government agencies. Resident Construction Shall report to the Resident Project Manager. He shall bSe Manager (RCM) responsible for construction activities related to this procedure, and shall co-ordinate with the Project Planning, QA/QC and site engineer for implementation of this procedure. Planning Manager Shall report to the Project Manager. He shall coordinate with Construction Manager, site engineer / supervisor in efficient completion of site work meeting scheduled dates. QA/QC Manager Shall report to Project Manager at Project office. He shall be overall responsible for QA/QC related matters and inspection in line with this procedure. HSE Manager Shall report to Project Manager. He shall be responsible for monitoring safety performance and where necessary initiating corrective action through line management. CP Engineer Shall report to the Resident Project Manager. He shall be responsible for execution and implementations of all CP system activities related to this procedure and verify the records. Site Engineer/Site Supervisor Shall be responsible for execution and implementation of all site activities related to this procedure and check the records submitted by vendor. “This document isthe propery of OWNER. Krust nol be stored, reproduced or Geclosed to ohers without wilten auhoizaton from the OWNER, Doc. No.: SSGP-L-DC-2601-A4Document Number METHOD STATEMENT FOR SSGP-L-DC-2601-A4 INITIAL TEMPORARY CATHODIC | Revision: | status: arc PROTECTION SYSTEM 2 Date: | 12" Aug 2009 Page 5 of 14 6.0 INSTALLATION 6.1 PRE-PACKAGED HIGH POTENTIAL MAGNESIUM ANODE All proposed Pre-Packaged High Potential Magnesium Anode (magnesium anode) shall be installed in-line with pipeline construction, i.e. during the pipe has been lower lay into its trench but not backfill yet. The following are the steps to install the anode: a) Magnesium anodes shall not be removed from their storage place and taken to site until excavation has been completed. Care shall be taken in handling the anodes. b) The proposed locations of package anode shall be checked against the Installation schedule and the actual construction. Consultation with the PCSB is necessary in those cases where location may be inconvenience and/or impractical by above ground pipework or any others obstruction. c) The subcontractor shall confirm with the PDPC/PCSB representative the anode type to be installed prior to loading the anodes. d) The anodes shall be removed from their packing bag in the presence of the PDPC/PCSB representative who will inspect the anodes and their cable prior to loading. e) Damaged anodes/cable shall only be used where, in the opinion of the PDPC/PCSB representative, such damage will not affect performance. f) Test cables shall be PVC taped, all cables from the pipeline/anode cable shall be coiled and paged in PVC bag ,placed below grade the location shall be marked with a wooden stake terminating in a red flag or tag.complete with marking g) Backfilling and reinstatement shall proceed on completion and final acceptance of the installation and coating repairing completed. Refer to drawing number ‘SSGP-PL-(GEN)-12-04-DD032 & 37 , Typical Sacrificial Anode Installation. 6.2 CABLE TO PIPE CONNECTION This section explains the procedure for cable to pipe connection works. Do refer to drawing number SSGP-PL-(GEN)-12-04-DD031,(0370-CP-DW-03) 6.3 EXOTHERMIC WELDING All locations of facilities which require cable attachment to the pipe. Exothermic welding or Cadweld has been use for this propose. It shall be done under pipeline construction, i.e. during the pipe has been lower lay into its trench but not backfill yet. The following are installation statement a) The equipment to be used shall be typically ‘Thermit Weld’ or ‘Cadweld’ brand type. The pipe coating shall be removed over an area of approximately 75 x 75 mm or equal to the mould base dimension at the top of the pipe. “This ooument isthe propery of OWNER, Kmust nat be stored, reproduced or esclosed to thers without writen auhorzaton fom the OWNER. Dos. No.: SSGP-L-DC-2601-A4Document Number METHOD STATEMENT FOR SSGP-L-DC-2601-A4 INITIAL TEMPORARY CATHODIC _ | Revision: | ctatus: arc PROTECTION SYSTEM Date: | 12" Aug 2009 Page 6 of 14 b) The distance between the two exothermic welding points should be at 900mm apart. c) The area shall be thoroughly cleaned using a power brush and then roughened to bright metal using a sand paper. d) Strip cable sheathing and/or insulation so as to expose the copper core for a length appropriate to the size of mould being used. e) Place metal disc within the mould so as to obscure the hole through the mould. f) Empty powdered contents of the thermite weld charge into the mould. Squeeze the polythene container so as to ensure discharge of the igniter powder from the bottom of the container. Close the mould lid. g) Lay the exposed cable core on the pipe and across the exposed area. Place the carbon mould over the exposed cable core, such that it lies in the slot at the bottom of the mould, Hold the mould firmly in position with one hand and ignite the powdered charge by operating the flint gun with the other hand. Safety goggles and gloves must be worn. h) An exothermic reaction takes place in which the powder is transformed to molten metal and melts the metal disc and drops onto the cable below. Allow the molten metal to cool slightly (about 5 to 10 seconds), before removing the mould. i) Test the strength of the connection by hitting the completed weld with a 500 gm copper headed hammer. j) The connection and surrounding coating should be cleaned and pruned for recoating. Note that there will be a small amount of slag that shall be removed. k) The cadweld shall not be placed with in 50 mm of a logitudinal/spiral pipe weld or within 200 mm of a circumferential pipe 6.4 PIPE COATING REPAIR After the cable has been attached to the pipe by mean of Thermite welding or Cadweld method, it is necessary to repair coating at connected point. The following are installation method statement a) The complete the cadweld shall be cleaned of all slag,dust,dirt,grease,etc immediately prior to coating repairand to ensure that the exposed metal sournding area coating is clean and dry. b) Immediately on completion of the exothermic welding, apply a coat of primer or equivalent and allow to dry to a non-glossy appearance, which will take about 1 to 2 minutes, depending on humidity and temperature. The area covered should be about 150 mm length of pipe. ¢) Remove the release paper from the bottom of the Royston Handicap. Bend the plastic sheet inward at the serrations when applying to small diameter pipe. Position and place the Handycap on the welded area with the tunnel over the lead cable. d) Push the dome of the cap firmly into the weld area. Now lift the lead cable away from the pipe and squeeze the black rubber compound completely around and underneath the cable. Then push the lead cable back down on the pipe and press the elastomeric compound into firm contact with the pipe over the entire area. “his Gaoument isthe propery OF OWNER. Rust nel be stored, reproduced or diciozed to others without writen aulhoiaton fem the OWNER, Doc. No.: SSGP-L-DC-2601-A4Document Number METHOD STATEMENT FOR SSGP-L-DC-2601-A4 INITIAL TEMPORARY CATHODIC | Revision: | status: arc 2 PROTECTION SYSTEM Date: | 12" Aug 2009 Page 7 of 14 6.5 6.6 e) Reinstate the coating by approved heat shrink sleeves around the exposed area for finishing to prevent ingress of moisture from environment and offer mechanical protection TEST LEAD CABLE All test lead cable shall be installed during the pipeline construction period, The following are installation method statement a) The proposed locations of all test stations shall be checked against the installation schedule and the actual construction. Consult with the client is necessary in those cases where location may be inconvenience and/or impractical by above ground pipework or any others obstruction. b) After location has been identified, the pipe coating will be removed and pipe cable(s) will be attached to the pipe by mean of exothermic welding, Number and size of cable will be specified in project drawing. ©) After pipe cable has been attached to pipe, the pipe shall be repaired its coating by coating repair material. d) Test/bonding cables shall be PVC taped, all cables from the pipeline/anode cable shall be coiled and paged in PVC bag ,placed below grade the location shall be marked with a wooden stake terminating in a red flag or tag.complete with marking ) All cables shall be inspected for any sign of damage and also shall be marked for future identification. f) After coating the connection point and testing for holidays at 18 kv, the pipe can be backfilled. Pipe-To-Soil Potential Measurement Pipe-to-soil potent a function of the average potential that exists on the given section of the pipeline within the field of the reference electrode. Pipe-to-soil potential measurements are used to determine the protective potential of the structure under test with respect to a reference electrode. Properly interpreted and correlated with other measurements, pipe-to-soil potential gives an indication of the cathodic protection level. Reference electrodes can be either portable or stationary. The porous plug of the portable electrode is placed such that it contact with the electrolyte (soll). A digital meter should indicate a negative reading, which indicate pipe-to-soil is negative to the reference electrode. If the meter reading is fluctuating, this may indicate either bad contact with the electrolyte or with the pipeline. a) Connect the test lead from the structure (pipe) to the voltage terminal of the multimeter b) Connect the test lead from the portable reference electrode to the common terminal of the multimeter. ¢) Keep the Multimeter in DC This document isthe propery of OWNER, K must nt be slored,reproduxed or dlsclosed to hers without witlen authorization from te OWNER. Dos. No.: SSGP-L-DC-2601-A4METHOD STATEMENT FOR INITIAL TEMPORARY CATHODIC | Revision: | status: AFC PROTECTION SYSTEM Document Number SSGP-L-DC-2601-A4 2 Date: | 12" Aug 2009 Page 8 of 14 d) Place the tip of the portable reference electrode close to the structure. e) Record the potential that is displayed directly on the multimeter. 7.0 TOOLS AND EQUIPMENT LIST Si. No. Description Purpose Quantity 1 bali welding mould and | pine to cable connection | 1 set. 2 | Excavation tools Anode installation iset 3 | Multimeter Pipe to soil measurement | 1 No 4 | Portable reference electrode | Pipe to soil measurement | 1 No 5 | Hand tools Pipe to cable connection | 1 lot 8.0 HEALTH, SAFETY & ENVIRONMENT a) Good housekeeping practices shall be followed. b) Personnel Protection Equipment (PPE) shall be provided to all workmen and supervisors. c) Scrap and Debris shall not be littered in area of work. Scrap and Debris shall be collected in a trash kept at suitable location. d) Containers and Equipment shall be maintained in a neat and clean manner. 9.0 ATTACHMENTS Attachment I Attachment IT Attachment [II ~ Inspection and Test Plan, Anode Calculation ~ Inspection formats. - Typical Drawing’s(where applicable) Ts documents the propery of OWNER, Kmust nol be sired, reproduced or dscloed to ober without wilten autherzation fom the OWNER, Dos. No.: SSGP-L-DC-2601-A4METHOD STATEMENT FOR INITIAL TEMPORARY CATHODIC PROTECTION SYSTEM Document Number SSGP-L-DC-2601-A4 Revision : 2 Status: AFC Date : 12" Aug 2009 Page 9 of 14 ATTACHMENT - I INSPECTION AND TEST PLAN/ANODE CALCULATION (ITP) “Tus documentisthe propery af OWNER. Rent nl be store, reproduced or disclosed lo hers without writen auharizaonfrem the OWNER. Doc. No.: SSGP-L-DC-2601-A4PETRONAS Carigali Sdn Bhd IOWNER: PETRONAS Carigali Sdn Bhd ICONTRACTOR :PUNJ LLOYD - DIALOG - PETRSAB CONSORTIUM SABAH - SARAWAK GAS PIPELINE PROJEC T Joc. No: ssGP-LDG-2601-A4 ea wes SS RELONSE Y= RRO [Structural = PWHT |W = WITNESS POINT INSPECTION & TEST PLAN ‘Scope of Work [Mechanical ‘Coating |R = REVIEW POINT [Piping Oo Electrical = INSPEGTION HOLD POINT, Fa 5 ee Sr. Description Reference Procedure or | Acceptance Criteria verifying Frequency of ispection level Involvement No. i Specification Reference Document | inspection/testing HMS PDPC fs MATERIAL INSPECTION [igh Potene PePacanes Magnes | intl TOP Watod Visco et + pene TCP reste] Meraeste 100% . Initial TCP Method Manufacturer test 2 eae TP Mat teste | Maw ‘00 e E NSTALATON + [anode ntatan ral 7EP Mates oevingmrecatize | inspectnepat | Evenson . w w 2 [Bet cave canecton Intel TOP Mates [ovens | insecn eset | soya ° w w PREPARED BY VENDOR RESPERSENTIVE CHECKED BY PUNJ LLOYD - DIALOG - PETROSAB CONSORTIUM ‘APPROVED BY PETRONAS Garigali Sdn Bhd lame: isin: pate: Name: sign: Date: Name: sign: bate: Page of 1‘OWNER: PETRONAS CARIGALI SDN BHD PROJECT: SABAH SARAWAK GAS PIPELINE CLIENT: PUNI LLYOD OTL & GAS (M) SDN BHD ‘SCOPE: CATHODIC PROTECTION SYSTEM FOR UNDERGROUND PIPELINES ‘SACRIFICIAL ANODE DESIGN CALCULATION (TEMPORARY CP SYSTEM) 4. Design Parameters Design Lie, ¥ : 2 years ‘Current Density, CD = 0.01760 mNme Sol resistivity, R = 23600 Ohman 2. Structure Details Line Number Diameter [Spread Kp 34270- PART % waa Tw7Eo Surface area, SA = Euxoxy 3,091.00" m? 3. Calculate Current Required, Treq SAxCBXCD%150% With 100% contingency 0.054 Amperes 4 Anode Specification Type ~ Pre-Packaged Nigh Potental Mg Anode ‘Anodes weigh, Wa 2 ag ‘Anode Length (pre-packaged), La > 8 om ‘anode Diameter, Da > 8m ‘Current capacty of anodes, CA = 77 Kg/ Amp.Year No of ane in paral, > 9 Nos ‘Anode spacing, S > 100 am Ubliation factor, UF > 90% '5 Calculate Minimum Anode Qty Per Casing Tota weight required, Wrea 2 Yeh trea UF = osmer 1a Minium Anede Qty, Na _ Wea Wa = 023s = 1 nes 6 Anodes resistance calculation Resistance of single anodes, Ras P/M La) x{ In Blafea )-1] 186.28 Ohms Resistance of multiple anodes, Ram [1#(p/(S Ras) )x (Ln 0.656 N )] «Ras / N = 3552 Ohms Open circuit voltage > 170 Volts Protected potental level = 095 volts Voltages, V (Open Circuit Voltage ~ Protected Potential Level 075 Voks 7 Calculate Total Anodes Required Single anodes cutent, Ia = V/Ram 0.021 Amp Total anode required, Na = lreq/la = 258) ros. = 3 nos '@ Counter check ule: Total Ta > Treg, hence = (lax Na) —Ireq 0.0089451 Amp Positive value means that CP requirements are met.METHOD STATEMENT FOR INITIAL TEMPORARY CATHODIC PROTECTION SYSTEM Document Number SSGP-L-DC-2601-A4 Revision : 2 Status: AFC Date : 12" Aug 2009 Page 11 of 14 ATTACHMENT - IT INSPECTION FORMATS “This dosument isthe proneny of OWNER. Kmust nol be stared, reproduced or declosed to thers without wilten authorization fom the OWNER, Doc. No.: SSGP-L-DC-2601-A4SABAH-SARAWAK GAS PIPELINE PROJECT. rons CARIGALL OWNER: PETRONAS Carigali Sdn Bhd CONTRACTOR : PUNJ LLOYD - DIALOG - PETROSAB CONSORTIUM PETRONAS Cast Sn Oh INSPECTION REPORT FOR ANODE INSTALLATION IREPORT No, LOCATION: NUMBER OF ANODE loate: ‘CABLE ANODE OPEN POTENTIAL WITH CulCuSO4] PIPE SOIL POTENTIAL WITH ‘ANODE NO DRAWING NO paan ALF CELL ‘CulCuSO4 HALF CELL, ICONTINUITY TEST BETWEEN ANODE TO CABLE OK /NOT OK lpIPE TO SOIL POTENTIAL (NATURAL) WITH Cu/CuSO4 HALF CELL. OMMENTS PREPARED BY VENDOR INSPECTED /CHECKED BY PDPC REVIEWEDIVERIFIED BY PCSB [sign sign: Sign: lame: Name name: sion lPostion position Date (Date: loate:SABAH-SARAWAK GAS PIPELINE PROJECT @® Puri ttoya i) CARIGAM OWNER: PETRONAS Carigali Sdn Bhd < CONTRACTOR : PUNJ LLOYD - DIALOG - PETROSAB CONSORTIUM | punj ior DilogPetressb Consortium FORMAT NO-SSGP-L-0C-2501-A‘ [SPREAD: rermonascoiesisénont | INSPECTION REPORT FOR PIPE TO CABLE CONNECTION —— Locarion: ltLP No arvee: loar PIPE SOIL POTENTIAL WITH SRNO CABLE SIZE LENGTH PURPOUSE OF CABLE esi tbie 4 2 3 4 8 8 7 8 8 JHounay Test OK NOT OK 10. Jcontinurry TEST BETWEEN PIPE TO CABLE OKINOT OK “ PIPE TO SOIL POTENTIAL (NATURAL) WITH Cu/CuSO4 HALF CELL 2 COMMENTS PREPARED BY VENDOR INSPECTED /GHEGKED BY POPC REVIEWEDIVERIFIED BY PCSB [sion sion: Sign: tame: Nome: Namo: sition Position Sion Date: bate: DateDocument Number METHOD STATEMENT FOR SSGP-L-DC-2601-A4 INITIAL TEMPORARY CATHODIC Revision : 2 Status: AFC PROTECTION SYSTEM Date : 12" Aug 2009 Page 14 of 14 ATTACHMENT - IIT TYPICAL DRAWING’S “Thus document isthe propery of ONNER, tsnust nel be stored, reproduced or diclosed to others without witen authorization fom the OWNER Doc. No.: SSGP-L-DC-2601-A4wud ae cane mare "CAL TEST PONT AND CP REFENERCE CEU ISTALATION = a a EER end-acee-ooomfrars[ 3GEMERR_TEST POST INSTALLATION ao TEST LeA05 AOVTING af TYPICAL TEST FOST AND TEST LEADS INSTALLATION. & Ltt ine eae oe a = 10 WIRE OST WIM GROWING OSTICE ——«2YB_= THO WIRE past Fn eowOING To OTER STRUCTURES P=. Bees i TYPICAL. caTHOO PROTECTION a a a TEST 80ST IDENTFICATION = fares a oe a feel wae ee afica ans we ensue SISTENT, ptgemeernen ene mio Sie ERAS, inewsiee O PSagrrnees jane qc0 | BETES iaaies a Caan BE : K — ARR “6 ae <> Eas Boocerementseonren = soe SERS "wena owterorre Browenuc wanna fee ———rrrer——rar| nvarones TF