PETRONAS TECHNICAL STANDARDS

Cathodic Protection Systems For Onshore and Shore

Approach Pipelines

PTS 11.32.01
January 2019

© 2019 PETROLIAM NASIONAL BERHAD (PETRONAS)

All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form
or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright
owner. PETRONAS Technical Standards are Company’s internal standards and meant for authorized users only.
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FOREWORD

PETRONAS Technical Standards (PTS) has been developed based on the accumulated knowledge,
experience and best practices of the PETRONAS group supplementing National and International
standards where appropriate. The key objective of PTS is to ensure standard technical practice across
the PETRONAS group.

Compliance to PTS is compulsory for PETRONAS-operated facilities and Joint Ventures (JVs) where
PETRONAS has more than fifty percent (50%) shareholding and/or operational control, and includes
all phases of work activities.

Contractors/manufacturers/suppliers who use PTS are solely responsible in ensuring the quality of
work, goods and services meet the required design and engineering standards. In the case where
specific requirements are not covered in the PTS, it is the responsibility of the
Contractors/manufacturers/suppliers to propose other proven or internationally established
standards or practices of the same level of quality and integrity as reflected in the PTS.

In issuing and making the PTS available, PETRONAS is not making any warranty on the accuracy or
completeness of the information contained in PTS. The Contractors/manufacturers/suppliers shall
ensure accuracy and completeness of the PTS used for the intended design and engineering
requirement and shall inform the Owner for any conflicting requirement with other international
codes and technical standards before start of any work.

PETRONAS is the sole copyright holder of PTS. No part of this document may be reproduced, stored
in a retrieval system or transmitted in any form or by any means (electronic, mechanical, recording or
otherwise) or be disclosed by users to any Owner or person whomsoever, without the prior written
consent of PETRONAS.

The PTS shall be used exclusively for the authorised purpose. The users shall arrange for PTS to be
kept in safe custody and shall ensure its secrecy is maintained and provide satisfactory information to
PETRONAS that this requirement is met.
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Table of Contents
1.0 INTRODUCTION ..................................................................................................... 5
1.1 SCOPE ............................................................................................................................ 5
1.2 GLOSSARY OF TERMS..................................................................................................... 5
1.3 SUMMARY OF CHANGES ............................................................................................... 7
2.0 DESIGN REQUIREMENTS ........................................................................................ 8
2.1 DESIGN INFORMATION .................................................................................................. 8
2.2 PROTECTION CRITERIA .................................................................................................. 8
3.0 SITE SURVEYS ...................................................................................................... 10
4.0 ELECTRICAL ISOLATION ........................................................................................ 11
4.1 isolating FLANGES ........................................................................................................ 11
4.2 EARTHING .................................................................................................................... 12
5.0 ELECTRICAL CONTINUITY ..................................................................................... 13
6.0 COATING, DESIGN LIFE AND CURRENT DENSITY REQUIREMENTS.......................... 14
6.1 PIPELINE COATING ....................................................................................................... 14
6.2 DESIGN LIFE ................................................................................................................. 14
6.3 CURRENT DENSITY REQUIREMENTS ............................................................................ 14
7.0 CHOICE OF CATHODIC PROTECTION SYSTEM ........................................................ 15
8.0 IMPRESSED CURRENT CATHODIC PROTECTION (ICCP) SYSTEM ............................. 16
8.1 SOURCE OF DC VOLTAGE ............................................................................................. 16
8.2 GROUNDBEDS .............................................................................................................. 17
8.3 CURRENT CONTROL AND DISTRIBUTION..................................................................... 19
9.0 SACRIFICIAL ANODE CATHODIC PROTECTION (SACP) SYSTEM............................... 20
9.1 ZINC ANODES ............................................................................................................... 21
9.2 MAGNESIUM ANODES ................................................................................................. 21
9.3 CHEMICAL BACKFILL .................................................................................................... 21
9.4 CABLES AND CABLE CONNECTIONS ............................................................................. 21
10.0 MONITORING FACILITIES ..................................................................................... 22
10.1 POTENTIAL MONITORING STATIONS ........................................................................... 22
10.2 FOREIGN PIPELINE BONDING FACILITIES ..................................................................... 22
10.3 TEST FACILITIES AT CASINGS........................................................................................ 22
10.4 TEST FACILITIES AT ISOLATION JOINTS / FLANGES ...................................................... 22
10.5 DRAIN POINT TEST FACILITIES ..................................................................................... 22
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10.6 MISCELLANEOUS MONITORING FACILITIES................................................................. 23

10.7 CABLES, TEST POSTS AND DISTRIBUTION BOXES ........................................................ 23
10.8 PROTECTIVE CASING .................................................................................................... 23
10.9 LIGHTNING PROTECTION ............................................................................................. 23
10.10 SURGE ARRESTOR ....................................................................................................... 23
10.11 MONITORING EQUIPMENT ......................................................................................... 23
11.0 CABLES AND CABLE ACCESSORIES ........................................................................ 25
11.1 CABLES ......................................................................................................................... 25
11.2 ANODE CABLE CONNECTIONS ..................................................................................... 25
11.3 CONNECTION OF CABLES TO THE PIPELINE ................................................................. 25
11.4 TEST POSTS AND DISTRIBUTION BOXES ...................................................................... 27
12.0 DOCUMENTATION............................................................................................... 28
12.1 DESIGN DOCUMENTS .................................................................................................. 28
13.0 BIBLIOGRAPHY .................................................................................................... 29
APPENDIX 1: SPECIMEN COPY OF DATASHEET ................................................................. 30
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1.0 INTRODUCTION

This PTS specifies the minimum technical requirements for the design of cathodic protection
systems for onshore buried pipelines and based on PETRONAS lesson learnt and best
practices.

1.1 SCOPE

1.1.1 This PTS applies for onshore pipeline system and shore approach section.

1.2 GLOSSARY OF TERMS

1.2.1 General Definitions of Terms and Abbreviations

Refer to PTS 00.01.03 for PTS Requirements, General Definition Of Terms, Abbreviations &
Reading Guide.

1.2.2 Specific Definition of Terms

No Term Definition

1 "OFF" Potential Pipe to soil potential taken prior to the

decrease of pipeline polarization once the
cathodic protection system is switched off and
the electrical current stops flowing to pipeline
surface.

2 "ON" potential Pipe to soil potential taken during the

operation of cathodic protection system.

3 “Instant- “OFF” Potential Instant-OFF potential measured with a short

delay after interruption with the aim of
approaching as much as possible the IR-free
potential.

A typical delay for direct measurements on

pipeline is about 300 ms to prevent the
influence of voltage spikes. On coupons,
shorter delays are used.

4 Cathodic Protection system All active and passive components associated

with the provision of active external corrosion
protection and its monitoring.

Cathodic protection is obtained either by

impressed current or by galvanic anodes using
one or more stations.

Impressed current and galvanic anode systems

consist of all the equipment necessary for the
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No Term Definition
application of cathodic protection, such as
impressed current stations, galvanic anodes,
bonds, and isolating joints.

5 Current Density Cathodic protection current per unit of bare

metal surface area of pipeline.

6 Drain Point Point of connection of the anode sled to the

pipeline.

7 Electrolyte A chemical substance containing ions that

migrate in an electric field. For the purposes of
this standard, “Electrolyte” refers to the soil or
liquid adjacent to and in contact with an
underground or submerged metallic piping
system, including the moisture and other
chemicals contained therein.

8 Foreign Structures/Pipelines Metal objects i.e. structures, pipelines, and

debris etc, located adjacent to the pipeline with
cathodic protection which present in the same
electrolyte and may cause interference to the
existing cathodic protection system.

9 Groundbed Buried or submerged electrodes system that

conduct the required current to protect the
steel surface through the electrolyte.

10 Midpoint The point on pipeline with generally lowest

protection level, located between two cathodic
protection station and the influence of both
stations on the point are expected to be equal.

11 Natural Potential Pipe to soil potential taken without the

application of cathodic protection system.

12 Pipe to Soil Potential Electrochemical potential difference between a

pipeline and a reference electrode in contact
with the electrolyte.

13 Pipeline Pipeline(s) and associated equipment to be

covered under cathodic protection design
contract.

14 Polarization Pipe to soil potential difference caused by

electrical current flow between electrolyte and
a steel surface.
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No Term Definition

15 Polarization Cell (Kirkcell) An electrochemical device that shunt hazardous

voltages to ground in case of installations not
grounded via metal conductors.

16 Reference Electrode An electrode that used as a reference for pipe to

soil potential measurements.

17 Stray Currents Current flow in the electrolyte that does not

originate from the cathodic protection system
designed to protect the pipeline.
Table 1.1: Specific Definition of Terms

1.2.3 Specific Abbreviations

No Abbreviations Description

1 AC Alternating Current

2 Ag/AgCl Silver/Silver Chloride type of reference

electrode

3 Cu/CuSO4 Copper/Copper Sulphate type of reference

electrode

4 DC Direct Current
Table 1.2: Specific Abbreviations

1.3 SUMMARY OF CHANGES

This PTS 11.32.01(January 2019) replaces PTS 11.32.01 (June 2015).

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2.0 DESIGN REQUIREMENTS

2.1 DESIGN INFORMATION

2.1.1 The Owner shall submit all the technical information required for cathodic protection design
to the Contractor which shall include but not limited to items below:

i. Pipeline details i.e. length, size, type of coating, intended protection scope.

ii. Intended cathodic protection design life.

iii. Cathodic protection system requirements and/or materials.

iv. Pertinent drawings i.e. pipeline route, existing systems, crossings, casing and
foreign structures/pipelines.

v. Existing CP system design records including inspection and maintenance (if any)

vi. Environmental and operating conditions

2.2 PROTECTION CRITERIA

"Instant-OFF" POTENTIALS, mV
REFERENCE ELECTRODE :
Cu/CuSO4 Ag/AgCl/ seawater

Protection potential for steel -850 -800

aerobic
in environment
Protection potential for steel -950* -900
in
anaerobic environment
Overprotection limit for -1150 -1100
carbon
steel
Table 2.1: Potential Limits for Cathodic Protection of Pipelines
NOTE(S):
i. Cu/CuSO4 reference is used for pipelines in soil,
ii. Ag/AgCl/seawater reference is used in seawater.
iii. In this specification the pipe-to-soil potential is used as a criterion for effective cathodic protection.
iv. *The more negative protective potential to be considered for anaerobic environment in case to case basis.

2.2.1 The "Instant-OFF" potential on all parts of the pipeline shall be equal to or more negative than
the protection potential value stated in Table 2.1 fo the pipeline to be considered fully
cathodically protected.

2.2.2 The "OFF" potentials for carbon steel shall not be more negative than the overprotection limit
value as stated in Table 2.1 to avoid detrimental effects on the applied coating or on the
pipeline due to overprotection.
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2.2.3 The protection criteria for corrosion resistant steel and some high strength steel pipelines
shall be determined by taking into account the material susceptibility to hydrogen induced
stress cracking. This shall include cathodic protection design for pipeline crossing or
approaching another pipeline made of such materials.

2.2.4 Presence of active sulphate reducing bacteria in anaerobic soil shall be confirmed via soil
investigation to determine the imminent protection for anaerobic environments.
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3.0 SITE SURVEYS

A site survey shall be carried out prior to execution of cathodic protection design. The site
survey shall collect the following data but not limited to;

i. General Terrain Description

ii. Resistivity of Soil

iii. Soil Investigation

iv. Current Drainage Test

v. Stray Currents

Seasonal changes shall be taken into consideration if the surveyed area is affected and
different seasonal condition surveys shall be performed if possible. The worst case out of the
surveys shall be taken as the basis for the design.
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4.0 ELECTRICAL ISOLATION

Electrical isolation preferably using MIJ shall be provided to separate pipeline cathodic
protection system from other plant, foreign structures/pipeline and electrical and instrument
earthing systems.

Isolation joint/flange may also be used and shall be installed above ground or in inspection
pits; and shall not be buried. Each isolation joint/flange shall be provided with test facilities.

The isolation joint/flange shall be equipped with earthing or surge arrestors in areas with risk
of high voltages presence on the pipeline i.e. due to adjacent power systems or lightning.

Locations for isolation joint/flange should be as follows:

i. At both extremities of a buried section of pipeline;

ii. At branch lines;

iii. Between pipeline sections with different external coating systems;

iv. Between pipeline sections running in different types of electrolyte (e.g. river
crossings) and/or different method of installation (e.g. HDD for river crossings,
highway crossings, railway crossings etc.);

v. In areas of high telluric activity.

Unless running in the same trench and having the same coating system, parallel pipelines shall
be electrically isolated from each other.

Pipelines should avoid touching or near any metal; and should be electrically isolated from
pipe supports.

Safety or instrument earthing shall be compatible with the cathodic protection system.

For design of Isolation joint refer to PTS 11.31.05 - PIPELINE ISOLATING JOINTS
(AMENDMENTS/SUPPLEMENTS TO MSS SP-75)

For design of Isolation spool refer to PTS 11.31.05 - PIPELINE ISOLATING JOINTS
(AMENDMENTS/SUPPLEMENTS TO MSS SP-75)

4.1 ISOLATING FLANGES

4.1.1 Raised face or full face flanges should use insulating gasket of neoprene coated phenolic resin
type. Sleeve and washer shall be made from phenolic resin or equivalent.

4.1.2 Both sides of the bolts shall be insulated with full length phenolic or composite sleeves and
phenolic resin insulating washers and steel washers.

4.1.3 Prior to welding onto the pipeline, isolating flanges should be assembled and tested. The
isolating flange shall withstand a voltage of 1500 volt DC across the flange assembly for one
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minute without causing breakdown of the insulation or flash over. The resistance across the
assembled flange shall be taken successively and shall read higher than 1 MΩ.

4.1.4 With the exceptional of sour service condition, flange protectors or protective tape shall be
applied to protect isolating flange from dirt and moisture ingress.

4.2 EARTHING

4.2.1 Cathodic protection system for pipeline shall be electrically isolated from common or plant
earthing system to prevent current leakage.

4.2.2 Electrical safety earthing application shall be made compatible with the cathodic protection
systems as per following requirements:

i. Installation of polarization cells or diode circuits.

ii. Suitably specified and rated for the purpose.

iii. Install in the earthing circuit or by the installation of separate earthing electrodes.

iv. Made of zinc or galvanized steel.

v. Buried in low resistivity backfill.

vi. No direct continuity with other earthing systems.

4.2.3 For the purpose of mitigating the AC induced voltages such as pipeline in parallel with
transmission line, earthing should be installed at the following locations:

i. Anticipated or measured highest voltages to the ground.

ii. Exposed pipeline.

iii. Pipeline accessible by personnel.

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5.0 ELECTRICAL CONTINUITY

Isolation joints installed at coating/electrolyte changes shall always be bonded at test posts;
to keep the pipeline electrically continuous when the cathodic protection is operational.

For non-welded pipeline applications, the continuity of the cathodic protection shall be
maintained and shall be tested i.e. by carrying out overlapping potential measurements. This
can be ensured by erection of permanent bonds over high resistance flanges/couplings, using
cables and approved attachment methods.
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6.0 COATING, DESIGN LIFE AND CURRENT DENSITY REQUIREMENTS

6.1 PIPELINE COATING

6.1.1 The appropriate design parameters for each coating type shall be used in the design in case
of adjacent structures having different type of coatings or significant difference in coating
condition. Pipeline isolation shall be provided should the interference is expected.

6.2 DESIGN LIFE

6.2.1 Unless stated otherwise by the Owner, the cathodic protection system shall be designed for
the pipeline design life.

6.3 CURRENT DENSITY REQUIREMENTS

6.3.1 The minimum current density design values shall be based on Table 3 from ISO 15589-1.

6.3.2 A current drainage test shall be carried out to determine the current requirement for existing
pipelines, where the actual condition of the applied coating is unknown.

6.3.3 The higher of the two values computed by above methods; pipeline current demand and
current drainage test, shall be used as the cathodic protection system capacity.
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7.0 CHOICE OF CATHODIC PROTECTION SYSTEM

By means of requisition, the type of cathodic protection system shall be indicated. In case not
specified, the type of cathodic protection system shall be proposed by the Contractor with his
justification included in the basic design.

The selection criteria should be considered as follows:

i. Soil resistivity

ii. Total current demand

iii. Economic considerations

iv. Presence of stray currents

v. Availability of power supply

vi. Site layout

vii. Presence of other conductors

viii. Maintenance

ix. Possibility to use existing Owner owned cathodic protection systems.

Impressed current shall be used if the above criteria do not clearly justify one particular
system.
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8.0 IMPRESSED CURRENT CATHODIC PROTECTION (ICCP) SYSTEM

8.1 SOURCE OF DC VOLTAGE

DC power source maximum output voltage shall be 50 volts.

8.1.1 Transformer/rectifiers

i. Transformer/rectifiers shall comply with IEC 146.

ii. Transformer/rectifiers shall be of a special design for cathodic protection service

and should be 3-phase units if available.

iii. Transformer/rectifiers shall be fit to operate under the normal service conditions.
The output voltage shall be adjustable from zero to the maximum rated output
when on load. Tapping switches shall be front-mounted; if required, with a step-
size of maximum 3% of maximum output. Transformer tapping using relocation
of jumpers shall not be used.

iv. Transformer/rectifiers shall not be installed in the same cathodic protection

circuit whether in series or in parallel.

v. The rectifier shall be fabricated to provide full wave rectification using high
current density selenium cells or silicon diodes. The current rating of the diodes
shall be higher than 1.25 times the maximum current rating of the rectifier and
have a minimum peak inverse voltage of 1200 V.

vi. The output rms ripple current shall not exceed 5% of the DC output current
between 5% and 100% of the rated current output.

vii. The transformer/rectifier shall consist of an isolator or Moulded Case Circuit

Breaker (MCCB) on its incoming circuit and, where appropriate, on its AC sub-
circuits. Additionally, the transformer/rectifier’s phase AC sub-circuits and the
negative DC output circuits shall be installed with suitably sized fuses (type gG to
IEC 269).

viii. The transformer/rectifier shall be able to withstand a short circuit of up to 15

seconds duration at the output terminals without damaging any of its devices.

ix. Meters of approximately 70mm diameter or similarly sized square pattern meters
with measuring accuracy better than 2% of full scale shall be provided to the
transformer/rectifier to read the output voltage and current.

x. The polarity of the DC terminals and AC supply terminals shall be clearly marked.
AC and DC cables shall be separated by an insulating panel.

xi. Unless otherwise stated, a built-in timer unit shall be required. The timer unit shall
be capable of switching the full output current in a sequence of 50 seconds on
and 10 seconds off and may be mechanical or electronic. All transformer/rectifier
timer units should be provided with a facility for synchronous switching in the
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event that a pipeline system is cathodically protected by more than one

transformer/rectifier. The timer shall be bypassed during normal operation.

xii. The incoming cables shall terminate in separate non oil filled cable boxes and
penetration into the tank shall be via bushings above oil level for an oil cooled
transformer/rectifier. A sight glass and thermometer shall be provided.

xiii. Transformer/rectifiers should be installed in a non-hazardous area. If this is

unlikely, the construction of the rectifier units shall fulfill the requirements of the
site hazardous area classification. The Owner shall provide the required
information on area classification to the Contractor.

xiv. The enclosure shall have a minimum degree of protection IP 54 in accordance with
IEC 529, if installed outdoors.

8.2 GROUNDBEDS

8.2.1 The groundbed of an impressed current cathodic protection system shall be designed such
that:

i. Its mass and quality is sufficient to last for the design life of the system.

ii. Its resistance to earth allows the maximum predicted current demand to be met
at 80% or less of the voltage capacity of the DC source during the design life of
the system.

iii. Its location is remote from the pipeline and any other buried structure, to provide
a regular distribution of current along the pipeline.

iv. The risk of causing harmful interference on other buried structures is minimized.

8.2.2 The selection of the location and the type of groundbed shall depend on local conditions such
as:

i. Soil conditions and resistivity at various depths.

ii. Groundwater levels and resistivity.

iii. Strong seasonal changes in surface soil conditions.

iv. Available terrain (for surface groundbeds).

v. Risk of shielding (especially for parallel pipelines).

vi. Risk of damage by excavation (surface groundbeds).

8.2.3 Deepwell groundbeds

Deepwell groundbeds should be used:

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i. If the soil conditions at the required depth are suitable to meet the requirements
in subsection 8.2.

ii. If there is a risk of shielding by other pipelines or buried structures.

iii. If the available space is limited.

iv. If there is a risk of stray currents on adjacent installations.

8.2.4 The Contractor shall include and specify information below in his basic design:

i. Groundbed resistance calculation using established methods and formula, based

on the most accurate soil resistivity data available.

ii. Deepwell drilling method.

iii. Soil resistivity establishment at depth.

iv. Borehole completion.

v. Anodes installation method.

vi. Backfilling.

Metallic casing (such as steel, iron or aluminium) may be used if the casing does not result in
undesirable current discharge at or near ground level. However, metallic casing should not be
used opposite anodes in open hole deep anode beds. Casing at depth shall be electrically
isolated from metal casing and structures at the surface. Non-metallic casing (such as cement,
thermoplastics or reinforced thermosetting materials) may be used to prevent current
discharge at or near ground level.

To prevent gas blocking of the well, adequate venting pipes shall be provided to the deepwell
groundbeds. The vent pipe shall be of chlorine resistant material. Vent pipe blockage by coke
backfill shall be avoided using filter gravel. The vent pipe should be carried to a sufficient
height to prevent damage to surrounding equipment and intrusion of surface water.

8.2.5 Surface groundbeds

Shallow surface groundbeds should be used:

i. If the soil conditions at the proposed groundbed depth, are suitable to meet the
requirements in subsection 8.2.

ii. If sufficient distance from the pipeline can be achieved and there is no risk of
shielding.

The anodes or the highest point of the carbonaceous backfill shall be not less than 1 metre
below ground level.
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8.2.6 Impressed current anodes and backfill

Anode material shall be selected from:

i. Graphite.

ii. High silicon iron /chromium alloy.

iii. Magnetite.

iv. Metal oxide plated metal.

v. Platinised titanium/niobium.

Unless the ground conditions dictate otherwise, a carbonaceous backfill or other low
resistivity backfill material shall be used.

For the purpose of measuring anode current outputs, individual anode circuits shall be
provided with shunts.

8.3 CURRENT CONTROL AND DISTRIBUTION

8.3.1 Current control

i. An individual negative connection shall be provided for each pipeline.

ii. If required, variable resistors shall be installed in the negative drain circuit to
balance the current to each of the adjacent pipelines. An appropriately sized
shunt and diode shall be provided at the DC source for each of the negative circuit.

iii. A distribution box for all cables, diodes and current measurement facilities shall
be installed.

8.3.2 Automatic potential control

By the means of requisition, the DC voltage source shall be provided with automatic potential
control. The suitable permanent reference electrode shall be buried close to the pipeline to
achieve this.

The potential measuring circuit shall have a minimum input resistance of 100 MΩ. The control
system shall have an accuracy of 10 millivolts and shall be provided with adjustable voltage
and current limiting circuits and/or alarms to protect the pipeline against overprotection in
case of failure of a reference cell. A panel mounted meter to read the pipe-to-soil potential
shall be provided.

8.3.3 Cables

All cables, cable connections and cable accessories shall be in accordance with section 12.
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9.0 SACRIFICIAL ANODE CATHODIC PROTECTION (SACP) SYSTEM

The use of a SACP system may be considered:

i. If the pipeline (section) runs in low resistivity soil, water, swamps or marshes.

ii. On short pipeline sections, for economic reasons.

iii. If no power for impressed current is available.

iv. For temporary protection on newly laid pipelines.

v. For temporary protection of existing pipelines, if pipeline isolation cannot be

immediately installed.

vi. If it can be assumed that maintenance of electrical equipment associated with

and Impressed current system cannot be carried out by the operator.

vii. For localised (hot-spot) protection to supplement impressed current systems.

If cathodic protection by sacrificial anodes is selected, the Contractor shall prove by

measurement and calculation that:

i. The resistivity of the soil is sufficiently low to allow successful application of

sacrificial anodes.

ii. The selected type of anode is capable of continuously supplying the maximum
current demand.

iii. The total mass of anode material is sufficient to supply the required current during
the design life of the system.

The anodes should be buried in low resistivity chemical backfill to obtain the required output.

The Manufacturer/Supplier of sacrificial anodes shall supply anodes which are clearly marked
with the type of material (trade name), anode weight (without backfill), and charge number.
The supplier shall provide full documentation of number, types, weight, dimensions, chemical
analysis and performance data of the anodes.

The anodes shall be inspected for mechanical damage, casting quality and the bonding of the
anode core/cable.
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9.1 ZINC ANODES

9.1.1 Zinc anodes can be considered if the resistivity of the electrolyte is 5000 ohm.cm.

9.1.2 For non-standard applications (e.g. high temperature) special alloys may be used which shall
be approved by the Owner.

9.2 MAGNESIUM ANODES

9.2.1 Magnesium should not be used if the resistivity of the electrolyte is higher than 10000
ohm.cm.

9.2.2 The use of chemical backfill around buried anodes shall be used to increase current output
and to avoid passivity.

9.2.3 For special applications (e.g. high output in high resistivity soil) special alloys may be used,
which shall be approved by the Owner.

9.3 CHEMICAL BACKFILL

9.3.1 Backfill for sacrificial anodes shall consist of a mixture of gypsum, bentonite clay and sodium
sulphate. The ratio of the components shall be such to obtain optimum results in the
prevailing resistivity and soil wetness.

9.3.2 The supplier shall include the composition of the backfill material in the anode
documentation.

9.4 CABLES AND CABLE CONNECTIONS

9.4.1 All cables, cable connections and cable accessories shall be in accordance with section 12.
Sacrificial anode cables shall be connected to the pipeline via a bondbox and shunts to allow
anode current monitoring.

9.4.2 For magnesium anodes it should be allowed to install a resistor in the anode circuit to limit
the protection levels to within the protection criteria.
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10.0 MONITORING FACILITIES

The contractor shall include in his design sufficient monitoring facilities to ensure effective
survey of the level of the cathodic protection along the pipeline. The minimum requirements
for monitoring facilities are given below.

10.1 POTENTIAL MONITORING STATIONS

10.1.1 To monitor pipe to soil potentials, test posts shall be installed at distances of maximum 1000m
along the pipeline. In urban or industrial areas, a closer distance (maximum 200m) should be
taken. At least one test post shall be installed between major obstacles such as waterways,
main roads and railways to allow unobstructed close interval potential surveys.

10.1.2 Two separate cables shall be attached to the pipeline and terminated in the test post.

10.1.3 If pipelines are running in parallel regardless in the same trench or not, each pipeline shall be
provided with separate potential monitoring facilities. Test posts should be installed not more
than 2.5m away from the pipeline.

10.2 FOREIGN PIPELINE BONDING FACILITIES

At crossings with foreign pipelines, a bonding facility shall be provided, consisting of two
separate cables attached to each individual pipeline, terminating in a test post with suitable
facilities to install direct or resistive bonds. The cables to each pipeline shall be identified by
colour coding or tags.

10.3 TEST FACILITIES AT CASINGS

10.3.1 If the casing is longer than 10 metres, a test facility shall be installed at both ends of the casing.
Shorter casings shall be provided with a test facility at one end only.

10.3.2 In each test facility, one test cable shall be connected to the pipeline and, if a steel casing is
used, one test cable shall be connected to the casing. Both cables shall be terminated in one
test post.

10.4 TEST FACILITIES AT ISOLATION JOINTS / FLANGES

10.4.1 At all isolation joints/flanges, two cables shall be connected to each side of the joint or flange.
All cables shall be separately terminated in one test post with suitable facilities to install direct
or resistive bonds.

10.4.2 The cables to each side of the isolation joint shall be identified by colour coding or tags.

10.5 DRAIN POINT TEST FACILITIES

10.5.1 At the drain points each negative connection to the pipeline shall be provided with current
measurement facilities. Where multiple negative connections are installed separate shunts
and blocking diodes shall be provided, installed in a distribution box.
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10.5.2 At the drain point a potential monitoring station shall be installed; except on an above ground
section of the pipeline, using a separate test cable connected to the pipeline for the
measurement of the drain point potential.

10.6 MISCELLANEOUS MONITORING FACILITIES

The Contractor should propose other test facilities which he considers necessary for cathodic
protection monitoring. Such test facilities may include in-line current measurement facilities,
buried polarization coupons, etc.

10.7 CABLES, TEST POSTS AND DISTRIBUTION BOXES

All cables, test posts and distribution boxes shall be designed and installed in accordance with
section 12.

10.8 PROTECTIVE CASING

Pipeline casing is not recommended due to interference and shielding of CP current.

10.9 LIGHTNING PROTECTION

Surge arrestors shall be installed across isolation joints/flanges and across the output
terminals of DC voltage sources.

10.10 SURGE ARRESTOR

10.10.1 Surge arrestors required to prevent elevated voltages due to faults in adjacent electrical
power systems or lightning shall be of the spark gap type and shall be designed such that:

i. The impulse breakdown voltage of the electrodes is lower than that of the
isolation joint across which they are mounted.

ii. The spark gap is capable of discharging the expected lightning currents without
sustaining damage.

iii. The spark gaps are fully encapsulated to prevent sparks in open atmosphere and
to protect the spark gaps from moisture.

10.11 MONITORING EQUIPMENT

10.11.1 For regular monitoring of cathodic protection systems the equipment to be used shall meet
the following requirements:

i. Portable voltmeters to measure DC voltages of cathodic protection equipment

shall have an accuracy of no worse than 1% of the voltage to be measured.

ii. In-line current meters shall not be used except for trouble shooting. Cathodic
protection currents shall be measured using fixed shunts or resistors or clamp-on
current probes.
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iii. Voltmeters and other monitoring equipment used to measure pipe to soil
potentials shall have an accuracy of better than 5 millivolts and shall have an input
resistance of at least 100 MΩ.

iv. Data loggers used to monitor pipe to soil potentials over prolonged periods shall
have an input resistance of at least 100 MΩ (also in a "dormant" mode, otherwise
shall be disconnected from the pipeline or reference electrode while the data
logger is in the "dormant" mode, e.g. by an automatic relay switch).

v. Cu/CuSO4 reference electrodes shall be used in combination with soil and fresh
water.

vi. Ag/AgCl/seawater reference electrodes shall be used in combination with saline

waters (e.g. seawater).

vii. Zinc reference electrodes shall only be used as permanent reference electrodes
in combination with soil and seawater.

viii. Reference electrodes shall be constructed such to avoid polarization of the

electrodes during monitoring in combination with the used voltmeters.

ix. Permanent reference electrodes shall be buried in moisture retaining backfill to

ensure their functioning during the design life under the prevailing conditions.
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11.0 CABLES AND CABLE ACCESSORIES

11.1 CABLES

11.1.1 All cables shall be single core stranded copper cables, suitable for DC use and shall be double
insulated and sheathed to withstand the prevailing chemical and mechanical (soil) conditions.
The minimum cable size shall be 6 mm2.

11.1.2 All cables shall be sized such that no excessive voltage drops occur which reduce the capacity
of the system.

11.1.3 Resistance of anode cables may be used to balance the output of different anodes or
groundbeds. The detailed design shall give calculations to support this design detail.

11.1.4 In industrial or urban areas armoured cables should be used.

11.1.5 All cables shall be laid without coils or kinks, buried in soft sand at a depth of at least 0.5m,
provided with cable protection tiles or warning tape as considered suitable for the area.

11.1.6 All buried cables shall be of one continuous length without splices. Cable to cable connections
should be made above ground inside distribution boxes to reduce the risk of damage and to
allow monitoring.

11.1.7 Cable routes shall be clearly marked using cable markers. These should be installed at
approximately 100 metre intervals and at every change of direction of the cable route.

11.2 ANODE CABLE CONNECTIONS

11.2.1 Minimum anode cable size shall be 10 mm2. Cable connections shall be insulated using epoxy
resin and/or heat shrinkable insulation sleeves.

11.2.2 The cables of impressed current anodes shall be connected to the positive feeder cable inside
an above ground distribution box to enable current monitoring. The cables of sacrificial
anodes shall be connected to the pipeline via an above ground distribution box to allow
current monitoring and disconnection.

11.3 CONNECTION OF CABLES TO THE PIPELINE

11.3.1 General

i. The connections of cables to the pipeline shall be designed to ensure adequate

mechanical strength and electrical continuity and to prevent damage to the
pipeline.

ii. The Contractor shall include in the design detail procedures of processes to be
used for cable connections. The detail procedures shall be approved by Owner.
Welders shall be fully qualified for the applicable welding process.

iii. Welding of cable connections shall not be carried out on bends or within 200mm
from welds.
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iv. All below ground electrical connections shall be fully encapsulated to comply with
the original coating standards before backfilling.

v. The following guideline for the selection of cable connections shall be followed:
a) Drain cables shall be connected using welding or studwelding.
b) Bond cables shall be connected using welding, studwelding or pinbrazing.
c) Potential measuring cables shall be connected using any of the referred
methods.

11.3.2 Welding

i. A metal plate, 50x50mm minimum, provided with a welded M10 threaded stud
bolt, shall be welded to the pipeline by two continuous welds in the
circumferential direction of the pipe only. The plate shall be made of the same
material as the pipeline.

ii. The cables shall be connected to the threaded studbolt using crimped or brazed
cable lugs, nuts and serrated washers.

11.3.3 Stud welding

i. Stud welding may be done using an electrical (resistance welding) or mechanical

(friction welding) process which shall be approved by the Owner.

ii. The stud material and consumables shall be compatible with the pipeline
material. The process shall not influence the pipeline material properties to fall
outside the original specifications.

iii. The size of threaded studs shall be 8mm or more to suit the cable size. The cables
shall be connected to the stud using crimped or brazed cable lugs, nuts and
serrated washers.

11.3.4 Pinbrazing

i. The pinbrazing process shall use specially designed cable lugs and brazing pins to
braze the cables to the pipeline and shall be approved by the Owner.

ii. The brazing materials shall be compatible with the pipeline material. Penetration
of copper and/or other brazing metals into the pipeline shall not be deeper than
1mm and the hardness shall remain inside the original pipeline requirements.

iii. Pinbrazing shall not be used on austenitic stainless steel and duplex stainless steel
pipelines.

11.3.5 Thermit welding (Cadwelding)

i. Thermit welding process shall be such that copper penetration into the pipeline
material shall not be deeper than 1mm and that the hardness shall remain inside
the original pipeline requirements.
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ii. Thermit weld charges shall not be greater than 15 grams and cable cores shall not
be heavier than 16mm2. If heavier cables need to be attached, the core shall be
separated into smaller strands of less than 16mm2 each and welded separately.

iii. Thermit welding shall not be used for austenitic stainless steel and duplex steel
pipelines.

11.3.6 Glued connections

Where welding, brazing or thermit welding is not possible, e.g. for safety reasons, the
Contractor may design glued electrical connections using metal plates bonded with electrically
conductive epoxy resin. This method shall not be used for current carrying cables (drain
cables, bond cables). The materials to be used and the installation procedure shall be
approved by the Owner.

11.4 TEST POSTS AND DISTRIBUTION BOXES

11.4.1 If installed above ground they shall be provided with lockable access doors or caps, or have
external insulated contacts fitted, to allow easy connection of test clips for regular monitoring.
Cable entry shall be at the bottom through protective tubes.

11.4.2 If test stations are required to be installed underground, they shall have adequate water
drainage facilities and they shall be provided with a closure to avoid ingress of dirt.

11.4.3 Distribution boxes shall always be installed above ground and shall be provided with hinged
doors giving access to all internal components.

11.4.4 Distribution boxes shall be weatherproofed in accordance with the minimum degree of
protection IP 54 in accordance with IEC 529.

11.4.5 Test posts and distribution boxes shall be accessible during all seasons and shall be designed
such that they are not prone to vandalism or damage.

11.4.6 Distribution boxes and test posts used for bonding of current carrying cables (including bonds
between pipelines/structures or across isolation joints) shall be located outside hazardous
areas. If this is not possible, a box approved for the relevant area classification shall be used.

11.4.7 The Contractor shall propose the type of test post and distribution box for each application in
the detail design.
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12.0 DOCUMENTATION

12.1 DESIGN DOCUMENTS

12.1.1 The basic design documents shall be submitted for approval by the Owner, covering the
following requirements:

i. Results of any site surveys and soil investigations that have been carried out.

ii. Results of any current drainage tests that have been carried out for retrofitting on
existing pipelines.

iii. Any requirements for modifications to existing pipeline systems such as electrical
separation or coating repair.

iv. Justification of the selected cathodic protection system and anode materials if the
choice is made by the Contractor.

v. Calculations of current requirement, pipeline attenuation, resistance and current

output of groundbeds.

vi. A summary of the used formulae and standards.

vii. A schematic diagram of the proposed cathodic protection system.

viii. A list of the estimated number and types of cathodic protection monitoring
facilities.

ix. Any sensitivities in the proposed cathodic protection system that requires special
attention.

x. Any other information that is regarded by the Contractor as essential for this stage
of the cathodic protection design.

12.1.2 The detailed design documents shall be submitted to the Owner for approval before
construction starts and shall cover the following requirements:

i. A schedule of materials.

ii. A complete set of design drawings.

iii. Installation procedures.

iv. Commissioning procedures.

v. Operation and maintenance instructions.

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13.0 BIBLIOGRAPHY

In this PTS, reference is made to the following Standards/Publications. Unless specifically

designated by date, the latest edition of each publication shall be used, together with any
supplements/revisions thereto:

PETRONAS TECHNICAL STANDARDS

Index to PTS PTS 00.01.01
PTS Requirements, General Definition of Terms, Abbreviations & PTS 00.01.03
Reading Guide
Index to Requisitions PTS 00.11.03
Pipeline Isolating Joints PTS 11.31.05

INTERNATIONAL STANDARDS
Semiconductor convertors IEC 146
Degrees of protection provided by enclosures (IP code) IEC 529
Petroleum, petrochemical and natural gas industries — Cathodic ISO 15589-1-2015
protection of pipeline systems — Part 1: On-land pipelines
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APPENDIX 1: SPECIMEN COPY OF DATASHEET

A specimen copy of sheet 1 of the data/datasheetsheet(s) is shown below. The latest revision of this
sheet (and its continuation sheet) shall be used and can be found in the Requisitioning binder (PTS
00.11.03).

PROJECT NAME:
DATASHEET FOR DESIGN OF CATHODIC PROTECTION SYSTEM FOR
ONSHORE BURIED AND SHORE APPROACH PIPELINES PROJECT NO:

ORDER/ENQUIRY NO:

A PIPELINE DATA
1 Pipeline Name/Code:
2 Pipeline Route:
3 Product(s) Transported: Sour Service
4 Years of Construction:
5 Design Life: years
6 Pipeline Length: m
7 Nominal Diameter: inches
8 Pipeline Material
9 External Coating:
10 Backfill Type:
11 Route Characteristic:
12 Branch Lines (use separate datasheet for each branch lines):

13 Attached Drawings:

B CATHODIC PROTECTION DESIGN REQUIREMENTS

1 Design Scope: Basic Detailed Both
2 Site Survey: Required By Contractor By Others
3 Electrical Isolation: Required By Contractor By Others
4 Type of System: Impressed Current Voltage Source: Transformer Other
Rectifier
5 Groundbeds: Deepwell Surface
6 Horizontal Vertical
7 Autopotential Required
Control:
8 Sacrificial Anode Material: Magnesium Zinc
9 Monitoring Facilities: Required By Contractor By Others
10 Temporary Protection: Required By Contractor By Others
11 Materials Schedule: Required By Contractor By Others
12 Installation Procedure: Required By Contractor By Others
13 Test/Commissioning Procedure: Required By Contractor By Others
14 Operating/Maintenance Manual: Required By Contractor
15 Colour Code for Cables: As specified below
16 CABLE COLOUR CABLE COLOUR
17 Positive feeder Negative drain
18 Test own Test foreign
19 Bond own Bond foreign
20 I.J. side line I.J. plant side
21 Carrier Casing
22
In shaded boxes, use ‘Y’, ‘N’ or ‘Check Mark’ to indicate selection
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C INFORMATION TO BE SUBMITTED WITH THE TENDER

1 Completed datasheet (i.e. all data fields not already completed by the Principal)
2
3
4
5
D REMARKS AND/OR DESCRIPTION OF REVISIONS
1 Cathodic protection system design shall comply with PTS 11.32.01)
2
3
4
5
Made by Date Equipment: Rev.
letter
Checked by Date Plant: Date

Approved by Date Consignee: Sign

Sheet No 1 (cont.d on sheet No.)
Eng. by : Equipm.
No.
Owner : Req. No.