ucPr THERMAX DESIGN DOCUMENT FOR SAGRIFIGIAL TYPE CATHODIG PROTECTION SYSTEM oF FIRE WATER PIPELINE AND GAS PIPELINE AT NATIONAL FERTILIZERS LIMITED, PANIPAT OWNER NATIONAL FERTILIZERS LIMITED PANIPAT MAIN CONTRACTOR THERMAX LTD CATHODIC PROTECTION SERVICES BY “Re UNIVERSAL CORROSION PREVENTION INDIA. Email: universal.cpi@gmail.com www.uepi.co.in (Old Berhumpur Road, Dakshin Para, Ranaghat, Nadia, West Bengal, pin «741201 Email: universal.cpi@gmail.com, Ph: 09332601292 (CP DOCUMENT NO: UCPI-TL-NFL-PANIPAT-CP DSIGN 00 Rev. I of [15.01.2020 Design BB (00 | 02.07.2020 Design BB Rev | Date Purpose UCPI 7 NFL TECHNICAL DOCUMENT Page 1 of 12 CP System for Underground Fire water Pipeline and Natural gas_| UCPLTLLNFL-CP. e PANPAT.09 ipeline at National Ferilizers Limited, Panipat Project raneucel THERMAX CATHODIC PROTECTION SYSTEM FOR FIRE WATER PIPELINE AND GAS PIPELINE AT NATIONAL FERLIZERS LIMITED, PANIPAT PREFACE External Corrosion of fire water pipeline is an electrochemical phenomenon. The control of this corrosion process can be achieved by employing ‘CATHODIC PROTECTION SYSTEM. The state of art cathodic protection system can be implemented by distributing uniform current over the entire surface to be protected to achieve uniform corrosion protective potentials. : ‘The External Surface of Underground Pipeline is to be protected against corrosion by implementing Cathodic Protection System during the construction phase, National Fertilizers Limited floated an Inquiry for tumkey contract and Ms Thermax Ltd bagged the job to undertake complete construction of Underground Pipeline. M/s Universa Corrosion Prevention INDIA, W.B is appointed by M/s Thermax Ltd to undertake the contract on turnkey basis for implementing cathodic protection system including design, engineering, supply of material, Supervision of erection & commissiot Mls Universal Corrosion Prevention INDIA is a’Company based on a group of dynamic & highly experienced IIT Engineers in the field of CORROSION PREVENTION & CATHODIC PROTECTION to safeguard important infrastructures, installations & facilies from corrosion. UCPI is confident that the Cathodic Protection System designed and installed by them shall match desired contract requirements of Cathodic Protection for the Project. TECHNICAL DOCUMENT Page 2 of 12 CP System for Underground Fire water Pipeline and Natural gas .[ UOPETLANAL-CP- Pipeline at National Fertizers Limited, Panipat Project | PANPAT-20 \ \ucel THERMAX ‘TABLE OF CONTENTS 1.0.0 SCOPE OF WORK. 05 2.0.0 CODES AND STANDARDS. 06 3.0.0 INPUT DESIGN PARAMETERS .. or 4.0.0 DESIGN FORMULA . os 5.0.0 DESIGN CALCULATION .. 08 6.0.0 BILL OF QUANTITY (BOQ) 09 7.0.0 CP SYSTEM CONFIGURATION .. seueeenne 09 8.0.0 CONNECTING CABLES 10 9.0.0 COMMISSIONING PROCEDURE. 10 TECHNICAL DOCUMENT Page3oft2 | @ OP rere aston Feces inte Panbat Pes | RAMEN\ uci THERMAX F CHANGE RECORD PAGE REVISION TABLE : ween [oe] mon [owe] ween [nome ofi oft LT [| 1 |x|x 26 [ 2 |x|x Ea 3 |x|x 28 I 4 |x|x 29 5 [X|x 30 1 e [x]x at 7 |x|x 32 8 |X|x 33 [ 9 |x|x 4 [ 10 |x|x 35 a1 |x|x 36 12 |x|x 37 t— 13 38 14 39 15 40 L 16 41 7 42 18 43 19 44 20 45 | 2 46 2 47 23 48 24 49 25 50 TECHNICAL DOCUMENT Page 4 of 12 ‘CP System for Underground Fire water Pipeline and Natural gas | UCPITLNFL-CP- Pipeline atNatonal Ferizrs Limited, Panipat Project | PANPAT Iucpl THERMAX CATHODIC PROTECTION SYSTEM FOR FIRE WATER PIPELINE AND GAS PIPELINE AT NATIONAL FERLIZERS LIMITED, PANIPAT 1.0.0 SCOPE OF WORK: The scope of work under this contract compromise of Design, Detailed Engineering, ‘Supply of Material, Supervision of erection & commissioning of Cathodic Protection ‘System using sacrificial method for the mitigation of external corrosion of underground pipeline, ‘The Scope and Design Basis for Cathodic Protection of upcoming U/G fire water pipeline and Gas pipeline at National Ferlizers Limited (NFL), Panipat, confirms standard Cathodic Protection Syatem design for Pipelines. ‘The main activities involved are Design Detail Engineering Supply of material ‘Supervision of erection Commissioning TECHNICAL DOCUMENT Page 6 of 12 GP System for Underground Fire water Pipeline and Natural gas | UCPFTLNFL-cP- PANIPAT-00 Pipeline at National Fertiizers Limited, Panipat Project aucel THERMAX 2.0.0 CODES AND STANDARDS: The Cathodic Protection system design is based on the guidelines of following listed codes, standards and tender specifications: NACE Standard RP-01-69, RP-0285-95, RP-0193-93, SP0572, SP 0502 and SP. 0286 corrosion control in petroleum production, TPC Publication No. 05 2.2.0 British Standard BS -7364 Part-1: Cathodic protection Code of practice for land and Marine Operations. 12.3.0 IS 8062 (1976): Code of Practice for C.P of Steel Structures. 2.4.0 IS §571(1971): Guide for selection of electrical equipment for hazardous areas. 2.5.0 1S015589-1: Petroleum and natural gas industries-CP of pipeline transportation system ~partt on land pipelines. 2.6.0 Indian Electricity act rules framed there under and Earthing as per IS3043 2.7.0 Fire Insurance regulations. 2.8.0 DNV TNA 702: Installation of Sacrificial Anodes. Note: Other relevant codes and standards applicable to equipment are not listed here and shall be followed. TECHNICAL DOCUMENT Fags 6 of 12 P System for Underground Fire water Pipeline and Natural gas | UCPLTL_NAL-CP- Pipeline et NatonalFertize’s Limited: Panipat Project | PANPATucel THERMAX 3.0.0 31.0 3.2.0 3.3.0 INPUT DESIGN PARAMETERS: The Cathodic Protection System Design is essentially derived from the available Input Data and information made available in the Cathodic Protection Specifications. The System Design envisaged bears on following basic inputs and considerations: PIPELINE PARAMETERS: Sr.No | Pipeline OD (MM) | Pipeline Length (M) | Surface Area (WF) 7 889 100 28 14 20 o7 168 400 203 Total Surface area = 238 DESIGN PARAMETERS FOR PERMANENT CP DESIGN : ‘TYPE OF CP. SYSTEM FOR PIPELINE, : Sacrificial PROTECTIVE CURRENT DENSITY 2 15mA/ MP LIFE OF SACRIFICIAL ANODE 25 Years ANODE UTILISATION FACTOR 90% PIPELINE NATURAL POTENTIAL (-)0.450V TYPES OF GALVANIC ANODES GALVANIC ANODES DRIVING POTENTIAL : Magnesium :-1.5V w.rct CuCuSO4 Ref Cell GALVANIC ANODES CONSUMPTION RATE —_: 7.9 Kg / Amp-Yr GALVANIC ANODE BACKFILL RESISTIVITY 50 Ohm Gm PERCENTAGE BARE STEEL 220% CATHODIC PROTECTION DESIGN CRITERIA : ‘The C.P. SYSTEM will be designed to meet the following criteria : ‘The pipe-to-electrolyte potential measurements shall be between (-) 0.85V and (-)2.0V with respect to a coppericopper sulphate reference electrode. Alternatively the pipeline shall be considered protected when a minimum (-)100mV potential shift has been achieved from the initial native potential to the protected ON Potentials. TECHNICAL DOCUMENT Page 7 of 12 CP Systom for Underground Fire water Pipeline and Natural gas | UOPFTNL-CP- Pipeline at National Feriizes Linted, Panipat Project | PANEAT-00ucel THERMAX 4.0.0 DESIGN FORMULA: ‘Surface area of pipe Where (Sa) = (22/7) xD xL D- Diameter of pipe L- Length of pipe C.P. Current required where dy Sa - Surface area of pipe Cd-C.P. Current density Sf - Safety factor in current Cable Parallel Resistance Riac= 1(1R144/R2 + —~ + 4/Ro) where Rt, R2... Rn = Resistance of individual Cable Anode Groundbed for vertical Configuration where ‘Single anode P - Soil resistivity in Ohm M La - length of anode in M. 1.00159. 1D - diameter of anode in M. Rm DON D5 BE 5 L 5.0.0 DESIGN CALCULATION: 5.4.4 SURFACE AREA OF PIPELINES Surface area of pipe Where (Sa) = (22/7) x D xt D - Diameter of pipe L- Length of pipe =238 SOM TOTAL SURFACE AREA OF PIPELINE = 286 SQM (20% EXTRA FOR SAFETY FACTOR) 5.1.2 PROTECTIVE CURRENT REQUIREMENT: It= SaXCdXSfX%H Amperes Where - Sa is Surface Area 1000 Cd is Current Density = 286X15X1.3X30 Amperes 1000 X 100 ‘% Holidays=30% = 1.673 Amps TOTAL PROTECTIVE CURRENT REQUIRMENT (It) = 1.673 Amp 5.1.3 NO. OF ANODE BY WEIGHT REQUIREMENT: Wi=ItX Q XY Amperes Where - Wtis Weight of total anode uf Qis Consumption rate Ufis Utilization Factor. 3.4 KG TECHNICAL DOCUMENT Page 8 of 12 GP System for Underground Fire water Pipeline and Natural gas_ | UGPLTLNELCP- Pipoline at National Fertiizers Limited, Panipat Project PANPAT-00ucPl THERMAX ‘TOTAL WEIGHT OF ANODE REQUIRMENT (Wa) =734KG Selection Galvanic Anode: Standard Dimensions Magnesium Anode of weight 7.7Kg Is selected for installation In Horizontal Ground bed. Installed with backfil material having dimension 1500MM x 200MM diameter, NO. OF ANODE REQUIREMEN |: Na= Wt/Wa Where - Wa is Weight of anode = 134177 = 9.5 Nos. Note : From the above design calculation the requirement of total 9.5 nos. of| Magnesium anode for feeding Total current of 1.673 Amps for 05 Years Life. UCPI will install Mg anode of 7.7 kg every 70-100 m of the pipeline to distribute uniform current over the entire surface to be protected to achieve uniform corrosion protective potentials. 6.0.0 Bill of quantity (80Q): Sr.No Tem Description vom Qty 01 | Prespacked Mg Anodes No 70 02 | Test Station No 7 03 | FCxtOsqram XLPE Copper Mir 250 Unarmoured Cable 04 | Permanent Cu/CuSod reference electrode No 08 7.0.0 CP SYSTEM CONFIGURATION: The CP system configuration is optimized for uniform current distribution over its entire surface of pipeline for protection in contact with soil in order to maintain the steel at uniform potentials between (-) 0.85V to (-) 2.00V window w.rt to Cu-CuSO, reference electrode, 74.0 Basic CP Configuration: Test Stations for PSP monitoring will be installed at every 70-100 meter distance: along the pipeline route, Sacrificial Anode is connected to the Pipeline through Test Station which feeds in the Protective currents. The Anodes are installed in horizontal Configuration at a distance of 5M from the center of Pipeline. TECHNICAL DOCUMENT Page 9 of 12 ter lergroune fr Pipeli UOPLILHAL-CP- GP System for Underground Firewater Pipeline and Natural gas_ VOPETL Pipeline at National Fertilizers Limited, Panipat Project PANIPAucPr THERMAX 7.20 9.0.0 Protection of Cased Crossing of Carrier & Casing pipeline : There is no cased crossing available in entire stretch of the pipeline. CONNECTING CABLES: Generally, cables used for Cathodic Protection applications are low voltage, double insulated single core with unarmoured, 650 /1100 V Grade XLPE / PVC insulated Copper Conductor. ‘The Anode tail Cables used is Single Core, 10 sq mm Unarmoured Stranded Copper| Conductor with XLPE insulation and PVC Sheathed, 650V grade. Cathode & measurement cables used are single core, 10sq. mm, unarmored stranded copper conductor XLPE insulated and PVC sheathed, 650V grade. Potential Measurement, Reference Cell cables shall be 1Core X 10sq. mm Copper| ‘conductor, unarmored, XLPE insulation and PVC Sheathing, 650V grade. TESTING & COMMISSIONING PROCEDURE: ‘The testing and commissioning of CP System is carried out as per the testing and commissioning procedure explained below. The formats for recording the CP parameters will be generated during Detalled Engineer. ‘The testing and commissioning procedure involves following steps: ‘Step 1: Before energizing the System, Measure Natural Pipe to Scil Potentials using portable Cu-CuSO, reference electrode at all Test Stations installed along the entire ROW of pipetine. ‘Stop 2: Connect the Magnesium Anodes in all Test Stations to achieve adequate (ON) Pipe to Soil Potentials not more than (-)2.0Volts with respect to Cu- CuSO4 Reference Electrode. Step 3: After a duration of 24 hours from connection of Magnesium, measure ON Pipe to Soil Potentials using portable reference electrode at all Test Stations installed along the entire ROW of pipeline. The potentials should be within a ‘window range of -0.85V (ON) to (-)2.0 (ON ) Volts with respect to Cu-CuSO,. TECHNICAL DOCUMENT Page 10 of 12 CP System for Underground Fire water Pipeline and Natural gas | UOPLTLNEL-OP- PANPAT-00 Pipeline at National Fertilizers Limited, Panipat Project aucel THERMAX ANNEXURE- A CATHODIC PROTECTION SYSTEM FOR FIRE WATER PIPELINE AND GAS PIPELINE AT NATIONAL FERLIZERS LIMITED, PANIPAT ‘Owner NATIONAL FERTILIZERS LIMITED, PANIPAT Contractor THERMAX LTD GP Contractor UNIVERSAL CORROSION PREVENTION INDIA Location PANIPAT Date Time Cathodic Protection Station — Monitoring Parameters: ‘ANODE CURRENT: No. Description Reading Units Remark (¥) 1 Anode #MA1 DC mA OK / NOT OK 2 [Anode # AZ DE mA ‘OK/NOTOK 3 [Anode # MAS Doma ‘OKINOTOK 4 [Anode # MAG | De mA (OKTNOT OK 5 | Anode # MAS De mA ‘OKINOTOK © [Anode # MAG DE mA ‘OK NOT OK 7_ | Anode # MAT De mA ‘OK/NOTOK 8 [Anode # MAB Do mA ‘OK7NOT OK 9 | Anode#MAS _ DC mA OK/ NOT OK 70__[ Anode # MA10 De mA OKTNOT OK PSP READINGS No. Description Natural PSP in ON PSP In Remark Volts Volts 1 Test Station #T1 uP/P/OP. 2 Test Station #T2 uP/P/OP 3_ | Test Station #13 UP/P/OP 4 ‘Test Station # T4 UP7PTOP: 5 ‘Test Station # TS. UPTP/OP’ [6 ‘Test Station # T6 UPTPTOP 7 Test Station # 7 UPTPTOP TECHNICAL DOCUMENT P System for Underground Fire water Pipeline and Natural gas — Pipeline at National Fertiizers Limited, Panipat Project Page 11 of 12 ‘UGPLTL-NFL-CP- PANIPAT-00 Rev?ucPI THERMAX ‘Summary of Performance of CP System: ‘Native Potential measured with respect fo Cu-CuS04 reference Electrodes. ‘The Protected Potentials should not be less than (-) 0.85 Volts or 100mV polarized potentials from Note: All PSP readings are recorded with respect to Cu-CuSO4 Reference Electrode. UNIVERSAL CP INDIA ‘THERMAX NFL “UP — UNDER PROTECTED, P ~ PROTECTED, OP - OVER PROTECTED Note: MA~Mq Anode Pipeline at National Fertlizers Limited, Panipat Project TECHNICAL DOCUMENT | ‘CP System for Underground Fire water Pipeline and Natural gas oe Page 12 of 12 UCPLTLNFL-OP- PANIPAT-O0| Rov: 0%weer fart fren PRLra tar mums souia Soma waUE| a ita GUL XVM ssenan a Pals mame GRUNT! 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