Document Review Status

Triune Energy Services Pvt. Ltd.

Job No. Name / Sign / Dept. / Date
Ram Narayan
Digitally signed by Ram Narayan Singh
DN: cn=Ram Narayan Singh, o=TESPL,
9637 ou=Electrical,
Singh email=Ram.Singh@Triune.co.in, c=IN
Date: 2016.06.08 17:20:30 +05'30'

(1) NO COMMENTS, CAN PROCEED

(2) PROCEED AS PER COMMENTS, REVISED
DOCUMENT REQUIRED

(3) NOT MEETING REQUIREMENTS, RESUBMIT

(4) RETAINED FOR RECORDS, CAN PROCEED

APPROVAL BY COMPANY DOES NOT ABSOLVE THE
CONTRACTOR / SUPPLIER OF HIS RESPONSIBILITY /
LIABILITY AS PER CONTRACT

A  06.05.2016  ISSUED FOR INFORMATION  M.L. T.T.  M.H. 

Rev.  Date  Description  Prepared Checked  Approved ‐‐‐‐‐‐‐‐‐‐‐‐ 
No. 

Contractor  Document Title 

CATHODIC PROTECTION SYSTEM (INSTALLATION MANUAL) 

Document No. 
Executive desk: Q1‐05, 
Office ;094/C Sharjah 
Airport International   Rev 
Scale
Free zone Sharjah , UAE  ERG  CAL  EMM  STE  P01  324  15  010  A 
Tel: +971 6557 0720           
Co.  Doc  Disc.  Unit  Prj.  Prj.  Prj.  DCC 
Org.  Type  Code  Code  Type  No  Year  SeqNo  Page 
Cod 
Ergil Group Middle East

Zubair Plant Project, Iraq

Installation Manul

CONTENTS

1 INTRODUCTION ....................................................................................................... 3
1.1 GENERAL ................................................................................................................. 3
2 INSTALLATION ........................................................................................................ 3
2.1 GENERAL ................................................................................................................. 3
2.2 MMO RIBBON & CONDUCTOR BAR ....................................................................... 3
2.3 SPOT WELDING PROCEDURE ............................................................................... 4
2.4 POWERFEED CONNECTORS ................................................................................. 6
2.5 POTENTIAL MONITORING FACILITIES .................................................................. 7
2.6 NEGATIVE TANK CONNECTION ............................................................................. 7
2.7 POSITIVE AND NEGATIVE HEADER CABLES ........................................................ 8
2.8 JUNCTION BOXES ................................................................................................... 9
2.9 TRANSFORMER RECTIFIER UNIT .......................................................................... 9
2.10 INTERNAL GALVANIC ANODE .............................................................................. 10
3 PRE-COMMISSIONING TESTS .............................................................................. 11
4 COMMISSIONING .................................................................................................. 12
5 MAINTENANCE SCHEDULE ................................................................................. 13
5.1 CRITERION FOR ACHIEVING CATHODIC PROTECTION .................................... 14

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Installation Manual

1 INTRODUCTION

1.1 GENERAL

This document is the installation manual relating to the permanent cathodic protection
systems installed to protect the tanks at the Zubair Plant, Iraq.

2 INSTALLATION

2.1 GENERAL
All installation works associated with the Cathodic Protection system shall be conducted in
accordance with this specification and the appropriate design drawings. Any conflict between
this specification and the drawings and / or other project specifications and drawings shall be
brought to the attention of the CPCL Engineer in writing for clarification as soon as it is
discovered.

2.2 MMO RIBBON & CONDUCTOR BAR

For the successful operation of the Cathodic Protection system it is imperative that the MMO
Ribbon is installed at a depth of 350 mm minimum below the tank bottom where possible. It
must be noted that the MMO Ribbon anodes and conductor bar assembly should be placed
above the leak containment membrane.

The membrane should be at least 50 mm below the proposed location of MMO ribbon grid. In
addition, it is essential that the membrane shall cover the entire inner face of the concrete
ringbeam foundations to isolate the reinforcing rebar from the anode network. The Tank
Construction Contractor shall confirm the membrane is a uniform depth below the proposed
bottom of the tank.

A layer of chloride free, clean washed sand shall be installed directly above the membrane
which shall be compacted as normal and the anode shall be installed in this layer. The pattern
of the anodes and conductor bar is shown in the design drawings. The Tank Construction
Contractor shall confirm the sand layer is uniform and at least 50 mm above the membrane
level.

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The anodes shall be rolled out onto the sand base layer in the pattern as shown in the
relevant design drawing. Where appropriate the anodes shall be temporarily weighed down to
avoid movement, however great care shall be taken to ensure that the coating of the anodes
is not scratched or damaged in any way.

As the anode ribbons are being laid out the conductor bars shall be placed over them in the
pattern shown in the relevant design drawing. At each and every crossover of the anode
ribbon with the conductor bar, the anode shall be resistance welded, (spot welded) to the
conductor bar. Prior to conducting the spot welding for each tank a sample spot weld shall be
made and inspected by Cathodic Protection Co Ltd Engineer or other suitably authorised
person. Refer to section below on spot welding procedure.

At each and every crossing of the perpendicular and parallel conductor bars, they shall be
resistance welded to each other. The welding equipment shall be operated in accordance with
the manufacturers Operation Manual. Where necessary, anodes and conductor bars shall be
extended using the same procedure.

2.3 SPOT WELDING PROCEDURE

The personnel used for welding must fulfill project certification requirements.
A recommended welding procedure that is compliant with the Project Specification API 650
Standard is required. API 650, Section 7-Welding Procedure and Welder Qualifications terms
relate to all welding shall be interpreted as defined in Section IX of the ASME Code.

The scope of the work for this procedure is responsibility of the installing contractor.

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ASME IX.par.QW-285 spot welding procedure

ASME IX.par.QW-196 testing

ASME IX .par. QW – 462.8

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ASME IX.par.QW -462.9

2.4 POWERFEED CONNECTORS

The powerfeed connections locations shall be identified as per the design drawings.

Power feed connectors shall be field connected to the 1c 25 mm² PVDF/HMWPE stranded
cable using a line tap and splice kit with the instruction supplied with the splice kit. Once
installed in the correct location the conductor bar tail from the powerfeed cable encapsulation
shall be connected to the conductor bar using where appropriate resistance welding (spot
welding).

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Upon completion of the powerfeed assembly, the powerfeed cable shall be routed to the
chosen exit point from the foundations and routed out of the foundations via a suitable conduit,
(cast into the concrete ringbeam), as shown in the design drawings.

A 25 mm ‘sand bridge’ shall be made at each powerfeed cable / anode crossing location to
ensure that they are not in direct contact. Once the cables have been routed out of the
foundations, the entire anode, conductor bar and cable assembly shall be covered with
another layer of chloride free, clean washed sand, which shall be smoothed flat and
compacted. The installation contractor shall confirm the sand layer is uniform and at least 50
mm above the MMO Ribbon layer.

The powerfeed cables shall be routed from the tank to the location of the positive / negative
junction box installed adjacent to the tank, outside of the bunded area. At all times the cables
shall be laid in a single length without further splicing, free from kinks and excessive bends.

2.5 POTENTIAL MONITORING FACILITIES

When at least a 150 mm layer of backfill over the MMO ribbon has been completed the slotted
monitoring pipe shall be installed as shown in the relevant design drawing, ensuring that the
pipe is straight and flat to allow a reference electrode to pass without hindrance.

Inside the pipe a loop of 8 mm polypropylene rope to pull the reference electrode through
should be installed and connected to the end cap by the eyebolts.

Also the permanent reference electrodes should be buried and surrounded by 100 mm of soft
clean washed sand. Note each reference electrode has different length of cable tail and must
be installed in the correct location to allow termination in the test box. Cable tails to should be
routed appropriately back the test box without damage to insulation.

2.6 NEGATIVE TANK CONNECTION

Negative tank connections shall be supplied and welded to each tank at two locations by the
main contractor in accordance with the appropriate project welding specification. These shall
be near to the positive / negative junction box for ease of laying cables and at 180o from the
first. The connection shall be a prefabricated assembly designed for welding to the side of the
tank as shown in the relevant design drawing.
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After completion of each connection the following tests shall be done:

 The electrical resistance of the connection shall be recorded by placing one
resistance probe on the bare metal of the connection and the other on the cable lug.
The measured resistance shall be recorded and if the recorded resistance value is
greater than 0.01 Ohm the connection shall be recorded as having failed. In the event
of a failure the cable connection shall be re-made.
 Test the mechanical strength of the connection hit the connection with a sharp blow
with a 2.2 kg copper headed hammer or exert a pull of 240 kg on the connection
cable.
 Where the connection has a satisfactory resistance the cable shall be inspected by
Cathodic Protection Engineer or other suitably authorised person. In the event of
failure of the connection or cable strands the connection shall be re-made.

Upon successful testing of the connection it shall be encapsulated taking care to avoid any
damage to either the cable connection and/or the cable.

2.7 POSITIVE AND NEGATIVE HEADER CABLES

All positive and negative header cables shall be laid in a single length without splicing where
possible, free from kinks and excessive bends. A minimum depth of 600 mm shall be
maintained at all times. The cable shall be laid in the centre of a 100 mm thick soft sand bed
and care shall be taken to avoid any damage to the cable insulation.

A stress relief loop shall be left in cable prior to entering equipment to prevent damage to the
cable in the event that the junction box is accidentally displaced and the cables are pulled.

During construction and prior to installation of the test facilities to prevent accidental damage
to or theft of the cable, the cable shall be looped and buried at a depth of 500 mm and a
wooden board placed over the cable to prevent damage when the cable is retrieved.

The location of the buried cable shall be suitably marked on the surface to ease location of the
cable when it is required.

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2.8 JUNCTION BOXES

The positive / negative junction boxes shall be installed on a concrete plinth in a location
shown in the marked up design drawings. The concrete plinth shall be provided with cable
conduits and support bolts. The DC cables shall be installed in the junction boxes but not
terminated. Termination shall be done by an experienced CP Engineer at the time of
commissioning. The DC cables shall be routed to / from the Transformer Rectifier Unit as per
the details of the design drawings.

The junction boxes shall be located in electrically rated locations according to their electrical
classification rating. The final location of the junction boxes shall be decided on site by the CP
Engineer in consultation with the Project Engineers. They shall, where practicable, be installed
in such a fashion that easy access to the junction boxes is maintained. Under no
circumstances shall a junction box unit be installed in a location where it could be damaged,
stolen and / or cause an obstruction or interference to the legitimate activities of the operator.

2.9 TRANSFORMER RECTIFIER UNIT

The Transformer Rectifier Unit shall be installed in non-hazardous location near to the tank,
outside of the bunded area on a concrete plinth in a location shown in the marked up design
drawings. The concrete plinth shall be provided with cable conduits and support bolts. The
Transformer Rectifier shall be mounted on the plinth and provided with AC power by the main
contractor.

The DC output cables shall be installed in the Transformer Rectifier but not terminated.
Termination shall be done by an experience CP Engineer at the time of commissioning. The
DC output cables shall be routed to / from the Transformer Rectifier to the positive / negative
junction box, as per the details of the design drawings.

The unction boxes shall be located in electrically rated locations according to their electrical
classification rating. The final location of the Transformer Rectifier units shall be decided on
site by the CP engineer in consultation with the main contractor and client. The Transformer
Rectifier units shall, where practicable, be installed in such a fashion that easy access to the
Transformer Rectifier unit is maintained.

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Under no circumstances shall a Transformer Rectifier unit be installed in a location where it

could be damaged, stolen and / or cause an obstruction or interference to the legitimate
activities of the operator.

2.10 INTERNAL GALVANIC ANODE

This procedure assumes that the tanks are fully constructed apart from coating patch repairs
on the tank internals:
Prior to anode installation, anode stand-off brackets shall be installed between the anode
insert and the tank as shown on the installation drawing. These should have been welded in
location during fabrication of the tanks.
In order to maximize galvanic anode water immersion and in turn maximize cathodic
protection of the tank bottom, installation of anode on support brackets shall be as close to the
tank bottom as possible.
Anode to floor distance shall be at least 100 mm but not more than 150 mm, unless field
owner engineers determines this spacing is not achievable.
There shall be a redundant welded metallic path established from the anode core bar or rod to
the tank bottom. In order to prevent tank interior coating damage from the act of welding
anode core rod to the pre-installed support bracket, floor coating shall be protected utilizing
protective blankets".
For each anode installation the following method shall apply:
 Secure the anode in place by installation of ‘U’ bolts across steel anode inserts to the
relevant mounting holes on each of the stand-off brackets.
 Re-coat the freshly welded sections and the stand-off bracket with project approved
re-coating material Do not coat the anode as this will render the anode useless
in water
 Visually inspect all anode insert to stand-off bracket connection
 Visually inspect all stand-off brackets to tank welds
 Record the anode locations

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3 PRE-COMMISSIONING TESTS
The following sections outline the pre-commissioning tests and procedures that shall be used to
determine that the CP system and materials as installed shall operate correctly and provide the
tanks with a satisfactory level of protection. Any conflict between this specification and the
drawings and / or other project specifications and drawings shall be brought to the attention of
the Main Client Engineer in writing for clarification as soon as it is discovered.

The tests shall include as a minimum:

 A visit to each piece of CP equipment installed to ensure that it is correctly
installed.
 Trial operation of power sources to their maximum capacity.
 Measurements and testing should be carried out to confirm satisfactory
connection of all cables and circuits.
 Resistance to earth testing of groundbeds.
 Calibration of permanent electrodes.

All the results shall be properly documented and signed off by all the relevant parties. This
documentation will form part of the final handover documentation.

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4 COMMISSIONING
The purpose of the commissioning procedure should be used to show that the installed systems
operate as specified and that the required design criteria have been met.

The test shall include as a minimum the following:

 Standard forms for recording commissioning results.

 Recording of natural potentials
 Activating the cathodic protection systems
 Measurement of potentials (“ON” and IR free / “instant OFF”)

A commissioning report will be prepared by CP Engineer, which shall include all commissioning
results. The report shall include a discussion of the results obtained giving conclusions. The
report shall also show the natural, “ON” and “instant OFF” potentials at all test stations in both
tabular and graphical formats.

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5 MAINTENANCE SCHEDULE

Inspection Type Works to be Conducted

Monthly Transformer Rectifiers:

 Record the output voltage and current.

 Record structure-to-electrolyte potential for permanent

reference electrode

Three Monthly As above plus:

Transformer Rectifiers:

 Calculate the circuit resistance from the output voltage and

current.

 Record general appearance, condition and efficiency of the

TR unit.

 Adjust output as required to achieve protection

Structures:

 Record structure-to-electrolyte potentials at each test

facility.

Annually: As above plus:

Transformer Rectifiers:

 Recalibrate to zero all output meters.

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5.1 CRITERION FOR ACHIEVING CATHODIC PROTECTION

The protection criteria for items in contact with soil are in line with document industry standard
and in summary:

 Steel in Soil -0.850 Volts verses vs. Cu/CuSO4 reference electrode.

 As an alternative a minimum of 100 mV of cathodic polarisation between the

structure and a stable electrode contacting the electrolyte.

All above potentials are IR free or “OFF” potentials.

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