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PT. PHE ONW J Specification for Pipeline Cathodic Protection

Revision Log Register

This is the first issuance. No revision has been performed.

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PT. PHE ONWJ Specification for Pipeline Cathodic Protection

Table of Content

Revision Log Register ........................................................................................................................... 2

Table of Content .................................................................................................................................... 3

1. Scope ............................................................................................................................................. 4

2. References .................................................................................................................................... 4

2.1 Local Regulation and Standards ........................................................................................ 4

2.2 Company Specification ...................................................................................................... 4

2.3 International Standards and Codes ................................................................................... 4

3. Definition of Terms ......................................................................................................................... 5

4. Abbreviations ................................................................................................................................. 5

5. Design ............................................................................................................................................ 5

5.1 Cathodic Protection for New Pipeline ................................................................................ 5

5.2 Cathodic Protection for Retrofit System............................................................................. 5

5.3 Cathodic Protection for Subsea Protection Structure ........................................................ 5

5.4 Electrical Isolation .............................................................................................................. 7

5.5 Design Parameter .............................................................................................................. 7

6. Material and Performance ............................................................................................................. 7

6.1 Galvanic Anode .................................................................................................................. 7

6.1.1 Anode Material ...................................................................................................... 7

6.1.2 Anode Core Material ............................................................................................. 8

6.1.3 Pre-production Test .............................................................................................. 8

6.2 Cabling ............................................................................................................................... 9

6.3 Impressed-Current System ................................................................................................ 9

6.4 Monitoring and Special Facilities for On-land Pipeline ...................................................... 9

7. Installation ...................................................................................................................................... 9

7.1 Galvanic Anode .................................................................................................................. 9

7.2 Impressed-Current System ................................................................................................ 9

8. Commissioning ............................................................................................................................ 11

9. Marking ........................................................................................................................................ 11

10. Documentation ............................................................................................................................. 11

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PT. PHE ONWJ Specification for Pipeline Cathodic Protection

1. Scope

This specification covers the m inim um requirements for the design, materials, construction,

inspection and testing of cathodic protection system for pipeline.

2. References

Design, manufacture, performance and testing should be in compliance with the following

codes and standard, except where otherwise specified. The following documents should form

an integral part of this specification:

2.1 Local Regulation and Standards

Decree of Mines and Energy

Work Safety of Oil and Gas Distribution Pipelines

300.K/38/M.PE/1997

Decree 84.K/38/DJM/1998 Inspection Guidelines for Safety on Facilities,

Equipm ent and Technology Used in O il and Gas and

Geothermal Activity

Regulation
Safety Audit to Inspection, Equipment and Technique

06P/0746/M.PE/1991
used In Oil and Gas Mining and geothermal Activities.

Regulation Number 11-

Working safely on Refinery and Processing Oil and

Year 1979
Gas

2.2 Company Specification

The following COMPANY Specifications should be applied to the subject work.

x PHEONWJ-W-PRC-0012 Offshore Pipeline Design

x PHEONWJ-W-SPE-0005 Line Pipe

x PHEONWJ-W-SPE-0006 Pipeline Corrosion Protection Coating

x PHEONWJ-W-SPE-0009 Riser Corrosion Protection Coating

2.3 International Standards and Codes

Except where otherwise noted, the latest edition of the following codes and standards

should apply:

EN 12474 Cathodic protection for submarine pipelines

ISO 15589-1 ISO 15589 (Cathodic protection of pipeline

transportation systems) Part 1: On-land pipelines

ISO 15589-2/NACE SP0607 ISO 15589 (Cathodic protection of pipeline

transportation systems) Part 2: Offshore pipelines

DNV-RP-F103 Cathodic protection of submarine pipelines by galvanic

anodes

DNV-RP-B401 Cathodic protection design

NACE SP0169 Control of external corrosion on underground or

submerged metallic piping systems

NACE SP0387 Metallurgical and inspection requirements for cast

galvanic anodes for offshore applications

NACE SP0492 Metallurgical and inspection requirements for offshore

pipeline bracelet anodes

NACE SP0502 Pipeline external corrosion direct assessment

methodology

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PT. PHE ONWJ Specification for Pipeline Cathodic Protection

3. Definition of Terms

COMPANY PT. Pertamina Hulu Energi ONWJ

CONTRACTOR The party that carries out all or part of the design, engineering,

procurement, construction, commissioning or management of a

project. The C O M PAN Y m ay undertake all or part of the duties of

the CONTRACTOR.

VENDOR The party that manufactures or supplies equipment and/or services

to perform the duties specified by the CONTRACTOR.

4. Abbreviations

EN European Standard

DNV Det Norske Veritas

ISO International Organization for Standardization

NACE National Association of Corrosion Engineers

5. Design

Pipeline shall be protected from subsea corrosion using a combination of external coatings and

cathodic protection. The design life of the cathodic protection shall cover the period from

installation to the end of pipeline operation.

For offshore pipeline operating at temperatures up to 50 °C, galvanic anode placed in the form

of bracelets (half shell or segmental) around the pipe is the preferred method. For high

operating temperature of the pipeline, anode bracelet installation on the pipeline may not

desirable.

U nless their perform ance is supported by appropriate test data to the contrary, zinc anode

should not be used at temperature exceeding 50 °C due to it can undergo a reduction in driving

potential.

For on-land pipeline, the impressed-current system is preferred. Alternatively, galvanic anodes

may be used. Unless their performance is supported by appropriate test data to the contrary,

zinc anode should not be used if resistivity of the electrolyte is higher than 30
Ω ⋅m and

magnesium anode should not be used if resistivity of the electrolyte is higher than 150 Ω ⋅m.

Depending on the pipeline installation method, the anodes can be susceptible to damage. This

concern is critical when the anodes pass over a stinger as the offshore pipeline leaves the lay

barge. For non-weight-coated pipelines, anodes with either tapered shoulders or taper cones

should be used to reduce the risk of the anodes catching on the stinger rollers. For weight-

coated pipelines, the thickness of anodes should match the thickness of the weight coating,

such that the anodes will roll smoothly over the stinger roller.

5.1 Cathodic Protection for New Pipeline

Submerged pipelines are protected using a system which is designed independently of

the systems used to protect the structures or installations to which they are connected.

Design calculation for the cathodic protection system shall demonstrate that the CP

gives current to the pipeline necessary to meet the current density requirements.

Unless otherwise stated, for offshore pipeline, all the requirements of the ISO 15589-2

are applicable. As a complement, requirements of EN 12474 and/or DNV-RP-F103 are

applicable when they are not in conflict with ISO 15589-2. For on-land pipeline, all the

requirements of the ISO 15589-1 are applicable.

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PT. PHE ONWJ Specification for Pipeline Cathodic Protection

Calculation of cathodic protection system for offshore pipeline shall be conducted using

the procedure described in Annex A of ISO 15589-2 or equivalent. Where applicable, all

design parameters shall be in according with ISO 15589-2 as mentioned in Section 5.5.

The cathodic protection of the conventional riser shall be included in the cathodic

protection calculation of the supporting jacket. Cathodic protection of SCR (steel

catenary riser) is designed within the associated pipeline.

The spacing between anodes shall be determined once the number of anodes has been

calculated. The anode spacing shall be close enough to maintain an adequate protection

in the event of mechanical or electrical loss of a single anode. Anode spacing should not

exceed 300m. Anode spacing exceeding 300m shall be justified by attenuation

calculations or other mathematical modeling.

The first and last pipeline length (about 50m , m easured from the respective bottom of

riser corrosion protection coating), anode spacing shall be half of that calculated using

design parameters and hence additional anodes shall be provided accordingly. For each

pipeline crossing, spool piece, branch connection or subsea flange, the anode spacing

shall also be half of that calculated using design parameters, up to a distance of 50m on

either side of those the possible interferences, and hence additional anodes shall be

provided accordingly.

F or sh ort pipelin es, ano des m ay be insta lled at e ach en d of th e pipe lin e, if it ca n be

demonstrated by mathematical calculations and modeling that cathodic protection can be

achieved. Attenuation calculations shall be carried out for these installations to determine

whether it is feasible to protect the mid-point of the pipeline using anodes located at the

ends.

5.2 Cathodic Protection for Retrofit System

Retrofit system is used for pipelines with galvanic anode failures, excessive anode

consum ption, operation beyond original design life or excessive coating deterioration.

Retrofit system shall be designed by a professional and experienced cathodic protection

engineering CONTRACTOR.

When a cathodic protection system is designed for retrofitting to an existing installation,

certain modifications to the installation may be necessary to comply with the minimum

specifications. Such requirements need to be determined by site investigations. The

design should focus on reduction of installation cost without sacrificing mechanical

reliability e.g. evaluates impressed current, galvanic anode and hybrid solution.

Retrofit system may provide differ current density as one would for a new facility.

Significant savings can be realized if existing maintenance current density can be

demonstrated to be much lower than conventional wisdom would dictate.

5.3 Cathodic Protection for Subsea Protection Structure

If the subsea protection structure is not conductively connected to the pipeline and it

requires its own cathodic protection, calculation of cathodic protection shall be conducted

using the procedure described in DNV-RP-B401 or equivalent.

Galvanic anode material shall conform to Section 6.1.

Manufacturing, inspection and testing of galvanic anode for subsea protection structure

shall be in accordance with DNV-RP-B401, NACE SP0387, ISO 15589-2 or equivalent.

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PT. PHE ONWJ Specification for Pipeline Cathodic Protection

5.4 Electrical Isolation

• Offshore pipeline

Electrical isolation may not need to be installed between the pipeline and the topside

piping. Clause 5.1 of ISO 15589-2 confirms electrical isolation is required where

different protection systems are used between the pipeline and the onshore or

offshore installations (cathodic protection by impressed current, cathodic protection by

sacrificial anodes). However the decision shall be subject to COMPANY’s approval.

• On-land pipeline:

Electrical isolation should be installed above ground whenever possible at both

extremities of a pipeline, and should also be considered at the following locations:

- at connections to branch lines

- between cathodically-protected pipelines and non-protected facilities

- in vicinity of high voltage electricity cables and overhead lines.

Electrical isolation should be provided using monobloc isolating joint wherever

possible. If the use of monobloc isolating joint is not practical, isolating flange kits may

be used. Isolating flange should be protected against ingress of dirt and moisture by

the use of flange protector or protective tape. Each isolating joint/isolating flange

should be provided with test facilities. The electrical resistance across isolating joints

should be more than 10 M Ω measured at 1000 V (dc) in dry air, before installation.

In areas w here there risk of high voltage e.g. caused by nearby pow er system or

lightning, the isolating joint or flange shall be protected using electrical earthing or

surge arrestor.

5.5 Design Parameter

Some of design data can be assessed from ISO 15589-2 as the following:

• seawater resistivity : Figure A.1 of ISO 15589-2

• coating breakdown factor : Table 3 of ISO 15589-2

• anode utilization factor : Clause 7.4 of ISO 15589-2

• electrochemical properties : Table 4 of ISO 15589-2

• design current density : Figure 2 of ISO 15589-2

6. Material and Performance

6.1 Galvanic Anode

6.1.1 Anode Material

Manufacturing, inspection and testing of galvanic anode for offshore pipeline

shall be in accordance with Clause 8 and 9 of ISO 15589-2. The mass fraction of

anode material shall conform to the following Table 1 and 2 (reference is made

to T a b le 5 o f 1 5 5 8 9 -2 fo r a lu m in iu m a n o d e a n d T a b le 6 o f 1 5 5 8 9 -2 fo r zin c

anode). An alteration in the mass fraction of anode shall be subject to

COMPANY’s approval.

The mass fraction of anode material for on-land pipeline shall conform to Table 3

and 4 (reference is m ade to Table 2 of 15589-1 for zinc anode and Table 3 of

15589-1 for magnesium anode).

Slight alteration in mass fraction of anode material may be allowed but it shall be

subject to COMPANY’s approval.

Anode length should not less than 200 mm.

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PT. PHE ONWJ Specification for Pipeline Cathodic Protection

Table 1-Mass fraction of aluminium anode Table 2-Mass fraction of zinc anode

Mass fraction
Mass fraction

Element
Element

min.% max.% min.% max.%

Zn 2,5 5,75

Cu - 0,005

In 0,016 0,040

Al 0,10 0,50

Fe - 0,09

Fe - 0,005

Si - 0,12

Cd 0,025 0,07

Cu - 0,003

Pb - 0,006

Cd - 0,002

Zn Remainder

Others - 0,02

Al Remainder

Table 3-Mass fraction of zinc anode Table 4-Mass fraction of magnesium

anode

Mass fraction
Mass fraction

Element
Element

min.% max.% min.% max.%

Cu - 0,005

Cu - 0,02

Al 0,10 0,50

Al 5,3 6,7

Fe - 0,005

Si - 0,1

Cd - 0,07

Fe - 0,003

Pb 0,006

Mn 0,15 -

Zn Remainder

Ni - 0,002

Other - 0,02

Zn 2,5 3,5

Mg Remainder

Other - 0,005

6.1.2 Anode Core Material

Anode core shall conform to Clause 8.3 of ISO 15589-2 with addition the

following requirement:

•
Steel core at least 6mm thick. Anode material shall surround the core.

•
Minimum main steel straps shall be of 2.

6.1.3 Pre-production Test

Prior to fabrication of the anodes, a pre-production test shall be carried out to

ascertain that all moulds, cores, casting equipment and other components are in

accordance with applicable standards, governing drawings and data sheets. At

least one of the anode assemblies cast shall be inspected destructively as

described in C lause 9.9 of IS O 15589-2. F or deliveries below 5 ton net alloy

and/or a lim ited num ber of anodes, the extent of testing is subject to special

agreement.

6.2 Cabling

Anode cable shall have a minimum cross section of 16 mm

, single layer of polyethylene

insulation 2.8 mm thick conform to ASTM D1248 type 1 class C category 5 grade E-4 or

E-5, i.e. HMW -PE (high molecular weight polyethylene) or equivalent. Surface printed

“manufacturer name, AWG size” .

Cable for environment where halogen gases and/or particularly chlorine are evolved and

concentrated around the anode and cable shall be double insulated with ECTFE

(ethylene chloro tri fluoro ethylene) or equivalent.

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PT. PHE ONWJ Specification for Pipeline Cathodic Protection

Cable shall sufficient length to run with the acceptable voltage drop as specified by the

IEE regulation.

At least two cables per anode shall be installed. For half-shell anodes, two half-shells

shall be considered as a single anode.

6.3 Impressed-Current System

Im pressed-current system shall be in accordance w ith C lause 11 of ISO 15589-2 for

offshore pipeline and Clause 6 of ISO 15589-1 for on-land pipeline.

6.4 Monitoring and Special Facilities for On-land Pipeline

The m onitoring and special facilities for on-land pipeline shall be in accordance w ith

Clause 8 and 9 of ISO 15589-1.

7. Installation

7.1 Galvanic Anode

Galvanic anode installation shall be in according with Clause 10 o f IS O 1 5 5 8 9 -2 a s

follows:

Welders and welding procedures should be qualified for any applicable welding process

to a recognized standard.

Bracelet anodes shall be clamped on or welded to the pipeline.

For bracelet anodes mounted on pipe joints that are concrete weight-coated, electrical

contact between the concrete reinforcement and the anodes shall be avoided by

providing a gap, typically of 25 mm, at each end of the anode. Gaps between bracelet

anode half-shells and between half-shells and the concrete shall be filled with non-

conductive mastic or similar compound.

Anode installation shall be carried out in such a way that damage to the coating is

minimized.

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

mechanical strength and electrical continuity and to prevent damage to the pipe at the

point of connection. The removal of the protective coating from the pipe should be kept

to a m inim um . After installation o f th e ca b le -to-pipe connection, the coating shall be

repaired using appropriate coating material.

A detailed cable-to-pipeline connection procedure shall be included in the CP design.

W elding of cable connections shall not be carried out on bends or within 200 mm from

pipeline welds.

For thermite welding of cables, the welding procedure shall be such that copper

penetration into the pipeline material shall be less than 1 mm and local pipeline hardness

shall remain within the requirements given in the pipeline specification.

Therm ite w eld charges should not be greater than 15 g. If cables larger than 16 m m

need to be attached, the cores shall be separated into a number of smaller strands each

less than 16 mm
and welded separately.

Thermite welding should not be carried out on corrosion-resistant alloy pipelines.

Alternative methods such as pin brazing, soft soldering, adhesive bonding or friction

welding may be used, provided that the detailed procedure and performance are reliable

and properly documented.

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All items to be protected by CP shall be electrically connected and should have a welded

or brazed connection to an anode. All bolted or clamped components with surface area

exceeding 1 m
shall have an all-welded or brazed connection to an anode. For all bolted

or clamped assemblies without an all-welded or brazed electrical connection, it shall be

verified that the electric resistance is less than 0.10 Ω . Coating on contact surfaces shall

be removed prior to assembly.

Cables should be copper-cored, and shall be insulated and sheathed to withstand the

prevailing chemical and mechanical conditions. The minimum conductor size for

m easurem ent cables shall be 4 m m

. C ables shall b e s ize d su ch th a t n o excessive

voltage drops occur which reduce the capacity of the system.

If the contact is made by using current-carrying copper cables welded or brazed at each

end, these shall be stranded and have a minimum cross section of 16 mm

and brazed

to the cable shoe. At least two cables per anode shall be installed. For half-shell anodes,

two half-shells shall be considered as a single anode.

Only in exceptional cases (e.g. the retrofit of a cathodic protection system or the use of

remote anode assemblies) should the underwater installation of anodes, utilizing either

boiled or clamped devices or welding be carried out.

Bolted connections with set screws or friction welding may be considered for the

electrical connection of anode retrofit systems.

For high strength materials (SMY > 550 MPa), welding of doubler plates for anode

connections shall be avoided, as this can cause local stress increase which can lead to

hydrogen embrittlement.

7.2 Impressed Current System

A separate impressed current system should be provided for each gate leaf. Each

system should consist of a rectifier supplying protective current to anodes, w hich w ill

distribute protective current to the gate structure. Cathodic protection should be installed

on those portions of the gates submerged at normal pool levels. The faces of the gates

should be protected to upper pool stages, except that the downstream face of the lower

gates should be protected to the lower pool. M eters should be provided as part of the

rectifier to monitor the cathodic protection system voltage and current.

This navigation lock will be subject to flooding and floating debris; therefore, the cathodic

protection system should be designed to permit for removal during periods of high water,

and the anode cables and sausage-type anodes will require impact protection to prevent

them from being damaged.

Installation of impressed current system shall consider regular control and maintenance.

The voltage and current readings of the rectifiers shall can be observed, monitored, and

recorded daily. C onsideration shall also be given to the need of evaluation of annual

reference cell voltage data that indicating the structure-to-electrolyte (lock-to-water)

potential is the accepted method for determining the adequacy of corrosion protection

provided by the cathodic protection system. Reference cell data are evaluated based on

the design (anode locations), the voltage adjustm ents, and the adequacy of the test

locations. Adjustments to the rectifier output (e.g. up to 120% of design operating output)

can be made to improve the protective potentials applied to the gate leaves. Sometime

DC voltage and current data indicate that the rectifiers and cathodic protection system

are working but do not guarantee that the system is properly optimized.

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PT. PHE ONWJ Specification for Pipeline Cathodic Protection

8. Commissioning

For galvanic anode system of offshore pipeline, commissioning is generally not applicable. For

impressed-current system the commissioning procedures shall include:

• testing of pipeline isolation where present

• energizing cathodic protection hardware, if necessary

• measurement of adequate protection levels (in according with Annex C of ISO 15589-2)

• interference testing, if applicable.

For on-land pipeline, commissioning shall be in according with Clause 10 of ISO 15589-1.

Upon completion of installation and commissioning phase, project team shall close the activity

by issuing Handover Certificate to Operation. Handover procedure shall refer to PHEONWJ-G-

PRC-0362. In this stage all category A punchlist shall be closed.

9. Marking

Galvanic anodes shall be marked with the type of material (e.g. tradename), anode mass and

melt number.

10. Documentation

The documentation content shall be as a minimum as follows:

•
drawings including detailed cathodic protection design, manufacturing/installation, anode

distribution.

•
inspection document (analysis certificates, electrochemical test certificates giving the

m ethod, the results and the m elt num ber in the casting operation, m ill certificates of the

steels used, net and gross weight of anodes, cable type/specification along with routine and

type test certificates).

•
drawings of wiring system and type test certificate for monitoring panel of impressed-current

applied (i.e enclosure protection equivalent of IP-51 or NEMA-12).

•
detailed technical study (hypotheses considered for the calculation including chosen type,

materials, and dimensions of cathodic protection system)

•
relevant design and installation manual including detailed calculation verifying that the

protection is assured for the pipeline and, if required, recommended means of anode

support and analytical information regarding the location of reference electrode (which has

to be located in least negative potential area).

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