1 AMC Visit Report of BPCL Bangalore 12-06-2019

1st AMC VISIT REPORT ON CATHODIC PROTECTION
SYSTEM OF MOUNDED BULLETS AT

BPCL LPG BOTTLING PLANT, BANGALORE
By
KB Singh & Associates

Consultants Coatings & Cathodic Protection
Rev 0
13 June 2019
Review by
Prepared by Approved by
Rev & Date Anshul Jain
Sanjaya Rath BPCL
(NACE Certified CP Level 3)
1st AMC 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. Results
7. Recommendation
Annexure – 1
CP Monitoring Parameters- 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
H. Initial condition of CP system
Annexure-2
CP Monitoring Parameters- New Mound
B. Potential readings at REJB
E. PSP at 12 o’clock position by portable Cu/CuSO4 reference cell
F. Isolation Joint testing
Page 2 of 16
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
awarded AMC contract for CP system of both the mounds to M/s KB Singh and Associates (KBSA).
The visit has been made by Mr. Sanjaya Rath (KBSA) from 29 th May to 3th June 2019 and was joined
by Mr. Anshul Jain from 11th June to 12th June. During the visit CP system for both old and new
mounds has been inspected and improvement in health of cathodic protection of bullets has been
brought. This report provides monitoring data, status of cathodic protection, activities performed
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 16
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
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 16
5. Status of CP system
Sr. New
Parameter Old
No
A. O/P Voltage and O/P DC Volt: 2.0 V O/P DC Volt: 8.1 V
Current O/P DC Current: 0.1 A O/P DC Current: 2.9 A
B. Permanent Reference Bullet 1: All 9 No Cu/CuSO4 Bullet 4:5 of 9 No Cu/CuSO4

electrodes meeting All 3 Zn All 3 Zn
protection criterion of - Bullet 2: All 9 No Cu/CuSO4 Bullet 5: 6 of 9 No Cu/CuSO4
0.850 VCSE Instant OFF. All 3 Zn All 3 Zn
Bullet 3: All 9 No Cu/CuSO4 Bullet 6: All 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 Electrical isolation of bullet Electrical isolation of Bullet 6

from foreign structures has has been achieved.
been achieved for all three Further investigation is
bullets Bullet 1, Bullet 2 and required for Bullet 4 and Bullet
Bullet 3. 5.
Note: CP current requirement of New Mound has increased in comparison to previous observations.
This is because there was anodic interference on New Mound from Old mound CP system. As
isolation of Old mound is achieved and CP current requirement of Old mound is reduced, so anodic
interference is not there anymore. Hence CP current requirement has increased for adequate
protection.
6. Results
a. In old mound Polarized PSP at all permanent reference cell locations of all 3 bullets (1, 2 and
3) is meeting NACE/OISD criterion of -0.850 V CSE Instant OFF.
In New Mound polarized PSP of Bullet 4 and 6 is meeting NACE/ OISD criterion of -0.850 V CSE
Instant OFF. However in Bullet 5, 2 number reference cell locations are not meeting the
criterion.
b. Anode strings for Old mound are OK.
Anode strings out of 8 in New Mound are not drawing CP current.
c. Electrical isolation of Old mound (Bullet 1, Bullet 2 and Bullet 3) has been achieved. Electrical
isolation of only Bullet 6 in New Mound has been achieved.
Page 5 of 16
d. Surge diverters across monolithic isolation joint has been replaced at following locations:
- In New Mound, vapour piping for Bullet 5 and Bullet 6
- In Old Mound, liquid piping for Bullet 2 and vapour for Bullet 3.
7. Recommendations
a. Further investigation and work is required for checking high current requirement of New
Mound. We shall go back to our home office and discuss with other corrosion experts. We
will revert with action plan in 1 week’s time. Further shall make another visit as per mutually
agreed plan.
b. Spares require:
- Surge Diverter 6 No.
Page 6 of 16
ANNEXURE-1
CP Monitoring Parameters: Old LPG Mound
Page 7 of 16
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
Mode of operation Manual -
Parameter By Manual measurement At Display Meter
AC Voltage 235 V 235 V
AC Current 0.0 A 0.0 A (Meter is Faulty)
DC Voltage 2V 2V
DC Current 0.08 A 0.1 A
On: -1.470 VCSE On: -1.475 VCSE
Potential at RE 1 Instant off: -1.193 VCSE Instant off: -1.192 VCSE
On: -1.497 VCSE On: -1.492 VCSE
On: -1.507 VCSE On: -1.501 VCSE
Observation:
 Card 104 and 106 require maintenance.
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)
-1.470 -1.193 -1.497 -1.198 -1.507 -1.192
Cu/CuSO4 1
-1.380 -1.195 -1.464 -1.194 -1.326 -1.176
Cu/CuSO4 2
-1.416 -1.188 -1.434 -1.197 -1.450 -1.187
Cu/CuSO4 3
-1.536 -1.196 -1.560 -1.187 -1.279 -1.130
Cu/CuSO4 4
-1.470 -1.193 -1.312 -1.060 -1.592 -1.192
Cu/CuSO4 5
Cu/CuSO4 6 -1.556 -1.188 -1.550 -1.192 -1.365 -1.055
Cu/CuSO4 7
-1.412 -1.197 -1.534 -1.196 -1.526 -1.186
Cu/CuSO4 8
-1.493 -1.189 -1.445 -1.179 -1.625 -1.195
Cu/CuSO4 9 -1.460 -1.192 -1.340 -1.090 -1.365 -1.124
Page 8 of 16
Zn RE 1 -0.477 -0.093 -0.435 -0.089 -0.550 -0.101
Zn RE 2 -0.533 -0.095 -0.525 -0.097 -0.590 -0.092
Zn RE 3 -0.471 -0.089 -0.519 -0.091 -0.598 -0.098
Interruption cycle: 8 sec ON and 2 Sec off.
Observations: All permanent Cu/CuSO4 reference cells are meeting NACE /OISD criterion of -0.850
mVCSE.
All 9 Zn reference cells are meeting protection criterion of -0.100 V to +0.250 V Instant OFF.
Terminal No. Current (A)

A1 0.02
A2
A3 0.03
A4
A5 0.03
A6
A7 0.02
A8
0.1
Total
Shunt rating: 15A / 75mV
Observation: Anode strings are OK.
MSV No Current(A)
C1
0.03
C2
C1
0.03
C2
C1
0.03
C2
Total 0.09
Page 9 of 16
E. PSP at 12 O’clock position by Portable Half Cell (Cu/CuSO4)
ON PSP(VCSE) INST. OFF(VCSE)

Bullet 1 -1.512 -1.198
Bullet 2 -1.450 -1.192
Bullet 3 -1.495 -1.193
Observation: 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 -1.255 -1.080 -0.384 -0.439
Vapor suction -1.255 -1.080 -0.384 -0.439
Vapor return -1.255 -1.080 -0.384 -0.439
MSV No 2
LPG inlet/ Outlet -1.206 -1.062 -0.410 -0.470
Vapor suction -1.206 -1.062 -0.410 -0.470
Vapor return -1.206 -1.062 -0.410 -0.470
MSV No 3
LPG inlet/ Outlet -1.290 -1.085 -0.345 -0.456
Vapor suction -1.290 -1.085 -0.345 -0.456
Vapor return -1.290 -1.085 -0.345 -0.456
Note: All PSP are wrt portable Cu/CuSO4 half cell kept at remote location.
Observation: Bullet is electrically isolated.
Page 10 of 16
S No Description Voltage Across Polarization Cell

1 Bullet 1 1.234 V
2 Bullet 2 1.272 V
3 Bullet 3 1.362 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 11 of 16
ANNEXURE-2
CP Monitoring Parameters- New LPG Mound
Page 12 of 16
Make Raychem RPG

Rating: 50 V / 75 A
Commissioned in 2009
Modes of operation Manual/AVCC/Auto
Input AC supply 240 V AC
Interrupter Yes
Parameter By Manual measurement At Display Meter
AC Voltage 238 V 238 V
AC Current 0.48 A (Meter is Faulty)
DC Voltage 8V (Meter is Faulty)
DC Current 2.5 A 2.5 A
Mode of operation AVCC
On: -3.344 VCSE On: -3.344 VCSE
On: -3.505 VCSE On: -3.505 VCSE
On: -4.234 VCSE On: -4.234 VCSE
Observation:
 Card 104 and 106 require maintenance.
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)
-3.184 -0.851 -3.451 -0.854 -4.076 -0.886
Cu/CuSO4 1
-3.441 -0.856 -3.251 -0.865 -3.343 -0.869
Cu/CuSO4 2
-3.507 -0.854 -3.435 -0.851 -4.007 -0.869
Cu/CuSO4 3
-3.384 -0.852 -3.606 0.914 -3.804 -0.867
Cu/CuSO4 4
-3.344 -0.919 -3.565 -0.886 -4.234 -0.836
Cu/CuSO4 5
Cu/CuSO4 6 -3.687 -0.867 -2.678 -0.668 -3.889 -0.942
Cu/CuSO4 7 -2.434 -0.851

-2.677 -0.890 -3.741 -0.908
Cu/CuSO4 8
-3.429 -0.854 -3.505 -0.916 -4.312 -0.912
Cu/CuSO4 9 -3.467 -0.913 -2.438 -0.780 -3.952 -0.936
Page 13 of 16
Zn RE 1 -2.334 +0.070 -2.517 +0.040 -3.158 -0.022
Zn RE 2 -2.548 +0.065 -2.325 -0.060 -3.109 +0.012
Zn RE 3 -2.145 -0.064 -2.619 -0.013 -3.176 +0.060
Interruption cycle: 8 sec ON and 1 Sec off.
Observations: 7 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.
Terminal No. Current (A)

0.429
A1
0.299
A2
0.351
A3
0.234
A4
0.481
A5
0
A6
0
A7
0.689
A8
Total 2.48 A
Observation: 2 Anode strings are not drawing CP current.
Page 14 of 16
MSV No Current (A)

C1 0.767
C2 0.481
C1 0.364
C2 0.143
C1 0.117
C2 0.494
Total 2.36 A
E. PSP at 12 O’clock position by Portable Half Cell (Cu/CuSO4)
ON PSP(VCSE) INST. OFF(VCSE)

MSV 4 -3.695 -0.890
MSV 5 -3.445 -0.990
MSV 6 -4.400 -1.101
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 4
LPG inlet/ Outlet -1.590 -1.027 -0.612 -0.910
Vapor suction -1.590 -1.027 -0.612 -0.910
Vapor return -1.590 -1.027 -0.612 -0.910
MSV No 5
LPG inlet/ Outlet -1.512 -1.008 -0.612 -0.910
Vapor suction -1.512 -1.008 -0.612 -0.910
Vapor return -1.512 -1.008 -0.612 -0.910
Page 15 of 16
MSV No 6
LPG inlet/ Outlet -2.266 -1.006 -0.612 -0.910
Vapor suction -2.266 -1.006 -0.612 -0.910
Vapor return -2.266 -1.006 -0.612 -0.910
Note: All PSP are wrt portable Cu/CuSO4 half cell kept at remote location.
Observation: Readings on unprotected side show instant OFF as -0.912, which is more
electronegative than natural PSP of steel. This requires further investigation.
S No Description Voltage Across Polarization Cell

1 Bullet 1 1.150 V
2 Bullet 2 1.189 V
3 Bullet 3 1.920 V
Page 16 of 16

1 AMC Visit Report of BPCL Bangalore 12-06-2019

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1st AMC VISIT REPORT ON CATHODIC PROTECTION

SYSTEM OF MOUNDED BULLETS AT

KB Singh & Associates

No Description Old New

a. IS 8062: Recommended Practice for Cathodic Protection.

3. Criteria of Cathodic Protection

CP System Design Parameters:

No Description Old New

1 Number of TRU per Mound One One

B. Permanent Reference Bullet 1: All 9 No Cu/CuSO4 Bullet 4:5 of 9 No Cu/CuSO4

E. Electrical isolation Electrical isolation of bullet Electrical isolation of Bullet 6

CP Monitoring Parameters: Old LPG Mound

A. Transformer Rectifier Unit

Make Raychem RPG

 Card 104 and 106 require maintenance.

B. Potential Readings at REJB

REFERENCE Bullet 1 Bullet 2 Bullet 3

Zn RE 1 -0.477 -0.093 -0.435 -0.089 -0.550 -0.101

Zn RE 2 -0.533 -0.095 -0.525 -0.097 -0.590 -0.092

Zn RE 3 -0.471 -0.089 -0.519 -0.091 -0.598 -0.098

Interruption cycle: 8 sec ON and 2 Sec off.

C. Monitoring of Anode Groundbed

Terminal No. Current (A)

Observation: Anode strings are OK.

D. Monitoring of Cathode Junction Box

Shunt rating: 15A / 75mV

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

ON PSP(VCSE) INST. OFF(VCSE)

F. Monolithic Isolation Joint Testing

MSV No Protected Side Unprotected Side

Observation: Bullet is electrically isolated.

S No Description Voltage Across Polarization Cell

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

Junction Box Maintenance Check

CP Monitoring Parameters- New LPG Mound

A. Transformer Rectifier Unit

Make Raychem RPG

 Card 104 and 106 require maintenance.

B. Potential Readings at REJB

REFERENCE Bullet 4 Bullet 5 Bullet 6

Cu/CuSO4 7 -2.434 -0.851

Zn RE 1 -2.334 +0.070 -2.517 +0.040 -3.158 -0.022

Zn RE 2 -2.548 +0.065 -2.325 -0.060 -3.109 +0.012

Zn RE 3 -2.145 -0.064 -2.619 -0.013 -3.176 +0.060

Interruption cycle: 8 sec ON and 1 Sec off.

C. Monitoring of Anode Groundbed

Terminal No. Current (A)

Shunt rating: 10A / 75mV

Observation: 2 Anode strings are not drawing CP current.

D. Monitoring of Cathode Junction Box

MSV No Current (A)

Shunt rating: 10A / 75mV

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

ON PSP(VCSE) INST. OFF(VCSE)

F. Monolithic Isolation Joint Testing

MSV No Protected Side Unprotected Side

S No Description Voltage Across Polarization Cell

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