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SECTION 13112:

GUIDELINE SPECIFICATION FOR

SACRIFICIAL ANODE CATHODIC PROTECTION OF
SUBMERGED AND BURIED UNDERGROUND
STRUCTURES

0 15/02/06 I Issued for Use

REV DATE DESCRIPTION PREPARED BY RC APPROVED

KINGDOM
OFSAUDIARABIA
~~~1 4I,}JJ!
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forJubail&Yanbu
RoyalCommission cw.1~~1~1
 SECTION 13112
SACRIFICIAL ANODE CATHODIC PROTECTION OF SUBMERGED AND BURIED UNDERGROUND
STRUCTURES

TABLE OF CONTENTS

Item No Title Page No

PART 1 GENERAL............................................................................................................ 1

1.01 DESCRIPTION OF WORK .................................................................................. 1

1.02 SECTION INCLUDES .......................................................................................... 1

1.03 RELATED SECTIONS ......................................................................................... 1

1.04 REFERENCES..................................................................................................... 2

1.05 DEFINITIONS....................................................................................................... 3

1.06 SUBMITTALS....................................................................................................... 6

1.07 QUALITY CONTROL ........................................................................................... 8

1.08 HEALTH AND SAFETY CONSIDERATIONS...................................................... 9

1.09 DESIGN CRITERIA.............................................................................................. 9

1.10 JOB CONDITIONS............................................................................................. 12

1.11 INTERFACES..................................................................................................... 12

1.12 DELIVERY, HANDLING AND STORAGE ......................................................... 13

PART 2 PRODUCTS ....................................................................................................... 14

2.01 GENERAL .......................................................................................................... 14

2.02 ANODES ............................................................................................................ 14

2.03 REFERENCE ELECTRODES............................................................................ 14

2.04 TEST STATIONS ............................................................................................... 15

2.05 FLANGE INSULATION KITS ............................................................................. 15

2.06 DC AND INSTRUMENT CABLING .................................................................... 15

PART 3 EXECUTION ...................................................................................................... 17

3.01 PREPARATION ................................................................................................. 17

3.02 INSTALLATION.................................................................................................. 17

Rev 0 i Contract No:

 SECTION 13112
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STRUCTURES

TABLE OF CONTENTS (Contd.)

Item No Title Page No

3.03 TESTING AND COMMISSIONING .................................................................... 19

3.04 INTERFERENCE TESTING............................................................................... 20

3.05 PROVISION OF OPERATION AND MAINTENANCE MANUAL....................... 21

3.06 PROVISION OF TRAINING IN SYSTEM OPERATION .................................... 22

Rev 0 ii Contract No:

 SECTION 13112
SACRIFICIAL ANODE CATHODIC PROTECTION OF SUBMERGED AND BURIED UNDERGROUND
STRUCTURES

PART 1 GENERAL

1.01 DESCRIPTION OF WORK

A. The Contractor shall design, install, commission and document a sacrificial anode
cathodic protection (CP) system of submerged and buried underground metallic
structures. The purpose of the CP system is to prevent external corrosion of
submerged and buried underground metallic structures, such as piping and sheet
piles, by passing a low voltage (direct current) from a galvanic anode to the metallic
underground structure.

B. The Contractor shall furnish all labor, materials, tools and equipment required to
complete the Work.

1.02 SECTION INCLUDES

A. This Section establishes the general criteria for the design, installation and
commissioning of cathodic protection (CP) of submerged and buried underground
metallic structures as required for corrosion control. The cathodic protection system
is of the sacrificial anode type, providing sufficient current to the structure to be
protected with the current sufficiently distributed so that the selected criteria for CP
system operation are effectively achieved.

1.03 RELATED SECTIONS

A. Section 01320 Construction Progress Documentation

B. Section 01330 Submittal Procedures

C. Section 01410 Regulatory Requirements

D. Section 01450 Quality Control

E. Section 01650 Product Delivery Requirements

F. Section 01660 Product Storage and Handling Requirements

G. Section 01780 Closeout Submittals

H. Section 01830 Operation and Maintenance

I. Section 02085 Underground Piping Materials

J. Section 02510 Water Distribution

K. Section 13111 Impressed Current Cathodic Protection of Submerged and Buried

Underground Metallic Structures

L. Section 13113 Impressed Current Cathodic Protection of Reinforced Concrete

Structures

Rev 0 1 of 23 Contract No:

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STRUCTURES

M. Section 13450 Central Control

N. Section 16060 Grounding and Bonding

O. Section 16075 Electrical Identification

P. Section 16150 Wiring Connections

Q. Section 16410 Enclosed Switches and Circuit Breakers

1.04 REFERENCES

A. The referred codes and standards are intended to provide an acceptable level of
quality for materials and products. In case of conflict between these References and
the text of this Specification, the Specification text shall govern.

B. The latest revision of the referred codes and standards shall be used wherever
applicable. In case of conflict between codes and standards, the Contractor shall
conform to BS EN standards.

C. BSI British Standards Institution

1. BS 6004 Electric Cables

2. BS 7361 P1 Code of Practice for Land and Marine Applications

3. BS EN 12473 General Principles of Cathodic Protection in Sea

Water

4. BS EN 12474 Cathodic Protection for Submarine Pipelines

5. BS EN 12495 Cathodic Protection of Fixed Steel Offshore

Structures

6. BS EN 12954 Cathodic Protection of Buried or Immersed Metallic

Structures - General Principles and Application for
Pipelines

7. BS EN 13174 Cathodic Protection for Harbour Installations

8. BS EN 13509 Cathodic Protection Measurement Techniques

9. BS EN 13636 Cathodic Protection of Buried Metallic Tanks and

Related Piping

10. BS EN 50162 Protection Against Corrosion by Stray Current from

Direct Current Systems

11. BS EN 60529 Specification of Protection Provided by Enclosures

(IP Code)

D. DNV Det Norske Veritas Industri Norge AS

Rev 0 2 of 23 Contract No:

 SECTION 13112
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STRUCTURES

1. DNV RP B401 Cathodic Protection Design

E. NACE National Association of Corrosion Engineers

1. NACE RP0100 Cathodic Protection of Prestressed Concrete

Cylinder Pipelines

2. NACE RP0169 Control of External Corrosion of Underground or

Submerged Metallic Piping Systems

3. NACE RP0193 External Cathodic Protection of On-Grade Metallic

Storage Tank Bottoms

4. NACE RP0196 Galvanic Anode Cathodic Protection of Internal

Submerged Surface of Steel Water Storage Tanks

5. NACE RP0285 Corrosion Control of Underground Storage Tank

Systems by Cathodic Protection

6. NACE RP0286 Electric Isolation of Cathodically Protected Pipeline

7. NACE RP0387 Metallurgical and Inspection Requirements for Cast

Galvanic Anodes for Offshore Applications

8. NACE RP0492 Metallurgical and Inspection Requirements for

Offshore Pipeline Bracelet Anodes

9. NACE RP0575 Internal Cathodic Protection Systems in Oil-Treating

Vessels

F. NFPA National Fire Protection Association

1. NFPA 70 National Electrical Code

1.05 DEFINITIONS

A. Also refer to SECTION 13111.

B. anode: The electrode of an electrochemical cell at which oxidation occurs.

C. anode ground bed: System of buried or immersed galvanic or impressed current

anodes.

D. bond: Metal conductor, usually copper, connecting two metallic points on the same
or on different structures usually with the intention of making the points equipotential.

E. buried structure: Any metal construction built or laid beneath ground level or built
on ground level and covered with earth.

F. cathode: The electrode of an electrochemical cell at which reduction occurs.

G. cathodic protection (CP): A process of protecting a metallic object or structure from

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corrosion by installing a sacrificial anode or impressed current system that makes the
protected object cathodic and thus resistant to corrosion.

H. cathodic protection system: Entire installation including active and passive

elements that provides cathodic protection.

I. coating: Electrically insulating covering bonded to a metal surface for protection

against corrosion by preventing contact between the electrolyte and the metal
surface.

J. coating breakdown factor (f): Describes the anticipated reduction in cathodic

current density due to application of an electrically insulating coating. f = 0 means the
coating is 100% electrically insulating, reducing the cathodic current density to zero.
f = 1 means that the coating has no protective properties, i.e. the cathodic current
density is the same as for a bare steel surface.

K. continuity bond: Bond designed and installed specifically to ensure electrical

continuity of a structure.

L. copper/saturated copper sulphate reference electrode: Reference electrode

consisting of copper in a saturated solution of copper sulphate.

M. current density: Electric current per unit area of an electrode surface.

N. drainage (electrical drainage): Transfer of stray current from a current source to

another structure by means of a bond. Note: For drainage devices (direct drainage
bond, resistance drainage bond, unidirectional drainage bond and forced drainage
bond) see EN 50162.

O. electrical continuity: Physical state of a structure such that a current circulating

within it does not produce a significant voltage drop.

P. electrical interference: See interference.

Q. electrical isolation: Electrical isolation exists when there is no electrical path

between structures or components.

R. electrolyte: Liquid, or the liquid component in a medium such as soil, in which

electric current flows by the movement of ions.

S. electrolyte resistivity: The specific resistance of the electrolyte assuming that the
electrolyte is homogenous. Note: Usually expressed in ohm.meter (Ω·m).

T. galvanic anode: Electrode that provides current for cathodic protection by means of
galvanic action.

U. galvanic anode station: Station which comprises the equipment and materials
required to provide cathodic protection by the use of galvanic anodes. Such materials
and equipment will include galvanic (sacrificial) anodes, cables, and test facilities.

V. galvanic current: Electric current between dissimilar metals.

W. immersed structure: Any metallic structure or part of a structure laid in a liquid

environment such as fresh water (rivers, lakes), brackish water (estuaries), or sea

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water.

X. insulated flange: Flanged joint between adjacent length of pipe in which the nuts
and bolts are electrically insulated from the flange(s) and the gasket is non-
conducting, so that there is an electrical discontinuity in the pipeline at that point.

Y. interference: Any change in the structure to electrolyte potential, which is caused by

foreign electrical sources.

Z. interference test: Test to determine the severity of corrosion interaction between

two buried or immersed structures.

AA. IR free potential: Structure to electrolyte potential measured without the voltage
error caused by the IR drop due to the protection current or any other current.

BB. isolating joint: Electrically discontinuous connection between two lengths of pipe,
inserted in order to provide electrical discontinuity between them, e.g. monobloc
isolating joint, insulated flange.

CC. measuring point: The point of which the actual measurement takes place. Note: In
the case of structure to electrolyte potentials this refers to the location of the
reference electrode.

DD. INSTANT OFF potential: Structure to electrolyte potential measured immediately

after synchronous interruption of all sources of applied cathodic protection current.

EE. ON potential: Structure to electrolyte potential measured with the cathodic protection
current flowing.

FF. permanent reference electrode: Permanently buried or immersed reference

electrode designed for a long life and installed close to the structure.

GG. polarization: Change in the potential of an electrode (e.g. structure) as the result of
current flow to or from that electrode.

HH. potential test probe: See external potential test probe.

II. protected structure: Structure to which cathodic protection is effectively applied.

JJ. protective current: Current made to flow to a metallic structure from its electrolytic
environment in order to effect cathodic protection of the structure.

KK. protection potential: Structure to electrolyte potential for which the metal corrosion
rate is acceptable.

LL. reference electrode: An electrode of which the potential is accurately reproducible

and which serves as a basis of comparison in the measurement of other electrode
potentials.

MM. sacrificial anode: See galvanic anode.

NN. silver/silver chloride reference electrode: Reference electrode consisting of silver,

coated with silver chloride, in an electrolyte containing a fixed concentration of
chloride ions.

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OO. service life: The time until safety, serviceability and acceptable appearance of the
structure or its main components falls below a defined minimum level or requires
unduly high costs for maintenance and repair.

PP. stray current corrosion: Corrosion caused by electric current from a source
external to the intended electrical circuit, for example, extraneous current in the
earth.

QQ. structure: Metallic construction, whether coated or not, which is in contact with an
electrolyte (e.g. soil, water). Note: The structure may represent a construction of
great length, such as a pipeline, pipe networks, underground electric cables, or well
casings as well as constructions on a smaller scale such as piles, sheet pilings, tanks
or other underground constructions.

RR. structure to reference electrode potential (also called electrode potential):

Difference in potential between a structure and a specified reference electrode in
contact with the electrolyte at a point sufficiently close to, but without actually
touching the structure.

SS. test station: Installation that provides measuring and test facilities for the buried
structure. Note: Such installations will include cabling and structure connections.

TT. zinc electrode: Measuring electrode made from sufficiently pure zinc.

1.06 SUBMITTALS

A. The Contractor shall submit to the Royal Commission, under the provisions of
SECTION 01330, the following items for review and approval before commencing
Work:

1. Manufacturer's Data

a) Submit copies of manufacturer's specifications and installation

instructions for all proprietary materials and products such as anodes,
reference electrodes, cables, junction boxes, etc. Include all
manufacturers' certifications and laboratory test reports as required.

2. Shop Drawings

a) Submit Shop Drawings as required, showing complete detail and

schedule for fabrication and installation of the sacrificial anode CP
system. The Shop Drawings shall include, but not be limited to anodes,
fixation, test stations, cables and reference electrodes, signals I/O list.
The Shop Drawings shall indicate component type, dimensions,
fastening devices, distribution, position and cable routings. Any special
handling requirements for each of the components shall be identified.

3. Calculations

a) Provide complete detailed design calculations for each component

demonstrating compliance with this Specification, BS EN standards,
DNV RP B401 or NACE Recommendations. Detailed calculations shall
be provided which demonstrate acceptance for each component.

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b) The calculations shall demonstrate that the sacrificial anodes supplied

are sufficient to meet the current density criteria and capable of
providing the required design life. The design basis including references
shall be included.

c) The detailed calculations to support the design shall include but not be
limited to the following:
1) Cathode Current Requirement
(a) Calculation of surface area and current demand including
initial/final and average current and current drain in the
actual environment. If the structure is coated, the coating
break down factor shall be included.
2) Anode System Requirement
(a) Calculation of anode mass, number, type, dimensions,
resistance and current capacity including initial and final
current.
3) Circuit resistance of each component.

4. Method Statements

a) Provide a method statement for any measurements included in the

preparation as specified in par. 3.01, e.g., continuity survey, 'as found'
potential survey and verification of environmental parameters.

b) Provide method statement for installation of each component, e.g.,

continuity bonding, anode system including cables, reference electrodes
and test stations.

c) Provide method statement for commissioning, e.g., visual inspection and

testing.

d) The method statement shall be prepared in strict accordance with the

manufacturer's guidelines.

5. Operation and Maintenance Manual

a) Submit copies of the Operation and Maintenance Manual per

SECTION 01830.

6. As-Built Drawings

a) Submit copies of As-built Drawings and signals I/O list per

SECTION 01780, following installation of the CP system. The Drawings
shall provide complete details including, but not limited to anodes,
fixations, reference electrodes, test stations, cables, and disconnect
switches. The As-built Drawings shall further indicate component sizes,
locations and cable runs.

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1.07 QUALITY CONTROL

A. The Contractor shall be responsible for the quality of work and shall develop and
propose programs and methods of construction and testing to achieve the specified
quality to the approval of the Royal Commission in accordance with
SECTION 01450.

B. The design, installation and commissioning of the CP system shall meet the Royal
Commission’s Quality Control standards. In addition, the CP system component
manufacturer’s own recommended installation procedure, material standards and
procedures shall be recognized as part of this Specification. No deviations to the
present specification or the manufacturer’s recommendations shall be permitted
without prior written agreement by the Royal Commission. The Contractor and
Subcontractor shall review and remain cognizant of all other specifications related to
this scope of work.

C. The design, installation and commissioning of the CP system shall be fully

documented and recorded. The documentation shall constitute part of the permanent
record of the Project. All documents shall be provided to the Royal Commission for
review and approval.

D. Field Representative, Inspection and Supervision

1. The Contractor shall be responsible for the coordination of all works relating to
the cathodic protection systems. It shall be the responsibility of the Contractor
to ensure that all work and equipment to be furnished under the Contract
results in a complete and satisfactory installation.

2. All work shall be carried out under the supervision of an experienced Cathodic
Protection Engineer. The Cathodic Protection Specialist/Engineer shall have a
Degree in Electrical or Electrochemical Engineering or Science Degree in
Physics or Chemistry from a recognized Institution, a minimum of 10 years
practical experience in cathodic protection design, installation and
commissioning. A professionally qualified NACE Certified Cathodic Protection
Specialist or a professional member of the Institute of Corrosion with a
bachelor degree in physical science or engineering is preferable.

3. All Contractor’s engineers and supervisory staff involved with the installation of
the cathodic protection (CP) system shall have had at least 3 years experience
in this type of work and the Contractor shall provide Resumes to the Royal
Commission for review and approval.

4. All installation work shall be supervised by the Cathodic Protection Engineer

who is nominated by the Contractor and who is approved by the Royal
Commission. The Cathodic Protection Engineer shall be on site at all times
when cathodic protection work is in progress and shall be responsible for the
workmanship and safety of all the cathodic protection works throughout the
Contract period.

5. Supervision shall be carried out to a high standard throughout the works. All
equipment shall be inspected upon delivery and again prior to installation.
Inspection hold points shall be introduced for items or works which will be
buried so that assurance and responsibility is recorded for all items or works

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prior to backfilling.

6. Any defects shall be reported to the Royal Commission and shall be recorded
in a retrievable data system. Corrective actions, which must be approved by
the Royal Commission, shall also be recorded.

7. The Contractor shall submit a quality plan, detailing his proposed procedure for
Quality Control, for review and approval by the Royal Commission.

8. All testing and commissioning work shall be carried out by the above Cathodic
Protection Specialist. Staff those are deemed to have insufficient experience
shall be prohibited from carrying out critical work tasks as described in the
relevant parts of the Specification. In such cases, replacement manpower and
any delays incurred shall be borne by the Contractor.

E. Codes, Standards and Specifications

1. The Contractor/Subcontractor shall comply with the provisions of the codes

and standards listed in par. 1.04 and Specifications listed in par. 1.03, except
as otherwise noted or specified.

1.08 HEALTH AND SAFETY CONSIDERATIONS

A. All works undertaken in relation to this Specification are to be completed in full

accordance with the respective health and safety requirements established by the
following:

1. Kingdom of Saudi Arabia

a) Legislation, Regulation, Standards and Codes.

2. Royal Commission Regulations

a) Standards, Contractual Conditions, and Health and Safety Systems.

3. Contractor

a) Health and Safety Standards and Systems as accepted by the Royal

Commission.

B. In the absence of any of the above, best accepted industry practice shall be
employed throughout.

1.09 DESIGN CRITERIA

A. System Description

1. The cathodic protection system shall consist of the following sub-systems:

a) Anode System
1) Consisting of the sacrificial anodes, associated cables, and all

Rev 0 9 of 23 Contract No:

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hardware for placement of the anodes. The anode system may

consist of different anode-types specific for the particular structure
being protected or the specific application as specified in the
approved Contract Drawings/Documents.

b) Cathode System
1) Consisting of the metallic structure to be protected as well as
structure continuity ties.

c) Monitoring System
1) Consisting of reference electrodes and test stations, test
connections to the structure and data acquisition system.
2) Remote monitoring, automatic control and data acquisition system
shall be as specified in the approved Contract Drawings/
Documents. For remote monitoring and control system refer to
SECTION 13450.

B. Criteria for Protection; Current Density Requirements

1. The CP system shall be designed, installed and commissioned to meet the

protective potential criteria as identified in the standards BS EN 12954 and in
BS EN 12473, DNV RP B401 or NACE RP0169 and NACE RP0196.

a) The acceptance criteria are given for the IR free potential measured with
respect to a copper/saturated copper sulphate reference electrode or a
silver/silver chloride reference electrode.

b) Interference currents or current drain to neighboring metallic structures

are to be minimized or the neighboring structures are to be made
electrically continuous with the protected structures and supplied with
additional sacrificial anodes for protection. Measurements in accordance
with BS EN 50162 shall be taken to document that there are no
deleterious effects from any stray currents. In cases where the system
resistance is high and/or the possible drainage of the current is
considerate, then impressed current cathodic protection system can be
considered.

c) Anode Circuit Criteria

1) The sacrificial anode system shall provide protection against
corrosion for a minimum of 15 years. Provisions shall be
incorporated for ease of anode replacement. The design and
installation of all elements shall be made such that no major
maintenance in the designed service life shall be required under
normal operation.
2) Design current densities for protection of the metallic structure
shall be in accordance with the appropriate standard unless
current densities from trial polarization are available in which case
they shall form the basis for the design.
3) The current requirement shall be calculated as 1.1 to 1.5 times
the maximum current demand depending on the geometry and
the coating of the structure. The effect of any coating shall be

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taken into account by application of a coating breakdown factor.

The factor is subject to approval by the Royal Commission.
4) The anodes shall be distributed to provide a sufficient uniform
current distribution taking the current demand due to, e.g.,
different surface areas, different coatings, different environmental
conditions used into account, ensuring an effective protection of
the entire metallic structure with the operational criteria. The risk
of current drain from the cathodic protection system to
neighboring structures shall be considered and possible
measures shall be identified against detrimental effects on
neighboring structures.
5) The anode distribution shall take any restrictions imposed by
fabrication, installation or operation into account. Anodes shall be
located with sufficient spacing between each other to avoid
interaction effects that reduce the current output or the interaction
effect shall be taken into account.

d) Cathode Circuit Criteria

1) All neighboring metallic structures shall be made electrically
continuous as necessary with the protected metallic structure to
minimize stray current corrosion. Electrical continuity is defined
as a closed electrical path using metallurgically fused joints
between metal components such that electrical current does not
flow between the metallic components through the electrolyte, be
it water or soil.
2) Local increases in metal density as well as other electrical
interference shall be considered when designing the cathodic
protection system.
3) It may be appropriate not to cathodically protect certain metal
items adjacent to the protected structure. Electrical insulation and
avoiding stray current corrosion of such items shall be addressed
during the CP system design phase.

e) Monitoring and Control Criteria

1) Test stations for potential measurements shall be provided to
facilitate CP system monitoring. A sufficient number of reference
electrodes shall be installed permanently and positioned such that
they represent the most exacting geometric configuration. Such
locations include, but are not limited to:
(a) Any critical areas where visual inspection is prevented.
(b) Potential areas of stray currents on other structures or
components.
2) The reference electrodes shall be designed for mechanical
integrity during installation and operation. Provisions shall be
made for in-situ calibration and sub-sea replacement of any
defective reference electrode.
3) Each reference electrode shall be accompanied by its own
discrete connection to the metallic structure being monitored,
positioned adjacent to the reference electrode.

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1.10 JOB CONDITIONS

A. Examine conditions of the Project site and the underground or submerged structures
for which the CP is to be installed. Inspect for interfering structures, other current
inducing systems and other installed CP systems in proximity, which may affect
operation. Field surveys shall be performed to evaluate the applicability of using the
sacrificial anode system. The installation shall not proceed until all unsatisfactory
conditions have been corrected.

B. Verify that all submerged and buried underground metallic structures and other
nearby metallic structures, including reinforced concrete structures, are electrically
continuous if necessary (see par. 1.09 B.1.d). Verify that the appropriate
methodology of producing continuity is in place (see par. 3.01 B). Verify that bonding
cables are present for those metallic components not yet placed, but to be installed.
Continuity shall be verified utilizing the approved method statement. If discontinuity
exists, document such conditions and verify that corrections are made.

1. Document continuity test results, which will include test location and resistance
reading. All resistance readings shall be recorded on a plan sheet designating
each location to be tested.

2. Any affected discontinuous steel must be bonded, (see par. 3.02 B), to the CP
circuit using external cabling materials and procedures, which duplicate those
for test connections.

3. Following bonding, the new continuity test results shall be documented on the
plan sheet. An original plan sheet shall be provided to the Royal Commission
for review and approval following continuity tests.

1.11 INTERFACES

A. The Contractor shall identify and define all interfaces between his works and other
parties’ work, including other plant and systems under the responsibility of the Royal
Commission, Industry, other Contractors' plant and systems and third parties' plant
and systems. The Contractor shall keep updated records of all interface agreements
made with other parties.

B. Examples of such interfaces are:

1. Integration with the Royal Commission remote monitoring system. For each
test station, the physical interface, the communication protocol, and the data
format and content shall be defined and agreed with the Royal Commission.

2. Other buried structures or components, which may be affected by interference

from the CP system, shall be identified. Construction details and time planning
of physical connection of bonds for electrical continuity, including any
excavation, backfilling and making good within the site belonging to the Owner
of the affected structure, shall be agreed with the Owner.

3. Construction details and time planning of the physical connections of cables

and test wires to the structure, including any excavation and backfilling, repair
of coating etc. shall be agreed with the Owner of the structure, whether it may

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be the Royal Commission or a Contractor prior to handing-over the structure.

1.12 DELIVERY, HANDLING AND STORAGE

A. The Contractor shall deliver, handle and store equipment and material in accordance
with SECTIONS 01650 and 01660, as well as fulfill the following requirements:

1. Deliver all CP components to the Project site in such quantities and at such
time as to ensure the continuity of installation. Each component shall be
securely wrapped, packaged, labeled and marked for safe handling.
Components shall be stored in a secure and dry storage facility to prevent
damage, distortion or deterioration. Components shall be handled in such a
way as to ensure against damage and that identification markings remain
clearly visible.

2. Copies of manufacturer's storage and handling procedures for the CP

components (anodes, reference electrodes, etc.) shall be submitted to the
Royal Commission for review prior to shipment to the site.

3. The Contractor shall be held responsible for damage to the materials or

equipment during storage and transportation.

Rev 0 13 of 23 Contract No:

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PART 2 PRODUCTS

2.01 GENERAL

A. All goods and products covered by these Specifications shall be procured, when
available, from an in-Kingdom manufacturer. Procurement of all goods and products
manufactured out-of-Kingdom must be approved by the Royal Commission.

2.02 ANODES

A. The sacrificial anode CP system shall comprise anodes as specified in the approved
Contract Drawings/Documents. The proposed anodes shall be manufactured by a
standard manufacturer company in accordance with NACE RP0387 and RP0492.

B. The sacrificial anodes shall have a minimum operational design life of 15 years in
which individual anode elements shall be capable of providing current continuously at
the selected design rating.

2.03 REFERENCE ELECTRODES

A. The Contractor shall furnish reference electrodes as per the approved Contract
Drawings/Documents, not limited to following:

1. The reference electrodes shall be appropriate for the environment that the
metallic structure to be protected are exposed to, whether it is sea water,
brackish water, fresh water, soil, etc. The reference electrodes commonly used
in sea water are silver/silver chloride (Ag/AgCl) or zinc (Zn) while
copper/copper sulphate (Cu/CuSO4) is most suitable for use in non-chloride
contaminated soil and fresh water (only for a short exposure time), but other
reference electrodes may apply. Zinc reference electrode shall be supplied
with bleeder to avoid contamination of the electrode surface.

2. The reference electrodes shall be suitable for a minimum of 25 years

operational life and they shall withstand the environment in which they are
installed.

3. Reference electrodes are to be calibrated and certificates provided by the

Supplier.

4. Each reference electrode shall be fitted with a 4 mm² screened cable as

specified in par. 2.06 and these cables shall be of sufficient length to reach
the test stations without splicing.

5. The reference electrodes shall be provided with test certificates showing the
reference electrode type, theoretical potential and test potential against an
approved standard reference electrode.

6. Potential of the reference electrode shall be ± 5 mV of nominal reference

electrode potential provided by the electrode manufacturer. The reference
electrodes shall be verified during installation.

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7. Each reference electrode shall be permanently identified in accordance with

SECTION 16075 with a unique identification number. The Contractor shall
submit details of identification numbering system to the Royal Commission for
approval.

2.04 TEST STATIONS

A. Test stations shall be of corrosion resistant materials and fitted with a permanent
engraved label as per SECTION 16075 with a location reference. Each test station
shall contain terminals for monitoring the potentials of the structure with respect to
the reference electrodes. Each terminal shall be fitted with an engraved traffolyte
label with a reference number, which shall be proposed by the Contractor and
approved by the Royal Commission.

2.05 FLANGE INSULATION KITS

A. Insulation kits shall be used to electrically isolate the sections of pipelines, if required
in order to avoid leakage of cathodic protection current and to enable control of the
CP system. The insulation shall comprise gaskets with insulating sleeves and
washers. The details of the insulation kits and installation procedures shall be
submitted to the Royal Commission for review and approval.

B. Two insulation kits shall be installed, one at each flange of a valve in existing valve
chambers. In absence of valve chambers, buried insulation kits may be installed
subject to approval by the Royal Commission.

C. The insulation kits shall be made of a material which has the following properties:

1. Dielectric strength of not less than 20,000 V/mm.

2. Water absorption of less than 1%.

3. Compressive strength of not less than 3000 kg/cm.

4. Withstand a temperature of 100°C for continuous use.

5. Minimum wall thickness 3 mm.

D. Electrical isolation shall be tested after installation by applying a cyclic DC current to

one side of the flange and recording the potentials on each side of the flange. If
insulation is obtained, the side to which no DC current is connected will show no
change in potential coincident with the switching cycle.

2.06 DC AND INSTRUMENT CABLING

A. The cables shall be capable of direct burial in salt-laden moist soil environments.
Cross sectional area of the anode cables shall be a minimum of 10 mm2 for power
carrying cables and a minimum of 4 mm2 for monitoring cables. Insulation for the
cables shall be high molecular weight polyethylene (HMWPE). Alternate materials,
which may be considered for approval, include XLPE and KYNAR.

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B. Anode cables shall be color-coded RED for all areas.

C. The reference electrode cabling for connection to embedded reference elements

shall be low-noise screened cable.

1. The conductor shall be 7-strand, annealed copper, insulated with polyethylene

over which shall be a layer of plain copper braiding. Overall sheathing shall be
PVC.

2. The capacitance shall be less than 103 pF/m at temperatures up to 50°C.

Cables shall be color-coded for identification.

3. Reference electrode cabling from the junction box to test stations shall run in
conduit and may be screened multi-core, multi-strand type.

D. All cables shall be terminated by crimped connectors suitable for the terminals
provided in the junction boxes. All cables and wiring shall be appropriately identified
within 25 mm of each end using permanent wire markers intended for the purpose.
Where cable identifications have been given in the Contract Drawings, these shall be
used. For termination of wires and cables, refer to SECTION 16150. Adhesive type
markers are not acceptable.

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PART 3 EXECUTION

3.01 PREPARATION

A. Verification of Environmental Parameters

1. The resistivity measurements shall be carried out for the environment of the
metallic structure using an AC resistance instrument or a conductivity meter.

B. Electrical Continuity

1. Perform continuity survey between all metallic structures identified as being

protected. The Contractor shall be responsible for ensuring that all metallic
structures within proximity of the structure to be protected are either isolated
such that they do not experience stray currents or are made electrically
continuous with the structure to be protected. If discontinuity exists, provide
electrical continuity.

2. Unless alternative test procedures and criteria have been selected in the
design, the electrical continuity between the metallic structures shall be tested
by DC reverse polarity resistance measurement technique. This technique
measures and compares the resistance using a DC resistance instrument and
then reversing the polarity of the test leads.

3. Another technique may be by the DC potential difference measurement

technique. The acceptance criteria for such testing shall be a resistance of less
than 1 ohm or a potential difference of less than 1 mV and the value stable. All
metallic objects shall be continuity tested, and any component failing the test
shall be continuity bonded to ensure resistance of 1 ohm or less.

C. Potential Survey

1. The potential ‘as found’ shall be measured on the metallic structures to be

protected and any neighboring metallic structures or facilities, which could be a
current drain or be effected by stray currents.

D. Coordination and Protection

1. Installation of the sacrificial anode CP system shall be coordinated through

discussions with the Royal Commission, the main Contractor and other
Subcontractors and shall be conducted in stages to ensure minimal disruption.

a) Special precautions and scheduling may be required to prevent damage

to the installed components by subsequent operation.

b) Consideration shall be given to the need to provide temporary protection

for all buried cables up to the time of final burial and thereafter.

3.02 INSTALLATION

A. Anode Installation

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1. The anode system shall be installed in accordance with the Contractor’s

method statement for installation, as shown on the Shop Drawings and as
described herein.

a) Prior to installation, all the anodes shall be inspected for any damage.
Anodes that do not conform to the Specification shall be rejected.

b) In order to enable the measurements of IR free potentials, the anodes

shall be connected via a test station where a significant IR drop is
expected. The electric circuit between the anodes and the metallic
structure shall be left open at the test stations until commissioning.

c) Electrical continuity across any connection of the anodes to the metallic

structure shall be verified by resistance measurements reference
requirements to electrical connections.

d) All wire insulation shall be compatible with the high chloride, high
temperature environment.

e) Connection of anode to cable and mounting device shall be as per the

approved Contract Drawings/Documents.

B. Test Connection

1. System test connections shall be made to the metallic structures in

accordance with the Contractor’s method statement for test connections and
as shown on the Shop Drawings.

a) The wire to structure connection shall be by thermite welding process.

b) The method of providing bonds is at the discretion of the Contractor.

However, the methodology and procedure must be provided to the
Royal Commission for review and approval prior to initiation.

c) The DC resistance between each connection shall be measured and

recorded. If the measured resistance is greater than 1 ohm, an
additional system test connection shall be made at a location approved
by the Royal Commission until the measured resistance is less than
1 ohm.

C. Reference Electrodes

1. The permanent reference electrodes shall be installed in accordance with the

Contractor’s method statement, as shown on the Shop Drawings and as
described herein.

2. The permanent reference electrodes shall be installed at predetermined

locations. The reference electrodes shall be placed at the level of, and parallel
to, the protected structure. At this location, a test connection shall also be
provided and connected to the submerged or buried underground metallic
structure in the manner described previously for test connections as specified
in par. 3.02 B.

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3. Capabilities for monitoring neighboring structures for stray current shall be

provided. Capabilities shall be provided for evaluating current pick up by
neighboring structures as well as possible means of tying the structure into the
CP system.

4. A sufficient number of reference electrodes shall be installed permanently to

monitor the effectiveness of the sacrificial anode CP system. The type, number
and location of reference electrodes shall be as specified in the approved
Contract Drawings/Documents.

3.03 TESTING AND COMMISSIONING

A. General

1. The testing and commissioning of the system shall be carried out under the
direct supervision of the Contractor’s Specialist Cathodic Protection Engineer.
A minimum notice of 1 week shall be given to the Royal Commission before
commissioning takes place to enable scheduling the presence of Royal
Commission’s CP Specialist, if so required by the Royal Commission.

2. The results of the testing and commissioning report shall be submitted to the
Royal Commission within 1 week of completion.

3. If the results from the testing and commissioning do not meet the performance
requirements, the Royal Commission at their discretion may instruct that the
commissioning exercise be repeated in part or in its entirety.

B. Pre-Commissioning Survey

1. Prior to commissioning after installation, as directed elsewhere in this

Specification, inspection and testing shall be carried out. The results shall form
part of the commissioning report.

C. Visual Inspection

1. After installation of all the sacrificial anode CP system, as directed elsewhere

in this Specification, a visual inspection shall be carried out to check that all
installations are in accordance with the design.

D. Preliminary Checking

1. The potentials of the metallic structures and anodes shall be measured with
respect to the permanent reference electrodes at all test stations and
supplemented by portable reference electrodes.

a) 'As found' potential survey shall be carried out on the submerged or

buried metallic structure to be protected and any neighboring metallic
structures in question. Reference electrode versus metallic structure
potential.

b) Resistance of the metallic structure against the anode measured using

an AC technique.

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c) The potential of the anode versus reference electrode.

d) Resistance of the anode versus the reference electrode using a low

impedance measuring method accepted by the Royal Commission.

E. Energizing Procedure for the Sacrificial Anode CP System

1. The potentials of the metallic structures and anodes shall be measured with
respect to the permanent reference electrodes at all test stations and
supplemented by portable reference electrodes, in order to signify an adequate
level of protection for all the facilities.

a) Anodes shall be connected to the metallic structure via the test stations
where relevant (to be approved by the Royal Commission). 2 weeks
after connection (energizing) the IR free potentials of the metallic
structures shall be measured and recorded at all the test stations.
Where the anodes and metallic structure are connected via the test
station, the potentials shall be measured 'ON' and 'INSTANT OFF,' while
in all other situations the 'ON' potential is considered similar to the IR
free potential.

b) If the IR free potentials recorded are more negative than

- 800 mV (Ag/AgCI), no further action shall be taken.

c) If the potentials recorded do not meet the design criteria, further action
shall be taken, e.g., the system shall be left for a longer period of
polarization or additional anodes shall be installed. The requirement for
remedial measures shall be agreed upon by the Royal Commission.

d) The recorded potentials and currents shall constitute part of the

permanent record for the CP system as specified in par. 1.07 C.

F. Operation

1. The Contractor shall operate the CP system for the period until the Royal
Commission’s initial acceptance of the CP system. After acceptance, the
Contractor shall operate the system for 1 year. The operation shall as a
minimum include performance monitoring and system review after 1, 3, 6 and
12 month.

3.04 INTERFERENCE TESTING

A. General

1. In parallel with the final testing and commissioning procedure as specified in

par. 3.03, interference testing of facilities in close vicinity of the protected
structures shall be carried out, as required.

2. Interference shall be deemed to be present if a steady change in potential of

the affected structure of greater than 20 mV is measured according to
BS EN 50162. The requirement for remedial measures shall be as agreed
upon by the Royal Commission.

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B. Test Procedures

1. The ‘as found’ potentials of the metallic structure and other facilities located in
close vicinity shall be measured before the commissioning of the CP system.

2. The interference testing shall be carried out as a part of the commissioning

procedure.

3. Interference shall be deemed to be present if the potential shift as measured

on the other facilities during commissioning exceeds 20 mV.

4. The Contractor shall submit full details for carrying out interference testing for
review and approval by the Royal Commission.

C. Data Analysis and Report on Interference Testing

1. The interference data shall be reviewed by the Contractor’s Specialist

Cathodic Protection Engineer. The Contractor shall prepare an interference
test report and shall submit it to the Royal Commission within 1 week of
completing the interference testing.

2. The test report shall include all data obtained, details and location of all tests
and report the level (if any) of interference observed. Recommendations for
rectification shall be included. Three copies of the test report shall be
submitted to the Royal Commission.

3.05 PROVISION OF OPERATION AND MAINTENANCE MANUAL

A. An Operation and Maintenance Manual shall be provided by the Contractor and shall
be a complete and comprehensive reference manual with all relevant information
within one document. The Operation and Maintenance manual shall be provided in
accordance with SECTION 01830.

B. The Contractor shall submit a procedure, as part of the Operation and Maintenance
Manual, detailing how the CP system should be managed. This management shall
include criteria, fault finding, system malfunction checks and details of presentation of
data.

C. The Contractor shall prepare a monitoring program for the CP system. The program
shall as minimum include the following measurements to be carried out every
12 month:

1. Anode potential measured versus permanent reference electrodes at test

stations.

2. Anode potential measured versus portable reference electrode.

3. Steel structure potentials (IR free) for all reference electrodes at test stations.

4. IR free potentials measured versus a portable reference electrode.

5. Thorough component check, if accessible.

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6. Interference testing.

3.06 PROVISION OF TRAINING IN SYSTEM OPERATION

A. Description

1. As part of the works, the Contractor shall provide training to nominated Royal
Commission staff in the operation and maintenance of the CP system,
including the system monitoring.

2. Each person trained shall be provided a full set of the course material. All
training material shall be supplied by the Contractor for training purposes.

3. The instruction course shall comprise of the following 4 parts:

a) Routine operation of the CP system and monitoring performance

(including maintenance requirements).

b) Operation of the test and inspection equipment.

c) Interpretation of test data.

d) Troubleshooting and fault diagnosis.

4. The minimum requirements for these are outlined below. Instruction may take
place in any order and at various times within the Contract period.

5. Details of the actual instruction course shall be submitted to the Royal

Commission for review and approval prior to commencement of instruction.

B. Routine Operation

1. General system operation to provide knowledge of the as-built details of the

system including location of parts, suppliers, cabling routes, anode locations,
test stations and reference electrode locations. Staff shall be made conversant
with the design, As-built Drawings and all documentation.

2. Routine operation with potential measurement and record keeping.

3. Other aspects of routine operation of the system as deemed necessary by the

Contractor and/or the Royal Commission. This shall include routine fault
finding in the event of system failure or inadequate performance.

C. Interpretation of Test Data

1. The data collected from the manual monitoring system and that from periodic
surveys shall be reviewed by an experienced Cathodic Protection Engineer.
Instruction shall be provided on the trend analysis of data and the type of data
required and changes in its recorded level which may signify that the CP
system requires adjustment or some form of remedial action.

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2. Troubleshooting and Fault Diagnosis

a) Instruction shall be provided on troubleshooting in order to identify

possible system mal-operation or under-performance. The instruction
shall be general in nature and shall indicate the obvious actions that
may be taken to ensure continued proper operation of the system. Any
serious fault or lack of performance shall be reported to an experienced
Cathodic Protection Engineer for action.

END OF SECTION

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