PROJECT- DEVELOPMENT OF ATLANTIC TERMINAL –

TAKORADI PORT OIL JETTY FACILITY

REFERENCE- AMANDI HOLDING LTD

Cathodic Protection of Steel Pipe Piles ©

1. Introduction
The specification refers to the supply and installation of aluminium sacrificial
anodes system (Al-Zn-In anode alloy) on all the pipe piles of the Takoradi Port
Oil Jetty. The cathodic protection system is designed to a lifetime of about 25-
30 years in combination with coating of the steel pipe piles with solvent free
epoxy coating SIKACOR SW 500 to a minimum total dry film thickness of 600
microns.
The anode assembly will be caisson mount for diver installation, consisting of two
coated pile clamps and two aluminium anodes for each pipe pile.

2. Scope of Work
1. Execution of electrical continuity between piles and bollards
according to plans.
2. Supply of aluminium anodes according to DNVGL RP-B401 with
clamps and continuity contact bolts, including complete set of EN
10204 Type 3.1 inspection certificates.
3. Anodes installation
4. Performing all required inspections and tests, including submittal of
protection potential readings for each pipe pile (100% of piles)
5. Repairs and re-testing as needed and required by the Engineer.
6. Submittal of as-made drawings.
7. Potential measurements (100% of piles) at the end of the warranty
year.
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3. Standards, Regulations and Codes of Recommended Practice

The following standards in their latest edition are binding upon the anode
manufacturer and the contractor in their work and will be considered an
inseparable part of this specification:
1. DNVGL RP-B401: Det Norske Veritas Industry AS (June 2017)
Recommended Practice RP-B401, Cathodic Protection Design.
2. NACE SP0387-2006: Metallurgical and Inspection Requirements for Cast
Sacrificial Anodes for Offshore Application.
3. NACE TM 0190: Impressed Current Test Method for Laboratory Testing of
Aluminium Anodes.
4. NACE RP 0169: Recommended Practice for Control of External Corrosion
on Underground or Submerged Metallic Piping Systems.
5. AWS D1.1M-2010: Structural Welding Code - Steel.
6. AWS D3.6M-2010: Specification for Underwater Welding.
7. EN 10204: Metallic Products - Types of Inspection Documents.

4. Submittals
4.1. Construction Submittals
The Contractor shall submit the following for approval:

a.) Anodes with anodes inspection certificates Type 3.1 and clamps for
anodes installation, including hardware, fastening devices and
accessories.
The Contractor shall submit detailed anode and clamp drawings for
approval, including anode core design and location. Anode cores and
anodes clamps shall be designed to provide the required utilization
factor, to ensure electrical continuity, and to support the anode during
all phases of fabrication, installation and operation.

b.) Electrical continuity system with a continuity test report.

c.) Potential Test Results – Structure to Water Potentials after installation

and after the Warranty Year.
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4.2. “As-Made” Drawings

The Contractor shall submit “As-Made” Drawings, showing the locations

and sizes of all anodes.

5. Preparations before Anodes Installation

The prerequisites before cathodic protection system installation are as follows:
1. Painting the piles according to the technical specification with painting
inspection certificates Type 3.2.
2. Piles paint repairs before and after driving in the piles (original coating and
underwater paint repairs).
3. Execution of electrical continuity between piles of each dolphin or
platform/jetty and between piles and bollards.
4. Cleaning anodes location just before installation of the anodes.
5. Supply of approved anodes + caisson mount systems with Type 3.1
inspection certificates.

6. Electrical Continuity and Potential Test Points

Pipe piles will be electrical continuity connected as required for grounding in the
electrical plan. The quick release hook of each dolphin will be connected to the
dolphin's piles.
In each axis, a hot dip galvanized St 37-2 steel strip with cross section of at least
6x80 mm will be welded to form electrical continuity between the piles.
Alternatively, a concrete reinforcing steel bar of diameter 25 mm can connect
between the piles and the bollards.
All electrical connections will be executed and inspected after pile driving in and
before casting concrete in place.
Welding slag will be removed before concrete casting. The contractor will submit
to the Engineer a continuity test report by qualified electrical technician.
The quick release hooks may serve as potential test points for measuring
cathodic protection potential of each pile of a dolphin.
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7. Description of Anodes Material

7.1. Anode Material

The anodes material will be Aluminium-Zinc-Indium alloy according to DNVGL-
RP B401, as well as NACE SP0387 and NACE TM 0190.

The following anodes manufacturers are approved:

Galvotec Alloys Inc, USA
Aluminium Anode Alloy: According to DNVGL-RP-B401: 2017 requirements.
Impalloy Ltd, UK
Aluminium Anode Alloy: Impalloy III-S (Mercury free) modified to DNVGL-RP-
B401: 2017 requirements.

Any anode manufacturer, as well as the above two manufacturers, should comply
with all the anodes testing and quality control requirements of this technical
specification.

The anode manufacturer and the anode material proposed by the Contractor
should be approved in advance by the Engineer.

7.2. Chemical Composition for the anode material

The chemical composition will conform to the latest requirements of DNVGL-RP-
B401, June 2017, Table A-5, especially regarding to the level of contamination
elements allowed in the alloy (Iron, Copper, Silicon and Cadmium).
Specific gravity of the aluminium material: 2,710 Kg/m3.

See attached chemical composition requirements in Table 1, below:

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Table 1 – Anode material chemical composition requirements

Elements DNVGL-RP-B401, June 2017

Table A-5, Al-base (wt. %)

Fe 0.09 max

Si 0.12 max

Cu 0.003 max

Zn 2.5 - 5.75

In 0.015 – 0.040

Cd 0.002 max

Aluminium Remainder (99.85 % purity)

7.3. Electrochemical Performance requirements

The anode material will have prior approval test certificate of electrochemical
performance for long term of minimum 12 months, e.g. – such as to DNVGL-
RP-B401-Annex C - Laboratory Testing of Galvanic Anode Materials for
Qualification of Electrochemical Performance (Test period minimum of 12
months).

During anode manufacturing, the electrochemical performance of the anode

material will be tested at 20 0C according to DNVGL-RP-B401 - Annex B –
Laboratory Testing of Galvanic Anode Materials for Quality Control (4-day
capacity test) and submitted to the Engineer for approval.

The requirements for electrochemical performance as measured during

manufacturing (Production Tests) are:

Minimum Capacity: 2,500 Amp.hrs/kg according to DNVGL-RP-B401 – Annex

B: Laboratory Testing of Galvanic Anode Materials for QC.
(Average Current Capacity: 2,580 Amp.hrs/kg)
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Closed Circuit Potential: - 1.05 V or more negative (w.r.t. Ag/AgCl/Sea water)

when measured at the end of 24-hour period operating at 0.4 mA/cm 2.
(Average Closed-Circuit Potential: - 1.11 V versus Ag/AgCl/Sea water reference
electrode).

8. Supply, Documentation, Inspection and Testing

8.1. General
The anode manufacturer will have quality assurance management system
certified according to ISO 9001.

The anode manufacturer will produce the anode according to DNVGL RP B401
(and where needed per NACE SP0387 and NACE TM 0190) and will submit
inspection documents of production tests from his independent quality control
department according to EN 10204, Type 3.1.

Anode identification: All anodes will be marked (stamped) with heat / charge
numbers and anode code (type of material).
The anodes will be packed on timber pallets suitable for handling by fork-
lift-truck. Tensioned steel straps will secure the anodes to the pallet. The
wood packing material used for this project will be treated and marked
under the official program of ISPM 15 Standards.

8.2. Inspection Documents

Each delivery will be completed with the following production test certificates:
- Certification to EN 10204, Type 3.1.
- Anodic material performance certificates (DNVGL-RP-B401 - Annex B - 4-
day capacity test). Current capacity tests, efficiency and closed-circuit voltage
tests will be performed for 25% of the casting heats and at least 4 tests per
order.
- Material chemical analysis reports for 20 % of all anodes.
- Visual inspection for cracks and quality of castings reports for 100 % of all
anodes.
- Dimensional inspection and identification reports for all anodes per NACE
SP0387.
- Weight list anode production test reports for all anodes.
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- Quality of steel inserts, surface preparation and welding before castings.

- Quality of steel-anode bonding and internal defects report for on cut anode
(Destructive examination of on anode) of each anode typ.
- Certificate of conformity (COC).
Material chemical composition will be performed with calibrated Spectrographic
analyzer.
Samples of each oven charge / each heat will be taken for chemical analysis.
The results shall be proved and recorded.

8.3. On-site Inspections

The anodes will be examined on-site for quantity, dimensions and weights,
storage and stacking, cracks, surface defects, cold shuts and steel core
conditions.
- 100% visual check
- Dimensional and weight inspection criteria:
Anode mean length: +/- 2 %
Anode mean width: +/- 5 %
Anode mean height: +/- 7.5 %
Anode weight tolerances: +/- 2%,

8.4. Cracks Acceptance Criteria

Cracks acceptance criteria will be per NACE SP0387: Metallurgical and
Inspection Requirements for Cast Sacrificial anodes for Offshore Application.
- Longitudinal cracks are not permitted.
- Transverse cracks from any length and depth, which are more than 3 mm
wide, are not permitted.
- Circumferential cracks are not permitted.
- Maximum ten cracks per anode are allowed.

Anode surface area will be clean, without any contamination, paint, grease,
oil and casting slag. Cold shuts are not permitted.

The anode material will thoroughly adhere to the steel core.

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8.5. Summary of Minimum Inspection Requirements

Inspection during and after fabrication of anodes shall be carried out by the
anode manufacturer and shall cover the following as a minimum:
1. Inspection certificates to EN 10204, Type 3.1.
2. Anode manufacture, materials, fabrication of anode inserts, casting of
anodes and inspection and testing of the anodes according to DNVGL-RP-
B401 and NACE SP0387-2006.
3. Dimensional checking, weight, identification, quality of casting and cracks
on 100% of the number of anodes from each cast per NACE SP0387.
4. Quality of steel inserts before casting, welding and surface preparation (Sa
2.5 at the time of casting) on at least 20% of inserts for the batch of
anodes from each cast per NACE SP0387.
5. Inspection of results of chemical analysis for each cast and at least 25% of
the anodes.
6. Quality of steel-anode bonding and internal defects on one anode from
each anode type, selected for destructive testing.
7. Open circuit voltage tests for each cast and at least on 25% of the anodes.
8. Capacity tests, closed circuit voltage test and efficiency for one quarter of
the number of heats, with minimum 4 tests per order done by the supplier
acc. to DNVGL-RP-B401 (2017): Annex B (Accelerated Laboratory
Testing
Procedure - 4-day test).
9. After transport to installation site, a final 100% visual check to be carried
out to ensure that anodes have not been damaged during transport and
handling.
10. Where any of the inspection, testing and documentation mentioned is not
met, the anodes and the relevant batch of anodes will be rejected.

9. Aluminium Anodes installation and Anode Location

On each pipe pile 2 aluminium anodes will be caisson mounted with coated pile
bracelets clamps and contact continuity galvanized bolts ISO 898/1 Class 8.8.
Anodes installation will be according to the following drawings:
Cathodic protection drawing 1 - Caisson mount, clamp connection.
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Cathodic protection drawing 2 - Typical installation on pipe piles.

The anode steel inserts will be welded continuously to the clamps along
their 100 mm long ends. Total length of the circumferential weld to the
clamp on each insert end will be ca. 220 mm.

The bracelets clamps will be installed by divers.

Before installing the anodes, the diver shall clear and clean the area
designated for the clamps of all sea growths. The cleaning is to be carried
out 1-2 hours before anode bracelets installation.

The bracelets clamps will be connected by galvanized threaded rods

M20x250 mm Class 8.8 with double galvanized nuts and flat washers
Class 8. At least two electrical continuity sharpened galvanized bolts
M16x60 mm will be installed for each half bracelet. (Minimum 4 contact
bolts per clamp).

Clamps will be painted with paint system No. 2 (without the top coat),
except at thread rod connections under the flat washer and double nuts
and at the contact bolt thread. The steel bracelet clamps may be painted
also by zinc rich epoxy primer Interzinc 52 @ 60 µm + two coats of epoxy
paint Interzone 954 @ 2x200 µm. TDF: 460 µm.

Anodes should not be painted.

Anodes will be clean from any contamination by paint, grease, oil etc.
Where possible the upper clamp of the caissons (upper bracelets) will be
installed at water depths about – 2.0 meter.
- Comment 1: It is highly preferred to install the anodes midpoint
between M.L.W and sea bed, if possible.
- Comment 2: At pipe piles near the embankment, upper clamp may be
higher, but always immersed in the water. If the stone fill of the oil jetty
disturbs to the assembly of the caisson, it is possible to continuously weld
mounting pads for the anodes on the piles before driving these piles into the
sea bed and later underwater weld the anodes onto the anode mounting
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pads. Anode mounting pads will be at least 200x350x10 mm, made of mild
steel St 37-2 with rounded corners of 5 cm radius. The coating of the piles
will include the painting of these anode mounting pads before pile driving.
If this option is not practical, anode core will be welded directly to the
pipe pile and anode will lie horizontally on the stone bed, but this is only
where water level is very low, preventing installation according to the
C.P. drawings and the technical specification.

10. Anode Type and Quantity

1. The expected total number of aluminium anodes for the Takoradi oil port
terminal will be 91 units. The exact number will be decided per local
installation conditions. Estimated quantities: 67 Piles 32" (diameter 813
mm) and 24 piles 24" (diameter 610 mm). Total estimated quantity of
anodes is 182 anodes. The exact final number of anodes and clamps will
be approved by the company.

Each anode:
Net anode weight: 65 Kg.
Gross anode weight: 70.5 Kg.
Anode insert: material St 37-2 (or EN 10025 S275 JR), double cranked
steel rod 20 mm. Insert will be abrasive blasted by angular grits to Sa
2.5 per ISO 8501-1:1998.
Anode output: based on 25 Ohm.cm minimum output is 2.74 Ampere.
Anode stand-off: minimum 165 mm.

2. All anode dimensions are in cathodic protection drawing 3 - Aluminium

Anode: T-650-Al-dc. Clamps to fit diameter of piles, according to the
latest edition of the pipe piles drawing and pipe piles selection.

11. Welding

Dry welding will be performed according to standard AWS D1.1 (and / or ISO
15609 or EN 10248, EN 12063 execution of pile works).
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Underwater welding will be performed if needed according to standard AWS

D3.6M2010. Inspection of underwater welds will be according to AWS D3.6M-
2010, Section 9, Part III – Examination, Class B Fillet Welds.

Underwater rutile electrodes should be specifically for underwater welding

according to AWS A5.1: E-7014, such as:
BROCO UNDERWATER, SOFTOUCHTM WET WELDING ELECTRODES or
SEA-WELD (Yellow) or Tweco Arcair / Sea Stinger Arcair or approved equivalent.
Diameter of the electrodes 1/8" (3.2 mm), 5/32" (4.0 mm), 3/16" (4.8 mm) as
needed.

12.0 Potentials Measurements for Cathodic Protection

The potentials will be measured underwater by a diver or from above the water by
experienced cathodic protection technician. Potential measurements by diver will
be executed with special underwater equipment. This device is sealed from water
having high impedance and Ag/AgCl/Sea water reference electrode. The
measuring equipment will be calibrated in a certified laboratory versus SCE
electrode.

From above the water the readings may be taken from the quick release hook for
the dolphin piles with calibrated portable Ag/AgCl/Sea water reference electrode
and a multimeter of above 10 Meg-Ohms internal impedance and resolution of 1
mV at range up to 2V-DC.

13. Cathodic Protection Criteria

The minimum protection potential for cathodic protection will be - 0.80 Volt
(Ag/AgCl/Sea water ref.) as required by the standards DNVGL RP-B401 and
NACE RP 0169.

If after full polarization (about one month from end of anodes installation) the
potential measured will be above - 0.80 Volt (Ag/AgCl/Sea water ref.), the
protection should be improved according to the Engineer requirements and on
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the contractor expense (e.g. – by improving electrical continuity of anodes to piles

or by adding aluminium anodes).

14. Final Inspection at End of the Warranty Year

The contractor will check and measure piles potentials at the end of the warranty
year.
Copies of the tests results will be submitted to the Engineer.

15. Top Corrosion Protection Supervision

The top inspection on the piles coating work and cathodic protection system
installation will be performed by the quality control department of the contractor
Amandi Holding Ltd by a corrosion protection technician approved by the
Engineer.

Attachments
Cathodic Protection Drawing No. 1 - Caisson mount clamp connection.
Cathodic Protection Drawing No. 2 - Typical installation on steel pipe piles.
Cathodic Protection Drawing No. 3 - Aluminium anode T-650-AL-DC.