HINDUSTAN PETROLEUM CORPORATION LTD

DESIGN BASIS FOR CATHODIC PROTECTION

SYSTEM

BARMER- PALANPUR PIPELINE PROJECT (BPPL)

MECON LIMITED DELHI

(ELECTRICAL SECTION)

Document No. Revision No. Date

MEC/23VE/05/E9/CP/001 0 24.04.2020
© Copyright MECON Limited – All rights reserved.
THIS DOCUMENT IS THE SOLE PROPERTY OF MECON AND ISSUED FOR THE SPECIFIC PROJECT MENTIONED HEREIN. THIS IS NOT TO
BE COPIED OR USED FOR ANY OTHER PROJECTS UNLESS EXPLICITLY PERMITTED BY MECON.
 MECON LIMITED BARMER- PALANPUR PIPELINE
Electrical Section, Delhi
DELHI PROJECT (BPPL)

Basic Engineering Design Basis-Cathodic Protection MEC/23VE/05/E9/CP/001 Page 1 of 15

System

Contents

Sl. No. DESCRIPTION

1. INTRODUCTION
2. SCOPE
3. CODES & STANDARDS
4. SITE CONDITIONS
5. AREA CLASSIFICATIONS
6. POWER SUPPLY DETAILS FOR CP SYSTEM
7. CATHODIC PROTECTION SYSTEM DESIGN
8. PROTECTION OF PIPELINE AT HT LINE CROSSING
9. CP AT CASED CROSSINGS
10. CATHODIC PROTECTION DESIGN CRITERIA
11. CP CABLES
12. STATUTORY APPROVAL
13. DRWINGS AND DESIGN DOCUMENTS
APPENDIX-I : LIST OF ABBREVIATIONS

Rev. No. Date Prepared By Checked By Approved By

Aashis Moyal, M.K.Jaiswara, D.G. Majumder,

0 17.04.2020 Sr.MGR Sr.MGR GM (E&I)
© Copyright MECON Limited – All rights reserved.
THIS DOCUMENT IS THE SOLE PROPERTY OF MECON AND ISSUED FOR THE SPECIFIC PROJECT MENTIONED HEREIN. THIS IS NOT TO BE
COPIED OR USED FOR ANY OTHER PROJECTS UNLESS EXPLICITLY PERMITTED BY MECON.
 MECON LIMITED BARMER- PALANPUR PIPELINE
Electrical Section, Delhi
DELHI PROJECT (BPPL)

Basic Engineering Design Basis-Cathodic Protection MEC/23VE/05/E9/CP/001 Page 2 of 15

System

1.0 INTRODUCTION

HPCL proposes to lay cross country POL pipeline from new Barmer Station in Rajasthan to
existing receiving Palanpur Installation of MDPL in Gujarat.

The project is named as Barmer-Palanpur Pipeline (BPPL) Project.

Salient features of the project are as below:

Originating Point : Barmer Cross Country P/L Station (in HRRL Refinery).

SVs,IPS : Total 4 SVs and 01 IPS.

End Marketing Terminal : Existing Palanpur POL Installation (MDPL)

Products : MS, HSD and SKO

Cross-country PL (18” x 216.3 km approx.) from DT Barmer to RT Palanpur.- (Section I- 18” x

106.8 km approx. ; Section II- 18” x 109.5 km approx.) includes 4 Nos. SV, 1 No. IP Station-
piping & valve station including civil, structural works for SV pit – (cage / fencing)

This document presents design criteria for TCP & PCP system for 3LPE Coate multiproduct
pipeline against corrosion for a service life of 40 years. It indicates minimum requirements for
detailed design of CP system and equipments.

In case of any conflict between the design basis & codes/ standards listed, the same shall be
brought to the notice of Owner/Consultant for final decision, which shall be binding.

2.0 SCOPE

Survey, Design, detailed engineering, supply, packing, transportation to site, installation,

testing and commissioning of the temporary cathodic protection system using Mg/ Zn galvanic
anodes for design life of minimum 2 years or till the commissioning of PCP system whichever
is later, to protect the external surface of 18” NB x 216.3 Kms. (approx.) pipeline from
Despatch Terminal at Barner (Ch 0.00km) to Receiving Terminal at Palanpur (Ch 216.3 km)
against corrosion. ICCP based Permanent Cathodic Protection system is also envisaged for a
service life of 40 years to protect the external surface of Pipeline. TCP & PCP system shall be
designed as per MECON’s standard Specification No. MEC/S/05/E9/016A & 16B for
Temporary & Permanent cathodic protection system respectively & Scope of Work, Data
Sheets & Other relevant standards.

3.0 CODES & STANDARDS

The system design, performance and materials to be supplied shall, unless otherwise
specified, conform to the requirements of the following latest relevant applicable
specifications:

I) NACE Standard SP-0169 : Standard Practice Control of External Corrosion

on Underground or Submerged Metallic Piping
Systems.
 MECON LIMITED BARMER- PALANPUR PIPELINE
Electrical Section, Delhi
DELHI PROJECT (BPPL)

Basic Engineering Design Basis-Cathodic Protection MEC/23VE/05/E9/CP/001 Page 3 of 15

System

II) NACE Publication 10A190 : Measurement technique related to criteria for

CP of Underground or Submerged Steel Piping
System (as defined in NACE Standard RPO169-
83)
III) NACE Standard SP-0177 : Standard Practice Mitigation of Alternating
Current and Lightning Effects on Metallic
Structures and Corrosion Control System.
IV) NACE Standard SP-0186 : Application of cathodic protection for external
surface of steel well casings
V) NACE Standard SP-0286 : Standard Practice the electrical isolation of
Cathodically Protected Pipelines.

VI) NACE Publication No. 54276 : Cathodic Protection Monitoring for Buried
Pipelines
VII) NACE Standard SP-0572 : Standard Practice for Design, Installation &
Operation of Impressed Current Deep Ground
beds
VIII) NACE Standard SP-200 : Standard Practise for Steel Cased Pipeline
Crossings
IX) NACE Standard SP-0104 : The Use of Coupons for Cathodic Protection
Monitoring Applications
X) BS 7361 Part I : Code of Practice for Cathodic Protection for land
and Marine applications
XI) VDE 0150 : Protection against Corrosion due to Stray
Current from DC Installations
XII) IS: 7098 Part I : XLPE insulated cables.

XIII) IS: 1554 Part I & II : PVC Insulated heavy duty electrical cables.

XIV) IS: 8062 : Code of practice for cathodic protection of

steel structures
XV) NACE TM 0497 : Measurement Techniques Related to Criteria
for Cathodic Protection on Underground or
Submerged Metallic Piping Systems
XVI) NACE SP21424 : Alternating Current Corrosion on Cathodically
Protected Pipelines: Risk, assessment,
mitigation & monitoring
XVII) ISO 15589 : Petroleum, petrochemical and natural gas
industries — Cathodic protection of pipeline
systems —Part 1: On‐land pipelines
XVIII) OISD 113 : Classification of Area for electrical installations at
Hydrocarbon processing and handling facilities
XIX) OISD 141 : Cross Country Pipelines
XX) OISD 188 : Corrosion Monitoring of Offshore & Onshore

- A.W. PEABODY- Book on control of pipeline corrosion

3.2 In case of imported equipments standards of the country of origin shall be applicable if these
standards are equivalent or stringent than the applicable Indian standards.

3.3 The equipment shall also confirm to the provisions of Indian Electricity rules and other
 MECON LIMITED BARMER- PALANPUR PIPELINE
Electrical Section, Delhi
DELHI PROJECT (BPPL)

Basic Engineering Design Basis-Cathodic Protection MEC/23VE/05/E9/CP/001 Page 4 of 15

System

statutory regulations currently in force in the country.

3.4 In case of any contradiction between various referred standards/ specifications/ data sheet
and statutory regulations the following order of priority shall govern.

 Statutory regulations.
 Data sheets.
 Schedule of rates.
 Design Basis.
 Scope of Work/ Job specification.
 Standard Specification.
 Codes and standards.

4.0 SITE CONDITIONS

The equipment offered and the installation shall be suitable for continuous operation under
the following site conditions:

Ambient temperature : 55°C/ 2˚C (max./min)

Max relative humidity : 90%
Altitude : less than 1000 m
Atmosphere : To withstand site condition
(Dust storm & High Temperature during summer and Low
temperature during winter)

5.0 AREA CLASSIFICATION

Classification of hazardous area will be in accordance with BIS and IS: 5572.

Following selection will be considered for proper selection of electrical equipment for use in
hazardous area:

a) Area Classification : Zone-1 & Zone 2

b) Gas Group : IIA and IIB

c) Temperature Classification : T3

All electrical equipment installed in hazardous area will be selected as per IS: 5571.

All the electrical equipment for hazardous areas shall be of Ex-d type suitable for temp
classification T3. All electrical equipment for hazardous area will be certified by CMIFR or
equivalent independent testing agency.

6.0 POWER SUPPLY DETAILS FOR CP SYSTEM

For Receiving, Intermediate Pigging & Despatch Terminals, Power supply to CP

system (TR unit)-

i) 230V AC, 50 Hz Supply.

 MECON LIMITED BARMER- PALANPUR PIPELINE
Electrical Section, Delhi
DELHI PROJECT (BPPL)

Basic Engineering Design Basis-Cathodic Protection MEC/23VE/05/E9/CP/001 Page 5 of 15

System

For SV stations, Power supply to CP system (CPPSM unit)-

ii) 48V DC from DCDB Panel.

7.0 CATHODIC PROTECTION SYSTEM DESIGN

7.1 Temporary Cathodic Protection (TCP) system

A. Type Sacrificial

B. Protection to Pipeline (TCP) Immediately after lowering

after lowering
C. Design life 2 Year or till commissioning of PCP
whichever is later
D. Pipeline coating Three Layer Polyethylene

E. Protective current densities As mentioned in Table#1

F. Protective current Density As per specification

G. Anode material (for sacrificial Sacrificial Mg/ Zn (Low Potential as per

CP System) specification).

H. Electrical resistance probes Shall be provided as per specification

a) Quantity of E/R probes 02 nos for each laying section

b) No. of E/R probe 01 nos for each laying section
reading instrument

I. Polarisation cell Solid state type (shall be provided as per

specification/scope of work)

J. Polarisation coupons Shall be provided as per

specification/scope of work

a) Size of exposed area of 25mm x 25mm in housing of 100x100 mm

coupon (as per the requirement of NACE
SP104:2014)

b) No. of coupons & magnetic As per scope of work (Min 1 at every 10

devised with reed switch
KM) and additional locations in corrosion
prone area observed during the soil
survey. Location To be decided by CP
contractor in consultation with Owner/
Consultant
 MECON LIMITED BARMER- PALANPUR PIPELINE
Electrical Section, Delhi
DELHI PROJECT (BPPL)

Basic Engineering Design Basis-Cathodic Protection MEC/23VE/05/E9/CP/001 Page 6 of 15

System

c) Proposed location of E/R To be decided by CP contractor during

probes / Polarisation Coupons detail engineering based on
specifications and in consultation with the
Owner/Consultant

K. No. of test stations At an average distance of 1Km interval

along the pipeline ROW and additional test
stations as per TCP specification. TLP/TS
should be concrete/non-metallic pillar.
L. Surge Arrestor (Spark-Gap Shall be provided at Insulating joints and
type)- Surge arrestor shall be shall be rated for the lightning and surge
suitable for the installation in protection (100kA for -10/350 uS lighting
explosion proof area current and 8/20 uS surge current). There
shall be no joints in Surge diverter cable
across the IJ.
M. Earthing of MOVs All MOVs installed on the cross country
portion shall be double earthed through
zinc anodes so that it will not allow CP
current to drain. Armour of cables of
MOVs installed on the cross country
portion shall be disconnected at MOV end
so that it will not allow CP current to drain.

Note -1 Polarisation coupons shall be installed along with the pipeline

construction activities and coupons OFF PSP shall be taken during the monthly
monitoring of the TCP system.

TCP Pipeline Protection current density

Table#1
Pipeline surrounding Minimum Protection current density*@30
Resistivity deg C
Temporary CP
(µA/m²)
Normal Soil (10-100 40
Ohm-Mtr)
Marshy Area/ HDD (<10 75
Ohm-Mtr)
High Resistivity Area 25
(more than 100 ohm-mtr.
Resistivity)

Pipe to soil "ON" potential shall not be more negative than (-) 1.2V during TCP.

* Actual current density to be adopted shall be decided based upon soil and other
environmental conditions, proximity of foreign pipelines and structures affecting
 MECON LIMITED BARMER- PALANPUR PIPELINE
Electrical Section, Delhi
DELHI PROJECT (BPPL)

Basic Engineering Design Basis-Cathodic Protection MEC/23VE/05/E9/CP/001 Page 7 of 15

System

interference. Where considered necessary for satisfactory protection of pipeline the

current density shall be suitably increased by contractor. Where operating temperatures
of U/G pipeline is above 30 deg. C, such as CP Stations located near Compressor
stations, protection Current Density shall be increased in minimum by 25% for every 10
°C rise in temperature over 30 °C up to a temperature of 60 deg.C.

7.2 Permanent Cathodic Protection (PCP) System

A. Type Impressed current type

B. Design life of protection 35 Years

C. Pipeline coating Three Layer Polyethylene

D. Design protection current As mentioned in Table#2

density

E. Pipeline coating resistance 15000 Ohm-M2 for normal soil.

F. Loop resistance of PCP <01 Ohm

system
G. Type of Anodes for anode Tubular mixed metal oxide titanium tubular
ground bed with individual cable termination in AJB.

H. Anode bed configuration Deep well or Shallow bed (Perpendicular to

Pipeline)
I. Backfill material Carbonaceous back-fill [lubricated calcined
petroleum coke breeze]
J. Polarisation cell Solid state type (shall be provided as per
specification)

K. Permanent Ref Cell Permanent Ref cell for PCP system shall be
high purity zinc type. There shall be min 2
nos. of permanent reference cell
(electrodes) at each CP station
L. Computerized test stations As per scope of work (Location of
(GSM based) computerized test station shall be decided in
detail engineering)
a) No. of computerised test As per scope of work & Location in
station readers / portable data consultation with owner/consultant
collection & storage
instruments.

b) Interval for data acquisition/ Once every day (Refer Note below)
storing
M. Acquisition of land or Lease By Bidder, Installation location shall be
(for 99 years/as per statuary decided by CP system Bidder based on
 MECON LIMITED BARMER- PALANPUR PIPELINE
Electrical Section, Delhi
DELHI PROJECT (BPPL)

Basic Engineering Design Basis-Cathodic Protection MEC/23VE/05/E9/CP/001 Page 8 of 15

System

regulations) for Anode bed, detailed engineering, specification and at

Anode junction boxes and availability of power source & land.
anode ground bed ROU for
cable laying.
N. Chain link fencing around the Shall be provided
ground Bed
O. Close interval potential logging Shall be carried out
survey

P. CAT Survey (Full Length of Shall be carried out including measurement

pipeline) of depth of the buried pipeline

Q. Soil Survey and Chemical Shall be carried out

Analysis

R. Additional tests to be DCVG or CAT with frame ‘A’ survey at Full

conducted for identifying pipe length of pipeline
coating defects/ holidays
S. Coating conductance survey at Shall be carried out at Type B (Current
B type stations & Pipeline measurement test stations installed at every
current mapping 10 KM pipeline and river crossings) and also
calibration of the current measurement test
stations for same thickness pipeline span.
T. AC/DC Interference Detection Shall be carried out through software
& Its Mitigation simulations.
U. Proposed location of CP To be decided by CP Bidder. (However
stations/Anode tentative location of CP station are
mentioned in the Scope of Work, Exact
location shall be decided in detail
engineering & approval of design document
in consultation with Owner/Consultant)*

V. CP stations/ anode ground bed for Impressed current system:-

W. Tentative locations of CP stations are mentioned in Scope of Work, actual numbers

of CP stations shall be finalized during the approval of design documents submitted
by the Bidder, Any other proposed location shall be included during detailed
engineering, if required without any cost implication. However PCP system shall be
designed in such a manner that CP stations & anode bed shall be located
coinciding with SV / IP stations, as far as possible.

* CP stations should be decided in such manner that Odd Number CP station

shall protect the full section whenever the Even number CP station between two
odd number CP station fails / not working. Similarly Even Number CP station shall
protect the full section whenever an Odd number CP station between Two Even
 MECON LIMITED BARMER- PALANPUR PIPELINE
Electrical Section, Delhi
DELHI PROJECT (BPPL)

Basic Engineering Design Basis-Cathodic Protection MEC/23VE/05/E9/CP/001 Page 9 of 15

System

numbers CP station fails / not working. Basis for such calculation, yet again shall
be Theoretical Attenuation Calculations.

PCP Pipeline Protection current density

Table#2
Pipeline surrounding Minimum Protection current density*@30 deg C
Resistivity Temporary CP
(µA/m²)
Normal Soil (10-100 250*
Ohm-Mtr)
Marshy Area/ HDD (<10
Ohm-Mtr)
High Resistivity Area
(more than 100 ohm-mtr.
Resistivity)

* 250μA/m2 is considered in design to take care any bonding/additional mitigation

measures.

Note -2: - For computerized test station: Interval of data acquisition/storing may be
kept for once in every hour. This feature will be helpful for detecting/trouble shooting
in case of encountering any interference. However in normal case, one reading per
day is enough.

8.0 INTERFERENCE STUDY AND MITIGATION PROTECTION OF PIPELINE AT HT

LINE CROSSING

Pipeline Interference study shall be carried out by modeling software’s for short term
and long term interferences for safe touch potentials along with AC corrosion study.
Remedial measures shall be implemented in accordance with codes & standards to
bring down the steady state touch voltage on pipeline below 15V (rms) for safety
reasons. In addition, any AC voltage indicating a current density of 30 mA/m2 or
above (assuming 1 cm2 sized area of holiday / defect) shall be grounded through
solid state DC de-coupling device to reduce the AC corrosion and touch potentials.

Where high voltage (66 KV and above) transmission line runs in parallel or crosses
the pipeline, the pipeline shall be grounded through polarisation cells of suitable rating
(solid state) & Grounding (a continuous length of Zn Ribbon Anodes/Copper
conductors with back fill material shall be laid along the pipeline) shall be done at
regular intervals of maximum 1 km where transmission lines run parallel within 1km of
the pipeline and have separation distance of 50 mtr on both side of the pipeline.
Mitigations resulted from interference study & mitigation report to ground any surges
on the pipeline that would appear in case of transmission line faults shall be
implemented.
 MECON LIMITED BARMER- PALANPUR PIPELINE
Electrical Section, Delhi
DELHI PROJECT (BPPL)

Basic Engineering Design Basis-Cathodic Protection MEC/23VE/05/E9/CP/001 Page 10 of 15

System

If any AC interference is observed along the pipeline due to low voltage electric lines
(below 66kV), its mitigation will be carried out by means of earthing of pipeline through
polarization cell has also been considered.

Interference detection & mitigation due to DC sources (i.e. HVDC transmission lines.
DC traction etc) shall be carried out as per DIN 57150/VDE 0150:Protection against
corrosion due to stray currents from DC installations and other applicable standards.

9.0 CP AT CASED CROSSINGS

a) Casing shall be avoided as far as possible. If cased crossing is unavoidable, Bare

casing is always recommended with selecting higher thickness allowance as per API
1102.
b) Any type of Casing filler conductive or insulating (wax/bentonite etc) shall not be filled
between annular space of casing and carrier.
c) No sacrificial anodes (ribbon anodes) shall be used inside casing & carrier annular
space.

10.0 CATHODIC PROTECTION DESIGN CRITERIA

10.1 Cathodic Protection Design Criteria for Cu/Cuso4 Type Permanent Ref Cell

Cathodic protection system shall be designed to meet the following criteria:

a) The pipe to soil potential measurements shall be between (-) 850 mV (Off) & (-) 1200
mV (Off) polarized potentials with respect to a copper/ copper sulphate reference
electrode.

b) A positive potential swing of 50 mill volts and above shall be considered as sufficient
to indicate the presence of an interaction situation (i.e. Interference on the pipeline)
requiring investigation and incorporation of mitigation measures by the BIDDER.

c) As such there is no limit for maximum "ON" negative potential; however, in general, it
should not be more negative than -2500 mV (Cu/CuSO4). If any special
circumstances exist where an “ON” potential of more than -2500 mV (Cu/CuSO4) is
required to be applied, then it shall be brought forward for Owner/Consultant approval
with proper justification supported by the pipeline coating Manufacturer's
recommendations.

10.2 CATHODIC PROTECTION DESIGN CRITERIA FOR Zn TYPE PERMANENT REF CELL

Cathodic protection system shall be designed to meet the following criteria w.r.t. Zn type
permanent ref cell (Electrode):

i) The pipe to soil potential measurements shall be between (+) 0.266 V (Off) & (-) 0.084 V (Off)
with respect to a Zn/ Zn sulphate reference electrode.
 MECON LIMITED BARMER- PALANPUR PIPELINE
Electrical Section, Delhi
DELHI PROJECT (BPPL)

Basic Engineering Design Basis-Cathodic Protection MEC/23VE/05/E9/CP/001 Page 11 of 15

System

ii) A positive potential swing of 50 mill volts and above shall be considered as sufficient to indicate
the presence of an interaction situation (i.e. Interference on the pipeline) requiring investigation
and incorporation of mitigation measures by the BIDDER.

Note 2: - For computerized test station: Interval of data acquisition/storing may be kept
for once in every hour. This feature will be helpful for detecting/trouble shooting in
case of encountering any interference. However in normal case, one reading per day is
enough.

Note 3: - Zn reference electrode shall be of reputed make and manufactured from High
purity Zn (Hi-Pure Zinc 99.99% ASTM B418-73 Type II).

10.3 Monitoring and Control Signal For SCADA

Digital and analogue signals as required for monitoring of CP system shall be

provided in CPPSM/TR Unit for connection to SCADA system.

CPPSM/TR unit shall be properly interfaced with SCADA RTU through Hardwired link
for various analogue and digital signals. Details of SCADA monitoring signals are
given below-

Sl MONITERING/ ANALOUGE
DESCRIPTION
No. CONTROL /DIGITAL
1 CP TR/CPPSM OUT PUT M AI
VOLTAGE
2 CP TR/CPPSM OUT PUT M AI
CURRENT

3 PIPELINE OVER M DI
PROTECTED

4 PIPELINE UNDER M DI
PROTECTED

5 PIPE TO SOIL M AI
POTENTIAL

6 ALL REFERENCE CELLS M DI

FAILED

7 UNIT WORKING IN AUTO M DI

REF MODE

8 UNIT WORKING IN M DI
MANUAL MODE

9 AC INPUT FAIL M DI
 MECON LIMITED BARMER- PALANPUR PIPELINE
Electrical Section, Delhi
DELHI PROJECT (BPPL)

Basic Engineering Design Basis-Cathodic Protection MEC/23VE/05/E9/CP/001 Page 12 of 15

System

10 Battey Low M DI For CPPSM

Only
11 CURRENT C DO
INTERRUPTER START
12 CURRENT C DO
INTERRUPTER STOP
13 CURRENT C DO
INTERRUPTER RESET

1 AI: Analogue monitoring signal from Equipment to PLC/Telemetry interface cabinet (TIC)
2 DI: Digital Monitoring signal from Equipment to PLC/(TIC)
3 M-Monitoring signal
4 C-Control signal
Control signal shall be provided only for remote operation of the current interrupter.

11.0 CP CABLES

TCP Cables

TCP Cables shall be annealed high conductivity, tinned, stranded copper conductor, XLPE
insulated 650/1100 V grade, armoured/un-armoured, PVC sheathed. The size of the copper
conductor shall be 6 sq mm for anode cable from anode to buried junction box, 10 sq mm
from junction box to test station, 10mm² from test station to pipeline. The size of the
conductor shall be 6 sq mm for potential measurement, 10 sq mm for current measurement
and 25mm² for bonding, polarization cell / grounding cell/Earthing and surge diverter
connection purpose. The anode cable from anode to junction box (buried) shall be
unarmoured. The length of anode tail cable shall be sufficient enough to reach junction box
(buried) in case of temporary CP anodes and up to test station in case of permanent CP
sacrificial anodes. PE Sleeves shall be provided for unarmoured cables.

Note- Underground buried junction box shall be provided only at locations where more
than two (02) nos. of anodes required for the pipeline protection.

PCP Cables

i) MMO Anode tail/lead cable (Size 1Cx10 Sqmm)-

Anode tail/lead cable shall be 1Cx10 Sqmm size, annealed high conductivity tinned stranded
copper conductor (7 Strands), PVDF insulated (Thickness 0.040 Inch), HMWPE
sheathed/Jacket (Thickness 0.065 Inch), un-armoured.

ii) Anode & Cathode Header Cable- (Size 1Cx35 Sqmm)-

Anode & Cathode Header Cable shall be 1Cx35 Sqmm size, annealed high conductivity
tinned stranded copper conductor, XLPE insulated, PVC sheathed, FRLS, 1.1kV Grade
armoured cable as per IS: 7098.

iii) TR/CPPSM Input Power Supply Cable - (Size 3Cx10 Sqmm)-

 MECON LIMITED BARMER- PALANPUR PIPELINE
Electrical Section, Delhi
DELHI PROJECT (BPPL)

Basic Engineering Design Basis-Cathodic Protection MEC/23VE/05/E9/CP/001 Page 13 of 15

System

TR/CPPSM Input Power Supply Cable shall be 3Cx10 Sqmm size, annealed high conductivity
tinned stranded copper conductor, XLPE insulated, PVC sheathed, FRLS, 1.1kV Grade
armoured cable as per IS: 7098 for Single Phase TR Units and 4 core type for 3 phase TR
units.

iv) Measurement cable & Permanent Reference cell tail cable- (Size 1Cx6 Sqmm)-

Measurement cable & Permanent Ref cell tail cable from Pipe/Tank/Bullet/Vessel to CJB &
CJB to TR/CPPSM Unit shall be 1Cx6 Sqmm size, annealed high conductivity tinned stranded
copper conductor, XLPE insulated, PVC sheathed, FRLS, 1.1kV Grade armoured, screened
cable as per IS: 7098 or Multi-core signal cable of suitable pair shall be considered for the
measurement cable & reference cell cable from CJB to TR unit. (For this bidder may consider
8/12 pair, Multi-core, FRLS, 2.5 Sqmm, 8/12 pair, twisted pair, shielded, armoured, signal cables
as per IS/BS).

v) The colour of outer sheath of the cables shall be as per the PJS/Scope of work/Design Basis
and outer sheath should have marking of “CP system Cable” in each one meter interval by
black colour for identification purpose.

vi) The cables for connecting various transducers from TR unit/ CPPSM to telemetry interface
junction box shall be twisted pair with individual pair shielded and overall shielded with
aluminium backed by mylar/polyster tape, PVC sheathed, armoured, PVC over all sheathed
type.

CABLING SYSTEM

Cable laying philosophy

A. Paved area: Cable tray/RCC trench

B. Unpaved area: Directly buried with sand cushioning and brick covered,
warning tape and cable marker.
C. Type of cable trays: Galvanized prefabricated

12.0 STATUTORY APPROVAL

The submission of application on behalf of the Owner to Govt. Authority/ Central Electricity
Authority, if required along with copies of required certificates complete in all respects, shall
be done by the contractor well ahead of time so that the actual commissioning of project are
not delayed for want of approval from authority. The actual inspection of work by the Govt.
inspector shall be arranged by the Contractor and necessary coordination and liaison work in
this respect shall be the responsibility of the contractor. However any fee paid to the Govt.
Authority in this regard shall be reimbursed by the Owner on submission of bills with
documentary evidence.

The Inspection and acceptance of the work as above shall not absolve the Contractor from
any of responsibilities under this contract.

13.0 DRWINGS AND DESIGN DOCUMENTS

13.1 The following documents shall be submitted along with the offer:
 MECON LIMITED BARMER- PALANPUR PIPELINE
Electrical Section, Delhi
DELHI PROJECT (BPPL)

Basic Engineering Design Basis-Cathodic Protection MEC/23VE/05/E9/CP/001 Page 14 of 15

System

a) Filled up data sheet/Checklist.

b) HSE Policy
c) Bar Charts & Project completion schedule
d) QAP
e) Approx. dimensions of the system
f) Catalogues for CP units, MMO & Sacrificial Anodes, polarization cells, spark gap arrestors,
ER Probe, reference cells etc.

13.2 The following drawings (in three sets) & documents shall be submitted for approval within 3
weeks of award of contract.

a) Various Procedures of CP system Installation Like- Soil survey (TCP & PCP), Thermit
weld, Pin Brazing, Sacrificial anode (Zn/Mg/Ribbon) installations, Test stations & Junction
Boxes installation, Cable laying, Installation of polarization cell, External ER probe, Surge
diverter & grounding cell, connection & sealing of sacrificial anode, Earthing of above
ground pipeline, anode ground bed, CP units etc.
b) Soil survey report and chemical analysis report with marked location vulnerable area.
c) QA & QC Procedures.
d) List of two years operation and maintenance spare.
e) Basis of system design and design calculations, equipment selection criteria and sizing
calculations, formulae used
f) Detailed design calculations of TCP & PCP system (Complete Design Package).
g) Equipment layout, Cable layout & schedule.
h) Construction drawing for fencing of anode bed & AJB.
i) Colour code identification for the various CP System cables used in the system
j) Procedures for Various Post commissioning surveys (CPL, CAT, CAT Frame ‘A’ DCVG &
coating conductance etc).
k) Procedure for AC & DC interference detection & mitigation.
l) Procedure for field testing, pre-commissioning & commissioning of TCP & PCP.
m) Procedure for Monitoring & maintenance of CP system.
n) Detailed design of Anode ground bed, typical lay out drawings for Anode bed connection &
installation for CP system.
o) Equipment layout, Cable layout & schedule.
p) TLP’s & junction boxes installation & erection details drawings.
q) Incorporation of Anode bed, Polarisation cell, surge arrester, TLP, Junction boxes & other
relevant feature in CP system design in Alignment sheet, pipeline route diagram & Plot
plan.
r) G.A. of TR/CPPSM unit.
s) Schematic
t) Wiring diagram for reference.
u) Tentative Bill of Material

13.3 After the job completion, contractor shall prepare AS-BUILT drawings/data sheets and
documents, submit catalogues/manuals (O&M) of major brought out items. Final certified as
built drawings, documents and manuals etc shall be submitted by the contractor to owner in
bound volume with one set in soft copy (CD) plus five sets of prints to owner & one set to
MECON..

Other drawings and documents shall be submitted by contractor along with AS-BUILT
Drawings/Datasheets-
 MECON LIMITED BARMER- PALANPUR PIPELINE
Electrical Section, Delhi
DELHI PROJECT (BPPL)

Basic Engineering Design Basis-Cathodic Protection MEC/23VE/05/E9/CP/001 Page 15 of 15

System

a) Original deed OR Lease agreement for acquired/leased land (In favour of M/s HPCL) for Anode
Bed, ROU for cable laying etc shall be handed over to M/s HPCL.
b) Test documents & drawings for bought out items.
c) Detailed commissioning report of pipeline CP system (Both TCP and PCP).

-x-x-x-

APPENDIX – 1

LIST OF ABBREVIATIONS

1) AC –Alternating current
2) CAT –Current attenuation test
3) CJB – Cathode Junction Box
4) CP-Cathodic Protection
5) CPPSM-Cathodic Protection Power Supply Module
6) DCVG –Direct Current Voltage Gradient
7) DC –Direct Current
8) FRLS-Fire Retardant Low Smoke
9) GSM –Global System for Mobile
10) HMWPE – High Molecular Weight Polyethylene
11) MMO–Mixed Metal Oxide
12) NACE- National Association of Corrosion Engineers
13) PCP–Permanent Cathodic Protection
14) PVC – Polyvinyl Chloride
15) PVDF– Polyvinylidene Difluoride
16) ROU – Right Of Use
17) RTU – Remote Terminal Unit
18) TCP–Temporary Cathodic Protection
19) TR- Transformer Rectifier
20) XLPE- Cross Linked Poly Ethylene