SITE VISIT REPORT ON CATHODIC PROTECTION

SYSTEM OF MOUNDED BULLETS AT

BPCL LPG BOTTLING PLANT, SOLUR, BANGALORE
By

KB Singh & Associates

Consultants Coatings & Cathodic Protection

Rev 0
20 Mar 2019

Prepared by
Approved by
Rev & Date Anshul Jain
BPCL
(NACE Certified CP Level 3)
 Site visit report on cathodic protection system
of mounded bullets at BPCL LPG Bottling plant,
Solur, Bangalore
KB Singh and LPG Bottling plant,
Associates, Noida Bangalore

Contents
1. Introduction
2. International standards
3. Criteria for cathodic protection
4. Overview of the system
5. Status of CP system
6. Recommendation

Annexure – 1
Monitoring data of CP System – Old Mound
A. Transformer Rectifier Unit
B. Potential readings at REJB
C. Monitoring of Anode Groundbed
D. Monitoring of Cathode Junction Box
E. PSP at 12 o’clock position by portable Cu/CuSO4 reference cell
F. Isolation Joint testing
G. DC Decoupler testing

Annexure – 2
Monitoring data of CP System – New Mound
A. Transformer Rectifier Unit
B. Potential readings at REJB
C. Monitoring of Anode Groundbed
D. Monitoring of Cathode Junction Box
E. PSP at 12 o’clock position by portable Cu/CuSO4 reference cell
F. Isolation Joint testing
G. DC Decoupler testing

Annexure – 3
CP current requirement calculation
A. Old Mound
B. New Mound

Page 2 of 17
 Site visit report on cathodic protection system
of mounded bullets at BPCL LPG Bottling plant,
Solur, Bangalore
KB Singh and LPG Bottling plant,
Associates, Noida Bangalore

1. Introduction
BPCL has an operational LPG Bottling Plant at Solur, Bangalore. This plant has 2 mounds. Details of
each mound are mentioned below in the table:

No Description Old New

i Storage Capacity 300 MT 600 MT
ii Diameter of Bullet (m) 5m 6m
iii Length of Bullet (m) TL-TL 32.5 m 42.5 m
iv Number of Bullets per mound  3 2
v Commissioned in 2003 2009
100% solid 100% solid elastomeric
vi External Coating on bullet elastomeric airless airless sprayed
surface sprayed Polyurethane Polyurethane

ICCP system has been provided to protect these bullets against external corrosion. BPCL has
requested M/s KB Singh and Associates (KBSA) for health check-up of CP system.

Field visit has been made by Mr. Anshul Jain (KBSA) on 17 th-19th Mar 2019. During the visit CP system
for both old and new mounds has been inspected. This report provides monitoring data, status of
cathodic protection and recommendations for improving corrosion protection of mounded bullets.

2. International standards

a. IS 8062: Recommended Practice for Cathodic Protection.

b. OISD –150 Standard.
c. NACE RP 0169- 2013 Standard Recommended Practice: Control of external corrosion of/on
underground or submerge metal piping system.
d. SP0285-2011, “Corrosion Control of Underground Storage Tank Systems by Cathodic
Protection”

3. Criteria of Cathodic Protection

 A negative polarized potential of -850 mV (or more negative) with respect to saturated
Cu/CuSO4 reference electrode. The polarized potential value shall be in range of -850 mV CSE
to -1200 mVCSE or -0.250 V to +0.100 V with respect to Zn reference cell.
 A minimum of 100 mV cathodic polarization between the structure surface and a stable
reference electrode contacting the electrolyte. The formation or decay of polarization can
be measured to satisfy this criterion.

Page 3 of 17
 Site visit report on cathodic protection system
of mounded bullets at BPCL LPG Bottling plant,
Solur, Bangalore
KB Singh and LPG Bottling plant,
Associates, Noida Bangalore

4. Overview of CP system

CP System Design Parameters:

No Description Old New

1 Number of TRU per Mound  One  One

2 AC Input Supply of TRU  240 V  240 V
3 DC Output Rating of TRU  50 V / 75 A  50 V / 25 A
4 Current Interrupter Availability  Yes  Yes
 Manual / AVCC /  Manual / AVCC /
5
Modes of Operation of TR unit Auto Auto
6 Number of Reference Cell in TRU 3  3 
7 Total number of Anodes in Mound 8
8 Anode Strings are Dual Feed No No
9 No of AJB (Anode Junction Box) per Mound One One
No of CJB (Cathode Reference Junction Box) per
10.1
Mound One -
No of CRJB (Cathode Reference Junction Box)
10.2
per Mound - Three
No of REJB (Reference Electrode Junction Box)
10.3
per Mound Three -
11 No of EJB (Earthing Junction Box) in mound One One
12 No of Monolithic Isolation Joints per Bullet Three Three
2 No 2 No
13
No of Surge Diverters per Bullet with make Dehn EXFSL300 Dehn EXFSL300
14 One
No of DC Decoupler per Bullet  One
15 Type of DC Decoupler, Rating and Make 5 KA Electrolytic 3.7 KA Solid state
type type
Make: Kirk Make: Dairyland
Engineering USA USA
No of permanent Cu/CuSO4 Reference Cell per 9
16
Bullet 9
17 3
No of Zinc Reference Cell per Bullet 3
No of Access Pits per Bullet for inserting
18
portable reference cell  One at top One at top
19 Distance Between AJB/CJB to TR Unit  Approx 100 m Approx 60 m

Page 4 of 17
 Site visit report on cathodic protection system
of mounded bullets at BPCL LPG Bottling plant,
Solur, Bangalore
KB Singh and LPG Bottling plant,
Associates, Noida Bangalore

5. Status of CP system

Sr. New
Parameter Old
No
A. O/P Voltage and O/P DC Volt: 12.0 V O/P DC Volt: 7.12 V
Current O/P DC Current: 2.3 A O/P DC Current: 1.5 A

B. Permanent Reference Bullet 1: 6 of 9 No Cu/CuSO4 Bullet 4: 8 of 9 No Cu/CuSO4

electrodes meeting All 3 Zn All 3 Zn
protection criterion of - Bullet 2: 6 of 16 No Cu/CuSO4 Bullet 5: 5 of 16 No Cu/CuSO4
0.850 VCSE Instant OFF. All 3 Zn All 3 Zn
Bullet 3: 4 of 9 No Cu/CuSO4 Bullet 6: 8 of 9 No Cu/CuSO4
All 3 Zn All 3 Zn
C. PSP at 12 o’clock Yes Yes
position of MSV wrt
portable Cu/CuSO4
meeting NACE/OISD
criterion of -0.850 mVCSE
Instant OFF.
D. Anode strings Anode strings are working OK. 6 out of 8 anode strings are
taking current.

E. Electrical isolation Bullet is electrically shorted to Bullet is electrically shorted to

foreign steel structures. foreign steel structures.

On and Instant OFF PSP is same On and Instant OFF PSP is same
on protected and unprotected on protected and unprotected
side of all side of all
Monolithic Isolation Joints. Monolithic Isolation Joints.

6. Results
a. Polarized PSP at all permanent reference cell locations of new and old mounds is not
meeting NACE/OISD criterion of -0.850 VCSE Instant OFF.
b. Anode strings for Old mound are healthy.
2 Anode strings out of 8 in New Mound are not drawing CP current.
c. Protected structure of mounded bullets is electrically connected with foreign structures in
Old and New mounds both. Hence there is no electrical isolation.

7. Recommendations

1. Achieve electrical isolation. Most likely areas of electrical short between bullet and foreign
structures are instrumentation cable armor and piping metallic supports.
Detailed inspection shall be performed and all connection points shall be removed.
Page 5 of 17
 Site visit report on cathodic protection system
of mounded bullets at BPCL LPG Bottling plant,
Solur, Bangalore
KB Singh and LPG Bottling plant,
Associates, Noida Bangalore

ANNEXURE-1

Monitoring data of CP System – Old LPG Mound

Page 6 of 17
 Site visit report on cathodic protection system
of mounded bullets at BPCL LPG Bottling plant,
Solur, Bangalore
KB Singh and LPG Bottling plant,
Associates, Noida Bangalore

A. Transformer Rectifier Unit

Make Raychem RPG

Rating: 50 V / 75 A
Commissioned in 2004
Modes of operation Manual/AVCC/Auto
Input AC supply 240 V AC
Interrupter Yes
Parameter By Manual measurement At Display Meter
AC Voltage 255 V 262.5 V
AC Current 0.7 A 0.7 A
DC Voltage 11.3 V 12 V
DC Current 2.1 A 2.3 A
Mode of operation AVCC
On: -4.370 VCSE On: -4.373 VCSE
Potential at RE 1 Instant off: -0.702 VCSE Instant off: -0.705 VCSE
On: -6.390 VCSE On: -6.392 VCSE
Potential at RE 2 Instant off: +0.818 VCSE Instant off: +0.815 VCSE
On: -6.517 VCSE On: -6.512 VCSE
Potential at RE 3 Instant off: -0.806 VCSE Instant off: -0.809 VCSE

Observation:

 Card 104 and 106 are faulty and should be replaced.

B. Potential Readings at REJB

REFERENCE Bullet 1 Bullet 2 Bullet 3

ELECTRODE ON PSP Instant off Instant off PSP ON PSP Instant off
ON PSP (VCSE)
NO. (V) PSP (V) (VCSE) (VCSE) PSP (VCSE)
-4.460 -0.772 -4.774 -0.836 -4.966 -0.801
Cu/CuSO4 1
-7.090 -0.713 -6.559 -0.946 - -
Cu/CuSO4 2
-6.481 -0.940 -7.310 -0.947 -6.780 -0.936
Cu/CuSO4 3
-4.486 -0.697 -5.154 -0.881 - -
Cu/CuSO4 4
-7.450 -0.927 -7.850 -0.922 -6.338 -0.941
Cu/CuSO4 5
Cu/CuSO4 6 -6.326 -0.908 -7.460 -0.996 -7.690 -0.785

Cu/CuSO4 7
-5.233 -0.855 -5.430 -0.930 -6.630 -0.936

Page 7 of 17
 Site visit report on cathodic protection system
of mounded bullets at BPCL LPG Bottling plant,
Solur, Bangalore
KB Singh and LPG Bottling plant,
Associates, Noida Bangalore

Cu/CuSO4 8
-6.930 -0.958 -6.540 -0.740 -6.750 -0.962
Cu/CuSO4 9
-6.324 -0.935 -6.560 -0.838 -6.800 -0.799
Zn RE 1 -3.528 +0.176 -3.783 +0.240 -4.026 +0.141

Zn RE 2 -3.700 +0.114 -4.101 +0.126 -4.436 +0.034

Zn RE 3 -4.199 +0.141 -4.397 +0.097 -5.025 +0.062

Interruption cycle: 4 sec ON and 1 Sec off.

Observations: 9 permanent Cu/CuSO4 reference cells of 27 are not meeting NACE /OISD criterion.

One of the 9 Zn reference cells are not meeting protection criterion of -0.100 V to +0.250 V Instant
OFF.

C. Monitoring of Anode Groundbed

Terminal No. mV drop across shunt Current (A)

0.25
A1
2.5
0.24
A2
0.23
A3
2.6
0.3
A4
0.34
A5
2.9
0.24
A6
0.26
A7
2.7
0.28
A8
2.14
Total 10.7

Shunt rating: 15A / 75mV

Observation: Anode strings are OK.

Page 8 of 17
 Site visit report on cathodic protection system
of mounded bullets at BPCL LPG Bottling plant,
Solur, Bangalore
KB Singh and LPG Bottling plant,
Associates, Noida Bangalore

D. Monitoring of Cathode Junction Box

mV across
MSV No Current (A)
shunt
C1 0.29
2.2
C2 0.16

C1 0.61
4.5
C2 0.3

C1 0.56
4.0
C2 0.25

2.17
Total 10.7

Shunt rating: 15A / 75mV

E. PSP at 12 O’clock position by Portable Half Cell (Cu/CuSO4)

ON PSP(VCSE) INST. OFF(VCSE)

Bullet 1 -7.910 -1.017
Bullet 2 -7.660 -1.038
Bullet 3 -7.600 -1.018

Observation:

Analysis: Instant OFF PSP of the bullets are meeting NACE/ OISD criterion of -0.850 V CSE Instant OFF.

F. Monolithic Isolation Joint Testing

MSV No Protected Side Unprotected Side

ON PSP (V) Instant off PSP ON PSP (V) Instant off PSP
(V) (V)
MSV No 1
LPG inlet/ Outlet -7.910 -1.017 -7.850 -1.018
Vapor suction -7.910 -1.017 -7.850 -1.018
Vapor return -7.910 -1.017 -7.850 -1.018

MSV No 2
LPG inlet/ Outlet -7.660 -1.038 -7.660 -1.038

Page 9 of 17
 Site visit report on cathodic protection system
of mounded bullets at BPCL LPG Bottling plant,
Solur, Bangalore
KB Singh and LPG Bottling plant,
Associates, Noida Bangalore

Vapor suction -7.660 -1.038 -7.660 -1.038

Vapor return -7.660 -1.038 -7.660 -1.038

MSV No 3
LPG inlet/ Outlet -7.600 -1.018 -7.600 -0.951
Vapor suction -7.600 -1.018 -7.600 -0.951
Vapor return -7.600 -1.018 -7.600 -0.951

Note: All PSP are wrt portable Cu/CuSO4 half cell kept at 12 o’clock position.

Observation: Bullet is not electrically isolated. CP current is draining to foreign steel

structures.

G. DC Decoupler testing

S No Description Voltage Across Polarization Cell

1 Bullet 1 0.263 V 
2 Bullet 2  0.282 V
3 Bullet 3  0.313 V

Electrolytic type DC Decouplers of Kirk Engineering USA make are installed.

Junction Box Maintenance Check

1 KOH solution is clear and transparent Yes
2 KOH Level OK
3 Mineral Oil level OK
4 SS Plates are clean Yes

Page 10 of 17
 Site visit report on cathodic protection system
of mounded bullets at BPCL LPG Bottling plant,
Solur, Bangalore
KB Singh and LPG Bottling plant,
Associates, Noida Bangalore

ANNEXURE-2

Monitoring data of CP System – New Mound

A. Transformer Rectifier Unit

Page 11 of 17
 Site visit report on cathodic protection system
of mounded bullets at BPCL LPG Bottling plant,
Solur, Bangalore
KB Singh and LPG Bottling plant,
Associates, Noida Bangalore

Make Raychem RPG

Rating: 50 V / 50 A
Commissioned in 2009
Modes of operation Manual/AVCC/Auto
Input AC supply 240 V AC
Interrupter Yes
Mode of operation AVCC
Parameter By Manual measurement At Display Meter
AC Voltage 262.9 V 260 V
AC Current 0A 0.1 A
DC Voltage 7.12 V 6.7 V
DC Current 1.44 A 1.5 A
On: -2.596 VCSE On: -2.5960VCSE
Potential at RE 1 Instant off: -0.950 VCSE Instant off: -0.952 VCSE
On: -2.332 VCSE On: -2.338 VCSE
Potential at RE 2 Instant off: +0.830 VCSE Instant off: +0.833 VCSE
On: -2.533 VCSE On: -2.537 VCSE
Potential at RE 3 Instant off: -0.770 VCSE Instant off: -0.771 VCSE

Observation: DC Voltmeter is fluctuating and shall be replaced.

TR Unit is working OK in Auto, AVCC and Manual mode.

B. Potential Readings at REJB

REFERENCE Bullet 4 Bullet 5 Bullet 6

ELECTRODE ON PSP Instant off Instant off PSP ON PSP Instant off
ON PSP (VCSE)
NO. (V) PSP (V) (VCSE) (VCSE) PSP (VCSE)
-2.183 -0.885 -2.419 -0.902 -2.764 -0.904
Cu/CuSO4 1
-2.345 -0.880 -2.146 -0.885 -2.653 -0.888
Cu/CuSO4 2
-1.594 -0.909 -2.356 -0.882 -2.665 -0.900
Cu/CuSO4 3
-2.384 -0.792 -2.385 -0.761 -2.823 -0.930
Cu/CuSO4 4
-2.486 -0.940 -2.631 -0.911 -2.791 -0.913
Cu/CuSO4 5
Cu/CuSO4 6 -2.690 -0.911 -1.972 -0.690 -2.842 -0.960

Cu/CuSO4 7
-2.160 -0.957 -1.289 -0.314 -2.536 -0.932
Cu/CuSO4 8
-2.446 -0.890 -2.596 -0.940 -2.707 -0.790

Page 12 of 17
 Site visit report on cathodic protection system
of mounded bullets at BPCL LPG Bottling plant,
Solur, Bangalore
KB Singh and LPG Bottling plant,
Associates, Noida Bangalore

Cu/CuSO4 9
-2.568 -0.960 -1.296 -0.322 -2.874 -0.934
Zn RE 1 -1.301 +0.016 -1.474 +0.026 -1.873 -0.011

Zn RE 2 -1.447 +0.010 -1.295 +0.054 -1.790 +0.004

Zn RE 3 -1.667 -0.110 -1.578 -0.029 -1.876 +0.030

Interruption cycle: 4 sec ON and 1 Sec off.

Observations: 6 permanent Cu/CuSO4 reference cells of 27 are not meeting NACE /OISD criterion.

All 9 Zn reference cells are meeting protection criterion of -0.100 V to +0.250 V Instant OFF.

C. Monitoring of Anode Groundbed

Terminal No. mV across shunt Current (A)

1.3 0.17
A1
1.7 0.22
A2
2.2 0.29
A3
1.3 0.17
A4
3.2 0.42
A5
0 0.00
A6
0 0.00
A7
3 0.39
A8
12.7 1.65
Total
Shunt rating: 10A / 75mV

Observation: 2 Anode strings are not drawing CP current.

D. Monitoring of Cathode Junction Box

Page 13 of 17
 Site visit report on cathodic protection system
of mounded bullets at BPCL LPG Bottling plant,
Solur, Bangalore
KB Singh and LPG Bottling plant,
Associates, Noida Bangalore

Bullet No MSV No mV across shunt Current (A)

C1 2.0 0.27
Bullet 4
C2 3.0 0.40

C1 0.6 0.08
Bullet 5
C2 0.3 0.04

C1 3.3 0.44
Bullet 6
C2 1.3 0.17

1.40
Total

Shunt rating: 10A / 75mV

E. PSP at 12 O’clock position by Portable Half Cell (Cu/CuSO4)

ON PSP(VCSE) INST. OFF(VCSE)

Bullet 1 -2.835 -1.027
Bullet 2 -2.826 -1.041
Bullet 3 -3.046 -1.001

Observation: Instant OFF PSP for the bullets are meeting NACE/ OISD criterion of -0.850 V CSE Instant
OFF.

F. Monolithic Isolation Joint Testing

MSV No Protected Side Unprotected Side

ON PSP (V) Instant off PSP ON PSP (V) Instant off PSP
(V) (V)
MSV No 4
LPG inlet/ Outlet -2.835 -1.027 -2.789 -1.015
Vapor suction -2.835 -1.027 -2.789 -1.015
Vapor return -2.835 -1.027 -2.789 -1.015

MSV No 5
LPG inlet/ Outlet -2.826 -1.041 -2.781 -1.049
Vapor suction -2.826 -1.041 -2.781 -1.049
Vapor return -2.826 -1.041 -2.781 -1.049

Page 14 of 17
 Site visit report on cathodic protection system
of mounded bullets at BPCL LPG Bottling plant,
Solur, Bangalore
KB Singh and LPG Bottling plant,
Associates, Noida Bangalore

MSV No 6
LPG inlet/ Outlet -3.046 -1.001 -2.826 -0.976
Vapor suction -3.046 -1.001 -2.826 -0.976
Vapor return -3.046 -1.001 -2.826 -0.976

Note: All PSP are wrt portable Cu/CuSO4 half cell kept at 12 o’clock position.

Observation: Bullet is not electrically isolated. CP current is draining to foreign steel

structures.

G. DC Decoupler testing

S No Description Voltage Across Polarization Cell

1 Bullet 4 0.015 V
2 Bullet 5 0V
3 Bullet 6 0.550 V

Solid state type DC Decouplers of Dairyland USA make are installed.

Page 15 of 17
 Site visit report on cathodic protection system
of mounded bullets at BPCL LPG Bottling plant,
Solur, Bangalore
KB Singh and LPG Bottling plant,
Associates, Noida Bangalore

Annexure – 3

CP Current requirement Calculation

CP Current requirement calculation

Type of Coating 100%  

Page 16 of 17
 Site visit report on cathodic protection system
of mounded bullets at BPCL LPG Bottling plant,
Solur, Bangalore
KB Singh and LPG Bottling plant,
Associates, Noida Bangalore

Elastomeric
Polyurethane
Dia of Bullet 5 m
Length of Bullet (tl to tl) 32.5 m
Surface area of the Bullet 588.75 sqmtrt
No of Bullets 3  
Total Surface Area 1766.25 sqmtrt
% of Bare steel at the end of design life 5%  
Current density for Bare steel 10 milliamp/m2
Microamp /
CP Current density for coated steel 25 m2
Current required by bare steel 0.88313 Amp
Current required by coated steel 0.04195 Amp
Total current required 0.93 Amp
Safety Factor 1.3 Amp
CP current required with Safety factor 1.20 Amp

Note: In the design document of CP system for old mound, CP current density for bare steel has
been considered as 25 microamp/m2. This is very low current density and will not be able to polarize
bullet structures cathodically.

Page 17 of 17