Professional Documents
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INDEX
1.0INTRODUCTION........................................................................................................................2
2.0ABBREVIATIONS.......................................................................................................................3
3.0CODES AND STANDARDS.......................................................................................................3
4.0POWER SUPPLY REQUIREMENTS.........................................................................................4
5.0SERVICE CONDITIONS............................................................................................................5
6.0GENERAL REQUIREMENTS....................................................................................................5
7.0EQUIPMENT DETAILS..............................................................................................................5
8.0QUALITY ASSURANCE...........................................................................................................19
9.0INSPECTION AND TESTS.......................................................................................................19
10.0MARKING...............................................................................................................................21
11.0PACKING AND DESPATCH..................................................................................................23
12.0REFERENCE DOCUMENTS.................................................................................................23
1.0 INTRODUCTION
This specification covers the minimum technical requirements governing the design,
manufacture, supply, testing, inspection, preparation for shipment & storage, and delivery to
site of Cathodic Protection System Equipment and Materials with all accessories built in
compliance with applicable standards, to be installed in 2 X 1000 MT mounded LPG storage
vessels as part of the Paradip Haldia Durgapur LPG Pipeline (PHDPL) project.
SPECIFICATION FOR DOCUMENT NO :
CATHODIC
PROTECTION SYSTEM
EQUIPMENT AND REVISION :
MATERIALS Page 3 of 24
2.0 ABBREVIATIONS
Unless otherwise specified in this specification, all components and equipment shall be based
on the following standard:
In the event of conflict between codes and standards being used, the most stringent one shall be
followed. Where Indian Standards do not exist or equipment is supplied by foreign manufacturer,
relevant international standards shall be applicable.
a) All the equipment/material shall be brand new with state of art technology and proven field track
record. No prototype equipment shall be accepted.
b) The equipment and materials shall be suitable for installation in locations having generally
corrosive, warm and humid or dusty atmosphere.
c) The equipment shall confirm to the provisions of Indian Electricity rules and other statutory
regulations currently in force in the country.
d) Equipments for hazardous area shall meet the requirement of IS: 2148 or equivalent international
standard and shall be suitable for a gas group IIA & IIB and temperature class-T3 or better.
e) The CPTR unit shall be field proven. The design, internal component layout and rating of
component shall ensure high MTBF and low MTTR.
f) The anodes shall be suitable for the composition/conditions of soil and should have a design life
of 25years (minimum).
The Cathodic protection system equipment and associated material shall broadly include
a) Protection from overload on the output in auto mode for TR unit will be provided by another
close loop SCR control circuitry giving automatic constant current control act as back up
control to main auto mode control. Separate PCB shall be used for main auto mode control
and the backup control. The current limit for backup control is to be set by two limit switches
marked "coarse" and "fine". The limits of the two switches shall be algebraically additive and
shall give equal steps of 3A each upto 110% rated current. One scale calibrated in Ampere
shall be provided with each limit switches so that current limit can be set by operator at any
desired value in 3A step. In any circumstances the TR unit output current should not exceed
the current limit set by the backup control even in case of short circuit.
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b) In addition to above electronic current limiting feature HRC fuse of suitable ratings shall be
provided at positive and negative terminals in addition to one double pole MCB.
The unit shall be designed to operate with number of reference cells connected to it. In case of
more than one reference cell, CPTR unit shall have feature to automatically select the
reference cell having less negative potential than the others and use the same for auto control
of the unit.
In case of open circuit or short circuit of reference cell or potential being less negative than a
minimum set potential (Vrs), the unit shall sense these conditions as reference cell failure and
shall automatically switch over to the other healthy reference cell for control. Should fault
occur in all the reference cells, the output voltage or current of the CPTR unit shall adjust
automatically to a preset value, which shall be adjustable.
The unit shall continuously monitor the PSP and necessary annunciation shall be provided in
case of PSP either exceeding the specified maximum limit or remaining lower than the
specified minimum limit.
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PROTECTION SYSTEM
EQUIPMENT AND REVISION :
MATERIALS Page 9 of 24
Continuous reading, rectangular type (having accuracy within 2% with full load at ambient
temperature) meters shall be provided for the following
(a) AC voltage
(b) AC current
(c) DC voltage
(d) DC current
(e) PSP
All meters shall be electronic digital type with LED display (of digit size 12.5mm min.)
arrangement and shall be able to indicate the current and voltage ranges up to a resolution of one
decimal place for DC Ammeter & Voltmeter and 3 decimal places for PSP meter.
All voltmeters shall be provided with separate fuse and toggle switch where as all Ammeters shall
be provided with only toggle switch.
7.1.6 Alarm and Annunciations:
The complete alarm and annunciations system shall be provided to indicate the following.
(a) Under protection
(b) Over protection
(c) Over current
(d) All failure
Transformer rectifier shall be supplied with a continuous signal light which will go out at loss of AC
input. In addition to this, T/R unit should give annunciation for Auto and Manual mode of operation
by continuous signal light. T/R unit should also indicate the failure of each fuse in bridge rectifier
and two DC output fuses by an independent LED.
One common signal for all the above annunciations is to be provided for remote annunciation in
control room.
block and the gland plate for the spreading and termination of external conductors.
g) All terminal blocks shall be shrouded or provided with transparent covers. Terminals for
different voltages shall be separated by partitions. Cable terminal arrangements for power and
control cables may be integrated with a barrier for separation between the same.
h) The printed circuit board contact pads will be chromium plated to provide easy conduction and
to eliminate contact corrosion. Completed printed circuit boards will be sealed with a circuit
card sealant to prevent atmospheric corrosion and fungus contamination. Circuit elements in
the control cards shall be derated properly and proper heat dissipation arrangements shall be
made in the PCB so that they function properly for full load operation of T/R unit at ambient
temperature.
7.2 Anodes
7.2.1 Anodes shall be suitable for outdoor underground application and shall be supplied from
the following types of anodes
(a) Mixed metal oxide coated on Titanium wire anode pre-packed with coke breeze backfill at
Manufacturer’s factory
(b) Long line Conductive Polymer Anode pre-packed with coke breeze backfill at
Manufacturer’s factory
Technical Requirements of anodes are as follows:
(a) Mixed metal oxide coated Titanium wire anode
Mixed Metal oxide coated Titanium anodes shall be dimensionally stable and will be supplied in
wire with a dimension of 3mm diameter (minimum). Each wire anode shall be supplied with anode
lead cable piggy back connected to it i.e there will be connection between the Primary anode and
the internal header cable at a minimum of every 3m. The connection shall be multi-step and water
proof. The length of the internal header cable shall be sufficient to reach the nearest AJB. The
specification of the internal header cable shall be same as anode lead cable given in the section
for cable specification.
Sl.No. Description Details
1 Anode Type Dimensionally stable Anode (DSA)
2 Anode Shape & Dimension 3mm+0.3mm OD
3 Anode weight As required
Commercially pure Titanium substrate, grade
1/2, ASTM B 338, ASTM B 265, DIN 3.7025,
4 Anode Material
3.7035, overlayed with mixed oxide of noble
metals.
5 Anode design life 25 years
6 Anode consumption rate to be 2 mg/A-yr.(min)
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PROTECTION SYSTEM
EQUIPMENT AND REVISION :
MATERIALS Page 13 of 24
Each anode to be supplied with different lengths of cables connected to each anode as per the
cable length schedule after actual site measurements.
Anode lead cable conductor shall be crimped with tubular anode at the center of anode or at the
ends and shall be sealed to prevent ingress of water at the joint.
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MATERIALS Page 15 of 24
a) The mounded vessel shall be electrically isolated at all inter connecting inlet, outlet and vapour
balance pipe connections using MONOLITHIC ISOLATING joints as per OISD 150 standard.
b) Monolithic Joints shall be of 300 Class, Pressure rating suitable for the design pressure.
c) All isolating joints shall be protected from over voltage using explosion proof spark gap
arrestors /Surge diverter (as per OISD) of 1KV/100KA rating.
A common anode lead junction box (AJB) will be provided to feed TR Unit output current to anode
strings. The individual (AJB) for each bullet will have provision for independent current
measurement of each anode string output. This will be accomplished by means of individual
shunts for each individual anode circuit.
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PROTECTION SYSTEM
EQUIPMENT AND REVISION :
MATERIALS Page 16 of 24
Cathode junction box (CJB) will be required for bonding multiple mounded bullets at drain point.
One common CJB shall be provided and shall be installed at one end of the bullet. Drainage
cables from each bullet shall terminate at cathode junction box and ultimately it will be connected
to negative terminal of TR unit.
7.4.4 The enclosure of Junction Boxes shall be structure/wall-mounted type. Shutter should be
provided with closed cell neoprene sealing gaskets. The terminal board shall be of 10mm WT
Phenolic laminated sheet on which all terminals and shunts are to be mounted. The terminals
shall be made of cadmium plated steel or stainless steel stud nut and washers of suitable sizes.
All cable entries shall be through Aluminum double comprehension glands. The external bolt, nuts
and clamps to be used for mounting the junction box with back plate/structures shall be MS
electro-galvanised or Cadmium plated.
7.4.5 The cable glands shall be FLP double compression type made of aluminum. Enclosure
need to be certified by CMRI. The shutter of the junction box shall be screwed to the body of
junction box by using MS electro galvanised/Cadmium plated nut, bolt and washers. The
enclosure of the junction box shall be made of cast aluminum. One earthing terminal shall be
provided for earthing the junction box.
a) All the reference cell cables and measurement cables from each TJB shall be terminated into
a single Monitoring junction box (MJB) which will be ultimately connected to TR unit by
monitoring cable.
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Monitoring Junction Box shall be suitable for non- classified area applications and shall have the
following requirements:
(a) Monitoring Junction Box will be installed near the TR Unit and shall be required for monitoring
potentials of multiple bullets. The enclosure for the MJB shall be of IP-42 construction made of
12SWG (2.67) WT sheet steel.
(b) The enclosure shall be structure/wall mounted type having removable hinged front shutter with
one handle and flush type locking arrangement. Shutter should be provided with closed cell
neoprene sealing gaskets. The terminal board shall be of 8mm thick Phenolic laminated sheet
on which all terminals shall be made of stainless steel stud, nut and double spring washers of
suitable size for reference cell/measurement cables. Bottom row of terminals will be utilised for
termination of measurement cables and upper rows for the reference cell cable termination
from each bullet. All cable entries shall be through Aluminum double compression glands. The
external bolt, nuts and clamps to be used for mounting the junction box with back
plate/structures shall be MS electro-galvanised or Cadmium, plated. Shutter should be
provided with closed cell neoprene sealing gaskets. One earthing terminal shall be provided
for earthing the junction box.
7.5 Cables
The requirements for the cables to be used for impressed current type cathodic protection system
are as follows:
Note: The Cable sizes shall be updated as per the Cathodic Protection Design Basis.
(a) Surface preparation - Grit/shot Blasted to SA2 1/2 as per swedish standard SIS 055900
(b) Galvanizing - Hot dip or spray galvanized to achieve a minimum zinc thickness of 150μm.
(c) Primer Application - Etch Primer with 10 μ DFT based on Polyvinyl Butyral resin + 1 coat of
epoxy zinc phosphate primer @40 μ DFT/coat.
(d) Paint Application - 1 Coat of 2 Pack high build epoxy with Polyamide hardener cure @100μ
DFT/coat followed by 1 Top coat of Acrylic Polyurethane finish paint @40 μ DFT/coat.
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(e) MS covers for shallow vertical Beds shall be painted with 2 coats of synthetic enamel paint of
reputed make. Colour of paint shall be yellow.
a) The Vendor shall comply with ISO 9001:2008 Quality Assurance System or may be
appropriate to the type of contract and his product.
b) If the Vendor elects to sub-contract part of the work he shall ensure that only those
subcontractors or suppliers are used who can demonstrate that they operate Quality Systems
based on ISO 9001 or ISO 9002 as applicable. The vendor shall give his sub-contractors or
suppliers assistance in attaining the required standard, if necessary. This shall not relieve the
vendor of his responsibility for the quality of the finished work. Owner reserves the right to
audit the Vendor’s Quality System.
c) The Vendor shall submit a “Quality Assurance Plan” for review within 3 weeks from the date of
Purchase Order.
a) The PURCHASER reserves the right to carry out any number of inspections during manufacturing
and witness factory tests.
b) Inspection and testing shall be carried out in accordance with the relevant standards. The
Inspection Test Plan (QA Plan) shall be submitted to PURCHASER at bid stage. PURCHASER
shall require a Factory Acceptance Test (FAT) which he may or may not attend at his discretion.
FAT procedure shall be submitted for approval at least three weeks prior to the proposed test
activities date will be held.
VENDOR shall carry out all tests including but not limited to the following tests as per the relevant
standards
9.2 Anodes
The following tests shall be conducted for Mixed metal oxide coated on Titanium wire
anode or Long line Conductive Polymer Anode
a) Visual inspection
b) Destructive testing
c) Chemical analysis
d) Electrochemical tests
e) Spectrographic analysis
f) Calibration test for permanent reference cells
9.3 Calcined petroleum coke breeze
The petroleum coke breeze shall be tested for chemical composition, bulk density, real
density, particle size and resistivity.
9.4 Cables
The tests for cables shall include but not be limited to the following as per relevant IS/IEC
standards
a) Routine tests
b) Type tests
c) Acceptance tests
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PROTECTION SYSTEM
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MATERIALS Page 21 of 24
10.0 MARKING
A nameplate of anodized aluminium with black back ground and white letters shall be fixed
to the inner side of the junction box. The nameplate shall carry the following minimum
information.
• Ground bed current rating
• Ground bed resistance
• Connection scheme
• Distance from pipeline in metres
• Distance from CP station in metres
A nameplate of anodized aluminium with black back ground and white letters shall be fixed
to the inner side of the junction box. The nameplate shall carry the following minimum
information.
• Chainage in km
• Connection scheme
• Distance from nearest pipeline in metres
• Direction of product flow
10.4 Cables
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PROTECTION SYSTEM
EQUIPMENT AND REVISION :
MATERIALS Page 22 of 24
The cable shall be wound on a drum and packed. The ends of the cable shall be sealed by
means of non-hygroscopic sealing material.
The cable shall carry the following information indelibly marked in English (all dimensions in
metric), on the surface of the cable over sheath (outer sheath) at regular intervals of 1 metre
over the entire length for ease of cable identification.
• Reference Standards IS/IEC (whichever applicable).
• Manufacturer’s name or trade-mark.
• Type of cable and voltage grade.
• Number of cores.
• Nominal cross sectional area of conductor.
• Cable code.
• Cable length.
• Year of manufacture.
The means of marking shall be as per IS-10418/IEC 60446. The start and finish numbers of the
metre marking shall be labeled on the drum. Actual lengths of cable on a drum should be about 3
percent more than specified, on the purchase order. No negative tolerances will be entertained.
a. The cable drum construction shall be in accordance with IS:10418 standard, good
engineering practice and each cable drum shall be suitable for transport, long term storage
and cable laying operation. The Manufacturer shall inform company of the special
conditions for storage and pulling of the drums.
b. EPIC Contractor / Supplier will be entirely responsible for any claim arising which is
attributable to defective and / or insufficient packing.
c. Cable drums shall be protected to prevent cable damage, tampering and water
penetration.
d. The inside diameter of the drum on which every cable is wound shall, in general, not be
less than twice the minimum permissible bending radius. Every cable drum shall have, on
its outside surface, a nameplate, label or indelible wording clearly indicating the
information specifically indicated by the contractual documents, applicable codes or project
specification. The minimum information is:
• Reference Standards IS/IEC (whichever applicable).
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PROTECTION SYSTEM
EQUIPMENT AND REVISION :
MATERIALS Page 23 of 24