ABU DHABI OIL REFINING COMPANY (TAKREER)

NEW ABU DHABI AIRPORT (ADIA) AVIATION FUEL DEPOT PROJECT; PROJECT NO. 5643
ENGINEERING, PROCUREMENT, CONSTRUCTION, COMMISSIONING AND START- UP (EPC) WORKS
AGREEMENT NO. 11-5643-E-1

ABU DHABI OIL REFINING COMPANY

EXHIBIT C.1.18

CATHODIC PROTECTION FOR BURIED PIPING, ON-GRADE TANK

BOTTOM EXTERNAL SURFACE & INTERNAL SURFACE AND
CORROSION MONITORING SYSTEM FOR CONCRETE STEEL REBAR

FOR

ENGINEERING, PROCUREMENT, CONSTRUCTION, COMMISSIONING

AND START- UP (EPC) WORKS

FOR THE

NEW ABU DHABI AIRPORT (ADIA) AVIATION FUEL DEPOT PROJECT

EXHIBIT C.1.18
CATHODIC PROTECTION PAGE 1 of 11
 ABU DHABI OIL REFINING COMPANY (TAKREER)
NEW ABU DHABI AIRPORT (ADIA) AVIATION FUEL DEPOT PROJECT; PROJECT NO. 5643
ENGINEERING, PROCUREMENT, CONSTRUCTION, COMMISSIONING AND START- UP (EPC) WORKS
AGREEMENT NO. 11-5643-E-1

TABLE OF CONTENTS

C.1.18.1 INTRODUCTION ........................................................................................................3

C.1.18.2 APPLICABLE DOCUMENTS ....................................................................................3

C.1.18.3 STRUCTURE DETAILS .............................................................................................4

C.1.18.4 SCOPE OF WORK ......................................................................................................5

C.1.18.5 AS-BUILT DOCUMENTS.........................................................................................11

EXHIBIT C.1.18
CATHODIC PROTECTION PAGE 2 of 11
 ABU DHABI OIL REFINING COMPANY (TAKREER)
NEW ABU DHABI AIRPORT (ADIA) AVIATION FUEL DEPOT PROJECT; PROJECT NO. 5643
ENGINEERING, PROCUREMENT, CONSTRUCTION, COMMISSIONING AND START- UP (EPC) WORKS
AGREEMENT NO. 11-5643-E-1

C.1.18 CATHODIC PROTECTION OF BURIED PIPING, ON-GRADE TANK

BOTTOM SURFACE, INTERNAL SURFACE & CORROSION
MONITORING SYSTEM FOR CONCRETE STEEL REBAR

C.1.18.1 INTRODUCTION
This section applies to Cathodic Protection works and services to be performed by
CONTRACTOR for the Engineering, Procurement, Construction and Start-up (EPC)
works on the following steel items or structures for the New Abu Dhabi Airport
(ADIA) Aviation Fuel Depot Project at New Abu Dhabi Airport (ADIA).
• Buried carbon steel Piping
• Bottom surfaces of on-grade Jet A-1 and fire water tanks in contact with soil
• Internal Surface of on-grade fire water tanks in contact with water
• Reinforcement steel bars embedded in concrete (Corrosion Monitoring)

COMPANY will not provide any Free Issue materials in this Project.

C.1.18.2 APPLICABLE DOCUMENTS

C.1.18.2.1 Specifications and Standard Drawings

The applicable Project specifications, Project Standard Drawings, COMPANY Design

General Specifications (DGSs) and any Amendments thereto for Cathodic Protection
of buried steel piping, on-grade tank bottom external surface, tank internal surface and
corrosion monitoring system for reinforcement bars are contained in EXHIBIT C.2.7.
CONTRACTOR shall perform the WORK in accordance these documents.

The Project specifications, Project Standard Drawings and Amendment to DGSs were
developed specifically for use on this Project. CONTRACTOR shall inform
COMPANY immediately, in writing, with any proposed deviations from these
specifications and standards or COMPANY original DGSs. All deviations require
written approval from COMPANY.

1. List of Project Specifications & FEED Documents:

5264-1501-PIP-AMD-2913 Specification for CP(Amendment to DGS-My-002)

5264-1501-PIP-CAL-2506 CP system SOW

DGS-MX-001 Painting

DGS-MY-003 Cathodic Protection system for buried onshore pipeline

DGS-CU-010 Concrete construction formworks and coatings

ASTM G 57 Field Measurement of Soil Resistivity using 4pin Wenner method.

NACE SP 0193 External CP of On grade CS storage tank structures

EXHIBIT C.1.18
CATHODIC PROTECTION PAGE 3 of 11
 ABU DHABI OIL REFINING COMPANY (TAKREER)
NEW ABU DHABI AIRPORT (ADIA) AVIATION FUEL DEPOT PROJECT; PROJECT NO. 5643
ENGINEERING, PROCUREMENT, CONSTRUCTION, COMMISSIONING AND START- UP (EPC) WORKS
AGREEMENT NO. 11-5643-E-1

NACE SP 0388 ICCP of Internal Submerged surfaces of CS water storage tank

NACE SP 0572
Design, Installation, operation and Maintenance of Impressed Current
Deep anode Ground bed.

Control of external corrosion on underground or submerged metallic

NACE SP 0169
Piping
NACE SP 0177
Alternating current and lighting effects on metallic structures and Cathodic
Protection System.

C.1.18.2.2 Drawings and Documents

As described elsewhere in the Agreement, CONTRACTOR is required to develop all

constriction drawings, equipment layout, specification, data sheet and documents
related to Cathodic Protection system required for the execution of the PROJECT.

CONTRACTOR shall familiarize itself with the entire Agreement and shall comply
with all requirements related to Cathodic Protection scope of work for the PROJECT.

C.1.18.2.3 Codes and Standards

All referenced Codes and Standards shall be the latest revision at the time of award of
the Contract.

C.1.18.3 STRUCTURE DETAILS

A. The schedule of on-grade storage tanks are as follows:

In accordance with the project CP specification, an impressed current cathodic

protection system is designed to provide corrosion control to the external bottom and
internal surface for the following new tank.

Tank Operating
Sr. CP System
Tank ID Diameter and Temperature Service
No. Required for
Height (m) (ºC)

1 1501-T-1001 36 & 24 45º C Jet A-1 External Surface

2 1501-T-1002 36 & 24 45º C Jet A-1 External Surface

3 1501-T-1003 36 & 24 45º C Jet A-1 External Surface

4 1501-T-1004 36 & 24 45º C Jet A-1 External Surface

45º C Fire Water Internal & External

5 TK-4001 22.5 / 16
Tank Surface

45º C Fire Water Internal & External

6 TK-4002 22.5 / 16
Tank Surface

B. Buried Jet A-1 Piping (CS)

EXHIBIT C.1.18
CATHODIC PROTECTION PAGE 4 of 11
 ABU DHABI OIL REFINING COMPANY (TAKREER)
NEW ABU DHABI AIRPORT (ADIA) AVIATION FUEL DEPOT PROJECT; PROJECT NO. 5643
ENGINEERING, PROCUREMENT, CONSTRUCTION, COMMISSIONING AND START- UP (EPC) WORKS
AGREEMENT NO. 11-5643-E-1

Sr. Pipe Diameter and Operating Pipe external

Pipe ID
No. Length (m) Temperature (ºC) Service Coating System

1 Jet A-1 P/L 0.508 / 200 45º C Jet A-1 3LPE

C. The schedule of Concrete Structure as follows (for Concrete Corrosion

monitoring)

Sl.No Structure Name

1 Piperack Foundation
2 Concrete Ring wall of the above ground water storage tank
3 Equipment / Structure Foundation
4 Building Foundation

C.1.18.4 SCOPE OF WORK

CONTRACTOR’S scope of WORK and supply shall include but not limited to the
following:

• CONTRACTOR shall refer and comply with the requirements of document

number 5643-1501-PIP-AMD-2913 “Specification for Cathodic Protection
(Amendment to DGS-MY-002 Rev 01)” and 5643-1501-PIP-CAL-2506 Cathodic
Protection system scope of work (design calculation and BOQ”.

• CONTRACTOR shall perform the Site survey, design, detailed engineering,

procurement, installation, testing, and commissioning of impressed Current
Cathodic Protection (ICCP) system for the storage tank bottom external surface,
internal surface and buried steel pipes.

• Pre-Design Site Visit / Survey, Engineering and Design for TCP / ICCP system,
construction drawings and layout, Procedures and Inspection and Test Plan for
Installation and commissioning, FAT procedure / report for TR unit, RMCS,
Supply of all CP / Corrosion monitoring materials, Installation, Testing and
commissioning of Temporary Sacrificial anode CP system (for during the
construction period for buried piping) and Impressed Current Cathodic Protection
system for the above structures (Refer clause C.1.18.3).

Concrete structures and foundations: Corrosion monitoring

Corrosion monitoring system shall be provided as per the DGS-CU-010 and its
amendments.

• Corrosion monitoring facility requirements have been determined based on a

review of the structural and architectural drawings of the structures. Corrosion
monitoring facility shall be provided for all critical and non critical concrete
structures.

EXHIBIT C.1.18
CATHODIC PROTECTION PAGE 5 of 11
 ABU DHABI OIL REFINING COMPANY (TAKREER)
NEW ABU DHABI AIRPORT (ADIA) AVIATION FUEL DEPOT PROJECT; PROJECT NO. 5643
ENGINEERING, PROCUREMENT, CONSTRUCTION, COMMISSIONING AND START- UP (EPC) WORKS
AGREEMENT NO. 11-5643-E-1

• In line with Project specification requirements, to prevent stray current corrosion

and to provide negative connection points for connection of future CP system, all
reinforcing steel embedded in concrete above and below ground shall be made
continuous during construction.
• In addition to the above, provision for external cable connection points shall be
made on each structure to facilitate future connections (if and when needed) with
tank form CP System.
• Small structures shall be provided with one connection point per structure for
large structure one connection shall be provided for every 64 sq m of concrete
surface area as minimum.
• Corrosion monitoring probe shall be provided for monitoring corrosion rates of
steel in corrosion for critical structures. Corrosion probe shall be supplied
complete with 5m long tail cable and lockable wall / flush mounted junction box.
• Permanent reference electrode shall be provided for monitoring corrosion rates of
steel in corrosion for non critical structures.
• One portable digital instrument shall be supplied to read the proposed corrosion
monitoring probes. (If no of proposed probe is more than ten, two potable digital
instruments shall be supplied for monitoring).

C.1.18.4.1 Material Procurement and Supply

CONTRACTOR shall supply all Materials, spares, services, equipment, tools, and
each and every item of expense necessary for the procurement and supply of
materials for the survey, design, procurement, supply to site, installation supervision,
testing and commissioning of cathodic protection systems for buried carbon steel
piping, tank external, tank internal (fire water tank) and concrete steel rebar corrosion
monitoring system .

The scope of supply for the cathodic protection system equipment shall be in full
compliance with COMPANY Project CP specification (as per the section 2.0). Any
technical deviation/changes to this specification are subject to approval from
COMPANY. Technical changes implemented prior to approval are subject to
rejection.

Procurement of all the required cathodic protection equipment and materials to

complete the project and delivery to site is in the CONTRACTOR Scope of work.

CONTRACTOR shall prepare and submit for COMPANY approval all the material
requisitions for equipments and materials, then issue the same for approved CP
VENDORS, evaluate the CP VENDOR offers and ensure that they fully comply with
the approved requisition requirements.

CONTRACTOR shall submit the purchase requisitions along with the selected offers
for COMPANY approval before placement the orders.

All materials shall be provided from the PROJECT VENDOR’S list.

CONTRACTOR shall be provided all Material data sheet, manufacturer functional
test and calibration certificates to the COMPANY for approval, prior to material
dispatch to the SITE.

All cost of the equipment and material supply shall be to the CONTRACTOR.

EXHIBIT C.1.18
CATHODIC PROTECTION PAGE 6 of 11
 ABU DHABI OIL REFINING COMPANY (TAKREER)
NEW ABU DHABI AIRPORT (ADIA) AVIATION FUEL DEPOT PROJECT; PROJECT NO. 5643
ENGINEERING, PROCUREMENT, CONSTRUCTION, COMMISSIONING AND START- UP (EPC) WORKS
AGREEMENT NO. 11-5643-E-1

CONTRACTOR shall provide two (2) years operation and maintenance spares for the
TR unit.

Following are, but not limited to, the main equipments and materials to be supplied
by the CONTRACTOR under this scope:

• Cathodic Protection Transformer-Rectifier units with RMCS facilities

• MMO tubular anodes (MMO) for buried pipeline Impressed Current CP (ICCP)
System.
• MMO Ribbon and titanium conductor bar for Tank bottom external ICCP system
• Platinized Niobium wire anodes for Tank internal ICCP system
• Corrosion Monitoring probe and permanent reference electrode for Concrete
Corrosion monitoring system.
• Negative Distribution Boxes and Anode Junction Boxes c/w Bus Bar, Shunt,
adjustable Resistor and supporting frame.
• Monitoring Test Post.
• Corrosion coupon / Magnetic Reed switch
• Backfilling materials.( Coke breeze and low resistivity chemicals for sacrificial
anode)
• Sacrificial anodes (Magnesium or Zinc anodes/ribbon for temporary CP system)
• Permanent reference electrodes.
• Cathodic protection cables, gland and cable lugs.
• Coating repair Materials.
• Thermit weld Materials
• Materials for Permanent anode ground bed system ( for piping ICCP system)
• Perforated monitoring tube (2” dia) for tank external monitoring system
• Spark Gap arrestor and isolation Joint Test station.
• Remote Monitoring and control system (Interface unit, software, Cables and Desk
top computer)
• Cableway route markers
• In addition, any other ancillary items as may be required.

CONTRACTOR shall provide guarantees for the CP equipment, in accordance with

the CP design conditions, details given on the referenced material data sheet and data
sheet and the project CP specifications.

The materials, integrity of construction and workmanship and satisfactory operation

of the complete equipment in accordance with the requirements of this Scope of work
shall be guaranteed for a period of twenty four (24) months after commissioning.

CONTRACTOR shall guarantee all work and materials in his supply against
defective material, poor workmanship, improper design, improper packaging and /or
failure in normal use and ensure that warranty requirements as required by Agreement
are complied with.

All equipment and material shall be new and unused and of current manufacture, of
the highest grade and free from all defects and imperfections, which affect
performance, and in all ways be fit for duty, as detailed by the project CP
specifications and Scope of wok.

EXHIBIT C.1.18
CATHODIC PROTECTION PAGE 7 of 11
 ABU DHABI OIL REFINING COMPANY (TAKREER)
NEW ABU DHABI AIRPORT (ADIA) AVIATION FUEL DEPOT PROJECT; PROJECT NO. 5643
ENGINEERING, PROCUREMENT, CONSTRUCTION, COMMISSIONING AND START- UP (EPC) WORKS
AGREEMENT NO. 11-5643-E-1

CONTRACTOR shall repair or replace within one (1) week, without any charge to
the COMPANY, the parts found defective within the guarantee period.

CONTRACTOR shall guarantee the performance of the painting (Shop and Field
applied) for a period of time from the commissioning and handover of the CP system.
The surface covered, timeframes and other requirements shall be in accordance with
project CP specifications.

C.1.18.4.2 Engineering Activity

Obtain, generate and evaluate necessary information to perform complete design,

detailed construction drawings / Layout, installation & commissioning procedures,
DC Interference, testing, commissioning and documentation of the cathodic
protection systems including a pre-design site visit / survey report.

Provide detailed design for temporary (during construction period) and permanent
cathodic protection systems in compliance with project CP specifications, referenced
standards and suitable for the project environmental conditions.
Detailed design basis and construction drawings for Corrosion monitoring system for
concrete steel rebar.

Commission, test and adjust the newly installed temporary and permanent cathodic
protection systems.

Check, locate and mitigate any shorts in the cathodic protection systems.

Check, evaluate and mitigate possible interference caused by cathodic protection

systems on other buried structures / ground bed / earthing network.

Provide documentation for system design, installation, ITP, special surveys and
commissioning.

Provide complete design and interfacing layout and drawings for RMCS.

Submit to the COMPANY a detailed cathodic protection design and installation

methods for review and approval. The design data shall include basis, calculations
and detailed drawings.

Prepare general cathodic protection SYSTEM layout. Location of anode ground bed,
Transformer rectifier unit, Test facility, Permanent reference electrode, isolating
joints, and other details shall be shown on applicable drawings.

Provide on commissioning report and as built drawing.

Provide an operations & maintenance manual for CP system.

C.1.18.4.3 Installation
CONTRACTOR shall submit manufacture test certificate and performance test
certificate for all materials prior to dispatch the materials to site.

EXHIBIT C.1.18
CATHODIC PROTECTION PAGE 8 of 11
 ABU DHABI OIL REFINING COMPANY (TAKREER)
NEW ABU DHABI AIRPORT (ADIA) AVIATION FUEL DEPOT PROJECT; PROJECT NO. 5643
ENGINEERING, PROCUREMENT, CONSTRUCTION, COMMISSIONING AND START- UP (EPC) WORKS
AGREEMENT NO. 11-5643-E-1

For all TR units FAT procedure and report shall be submitted for review and approval.
CONTRACTOR shall submit detailed Installation Procedure, pre/post installation
check sheets, Inspection and Test Plan to the COMPANY for approval
CONTRACTOR shall carry out the CP installation works for all structures, pre/post
installation check, calibration and testing activities as per the approved design,
construction drawings codes, standards, procedures and regulations. During the
installation CONTRACTOR shall use its own instruments and equipments for pre /
post installation check / test. All instruments shall be used with calibration certificate.
Transformer Rectifier (TR) unit, Anode Junction Box (AJB) shall be installed in the
non-hazardous area. If this is not possible, the installation of the TR unit and AJB
shall fulfil the requirements of the hazardous area classification applicable for the site.
Remote monitoring and control system, Deep well ground bed system, MMO anode
grid system, Platinized niobium anodes, permanent reference electrode, bonding
facilities for mitigation for DC interference problem shall be tested and checked (pre
/post installation) by a qualified and experienced CP Engineer.
During the construction period, buried piping external surface shall be protected by
sacrificial anode CP. All sacrificial anodes connected to the pipeline through Test post.
(Till the time the ICCP system is commissioned, Tank bottom external surface shall be
temporarily protected with temporary DC power source.
All CP materials and equipment shall be supplied from approved manufacturers.

C.1.18.4.4 SUBCONTRACTOR
It is a requirement of this specification that the CONTRACTOR shall engage a
specialist cathodic protection VENDOR / SUBCONTRACTOR to execute the
engineering design, procurement, installation, specialized surveys, commissioning and
final documentation of the CP system. Such expertise shall be sufficient to satisfy the
following:
A Qualified and experienced (minimum 10 years) or NACE accredited CP engineer
(with minimum 10 years experienced) should be provided on a full time basis for the
duration of the Contract.
The CONTRACTOR is required to submit CV of the designated candidate for
position for COMPANY approval as part of his technical submittal.

C.1.18.4.5 Pre-commissioning and Testing

CONTRACTOR shall perform all pre-commissioning tests in the presence of
COMPANY to confirm satisfactory installation and operation of all equipment.
CONTRACTOR shall submit the Pre Commissioning and Commissioning procedure
to COMPANY for approval.
Before COMMISSIONING of the permanent CP system, the Commissioning
Engineer shall carry out the following pre-commissioning tests as a minimum:
• Review all the pre / post installation check sheets.
• Check / Review the transformer performance test reports, rectifier internal
components, fuses, cooling systems, oil breather, cable termination & polarity,
RMCS connections and measure the total circuit resistance.
• Check / Review the material data sheet & test report of the CP equipments.
• Check the internal components of the Junction box and test post.

EXHIBIT C.1.18
CATHODIC PROTECTION PAGE 9 of 11
 ABU DHABI OIL REFINING COMPANY (TAKREER)
NEW ABU DHABI AIRPORT (ADIA) AVIATION FUEL DEPOT PROJECT; PROJECT NO. 5643
ENGINEERING, PROCUREMENT, CONSTRUCTION, COMMISSIONING AND START- UP (EPC) WORKS
AGREEMENT NO. 11-5643-E-1

• Disconnect all temporary anodes / temporary DC power supply (for tank bottom)
from the structure and allow the structures to depolarization.
• Check the integrity of the Isolation joint / Flange.
• Measure the anode ground bed resistance and individual anodes.
• Check the total circuit resistance.
• Record all structure to soil / water potentials (As found/Natural potential) on the
entire test points with respect to the Permanent (where appropriate) and Portable
reference electrode.
• Check the spark gap arrestor.
• Check and calibrate the permanent reference electrode.
• Check the connection and interface unit of the remote monitoring and control
system.
• Check all cable continuities where appropriate.

C.1.18.4.6 COMMISSIONING
The CONTRACTOR shall perform all commissioning tests to confirm satisfactory
installation and operation of all equipment. All testing and commissioning shall be
carried out in the presence of the responsible COMPANY’S representative. The
system shall be considered satisfactory when the cathodic protection criteria is met at
test stations and any other accessible points of the structure to be protected where
COMPANY requires tests to conform effectiveness of CP system.
On satisfactory completion of the Pre commissioning, the Commissioning Engineer
shall carry out the following activities:
• Switch on the TR unit to energize the CP system and adjust the TR output current
to get structure to achieve the protection level.
• Allow system to achieve full polarizations and study potential.
• After the sufficient study polarization, structure to soil / water ON/OFF (4:1
cycle) potential with respect to permanent (where appropriate) and portable
reference electrode shall be measured.
• Structure to soil / water potentials shall be recorded at all test points.
• Adjust cathodic protection system output as required to achieve protection in
accordance with the Protection criteria as per the CP specification.
• Measure the potential (swing test) at Isolation Joint (both side), to confirm
satisfactory isolation of the structure.
• Confirm no interference is occurring on other buried structure because of the
operation of the cathodic protection system.
• Make final adjustments as required.
• Measure the Anode output current at AJB and adjust the current.
.
Upon completion of the final adjustments to getting the polarized potential, remote
monitoring system shall be commissioned and parameter verified by accessing data
locally using LAN connection as well as remotely.

C.1.18.4.7 Documents and Drawings Deliverable

The CONTRACTOR (CP Subcontractor / Vendor) shall submit the following
minimum documents and drawings to COMPANY approval.
• Deliverable list of CP documents and drawings.
• Engineering Document and Materials deliverable schedule.
• Weekly and Monthly progress Report (Engineering and Installation)

EXHIBIT C.1.18
CATHODIC PROTECTION PAGE 10 of 11
 ABU DHABI OIL REFINING COMPANY (TAKREER)
NEW ABU DHABI AIRPORT (ADIA) AVIATION FUEL DEPOT PROJECT; PROJECT NO. 5643
ENGINEERING, PROCUREMENT, CONSTRUCTION, COMMISSIONING AND START- UP (EPC) WORKS
AGREEMENT NO. 11-5643-E-1

• Pre design site survey procedure.

• Pre design site survey report.
• Detailed Engineering design report.(TCP / ICCP system)
• Detailed design basis and construction drawing for Concrete corrosion monitoring
system
• Equipment layout and Construction drawings.
• CP Bill of materials.
• Materials data sheet for all CP Materials and Equipments.
• Transformer rectifier unit specification and circuit diagram.
• FAT Procedure for CP Materials and Equipments
• FAT Report for CP Materials and Equipments
• RMCS Design Report & Layout and construction drawings
• List of the output signals of the CP TR unit
• RMCS installation & commissioning procedures
• ITP for Installation, pre commissioning and Commissioning.
• ICCP & TCP Installation procedure and check sheets.
• ICCP & TCP Commissioning procedure and check sheets.
• DC interference survey procedure and report
• Commissioning report.
• List of Spare Parts ( for 2 year operation and Maintenance)
• As built drawings.
• Operation and maintenance manuals (shall be compiled with Design Report,
Installation Procedure, Installation and pre commissioning & Commissioning
check sheet, Material data sheet, performance test certificate for all CP materials,
Commissioning Procedure, Commissioning report, As Built Drawing, Spare Parts
List, and Operation and maintenance procedure and instruction for Trouble
Shooting).

C.1.18.5 AS-BUILT DOCUMENTS

On successful completion of Cathodic Protection systems, CONTRACTOR shall

prepare “As-Built” drawings/reports for the entire Cathodic Protection TEMS as
specified in EXHIBITS B.35 and B.39.
All documentation shall be handed over to COMPANY in the formats and quantities
required by EXHIBITS B.35 and B.39.

EXHIBIT C.1.18
CATHODIC PROTECTION PAGE 11 of 11