EPC OF LAWE-LAWE FACILITIES

RDMP RU-V BALIKPAPAN

Doc. No. : 26076-110-GPP-GCX-00060 CATHODIC PROTECTION Rev No. : 002
Job No. : 26076 INSTALLATION PROCEDURE Page No. :1/20

ENGINEERING, PROCUREMENT AND CONSTRUCTION (EPC)

OF LAWE-LAWE FACILITIES RDMP RU-V
BALIKPAPAN

CATHODIC PROTECTION INSTALLATION PROCEDURE

Lukeyi
2021.03.22 2021-03-23 08:
17:18:39 +08'00' 40:17

Agus
002 22-Mar-21 Re-Approved for Design Lu Keyi Cui Guojun
S./Sugeng S.
Agus
001 25-Feb-21 Re-Approved for Design Lu Keyi Cui Guojun
S./Sugeng S.
Agus
000 22-Oct-20 Approved for Design Lu Keyi Cui Guojun
S./Sugeng S.
Agus
00A 26-Sept-20 Issued for Review Lu Keyi Cui Guojun
S./Sugeng S.
Rev. Date Description Prepared By Reviewed By Approved By
 EPC OF LAWE-LAWE FACILITIES RDMP
RU-V BALIKPAPAN
Doc. No. : 26076-110-GPP-GCX-00060 CATHODIC PROTECTION Rev No. : 002
Job No. : 26076 INSTALLATION PROCEDURE Page No. :2 / 20

REVISION LOG

Rev. No. Date Page Description

00A 26 September 2020 All Issued for Review
000 22 October 2020 4 Add description in point 1
000 22 October 2020 4-7 Add reference document
000 22 October 2020 9 Revised mistyping
000 22 October 2020 11 Add description in point 10 and 11.1
000 22 October 2020 14 Add description in point 10 and 11.1.3
000 22 October 2020 16 Add description in point 10 and 11.2
000 22 October 2020 18 Change and add description in point 12
001 25 February 2021 - See attached Comment resolution sheet
002 22 March 2021 - See attached Comment resolution sheet
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TABLE OF CONTENT
1 PURPOSE .................................................................................................................................................5
2 DEFINITIONS ............................................................................................................................................5
3 ABBREVIATIONS ......................................................................................................................................5
4 STANDARD & CODES ...............................................................................................................................6
5 HSSE (HEALTH, SAFETY , SECURITY AND ENVIRONMENT) ......................................................................9
5.1 HEALTH AND SAFETY ...............................................................................................................................9
5.2 SECURITY ...............................................................................................................................................10
5.3 ENVIRONMENT......................................................................................................................................10
6 MANPOWER ..........................................................................................................................................10
7 ROLES AND RESPONSIBILITIES ...............................................................................................................11
7.1 SUPERVISOR ..........................................................................................................................................11
7.2 TECHNICIAN...........................................................................................................................................11
7.3 CERTIFIED WELDER................................................................................................................................11
7.4 HELPER ..................................................................................................................................................11
7.5 SECURITY ...............................................................................................................................................11
7.6 DRIVER...................................................................................................................................................11
8 EQUIPMENT...........................................................................................................................................11
9 WORKING TIME .....................................................................................................................................12
10 QUALITY.................................................................................................................................................12
11 INSTALLATION PROCEDURE ..................................................................................................................12
11.1 IMPRESSED CURRENT CATHODIC PROTECTION (ICCP) .........................................................................12
11.1.1 Installation of negative cable to pipe by means thermit welding............................................12
11.1.2 Installation of MMO Anode in Groundbed Hole ......................................................................14
11.1.3 Installation of Junction Box (Positive & Negative) ................................................................... 15
11.1.4 Installation of Transformer Rectifier ........................................................................................16
11.2 BARCELET ANODE CATHODIC PROTECTION..........................................................................................17
11.3 CRUDE OIL TANK CATHODIC PROTECTION INSTALLATION ...................................................................18
11.3.1 Installation preparation for cathodic protection ..................................................................... 18
11.3.2 Construction procedure of cathodic protection of crude oil tank ...........................................19
11.3.3 Tank cathode Protect system test............................................................................................19
11.4 SPM & PLEM BRACELET ANODE CATHODIC PROTECTION INSTALLATION ...........................................19
12 PRECOMMISSIONING, TESTING AND INSPECTION ...............................................................................20
13 DOCUMENTATION.................................................................................................................................20
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APPENDIX - 1 DETAIL PROCESS OF THERMIT WELDING

APPENDIX - 2 EXAMPLE OF QC REPORT

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1 PURPOSE

This document is intended to provide Cathodic Protection Installation procedure for EPC of Lawe-
Lawe Facilities RDMP RU-V Balikpapan project. The procedure cover cathodic installation
procedure for Onshore Pipeline, Offshore Pipeline, Tanks, Pipeline End Manifold (PLEM), Single
Point Mooring (SPM).

2 DEFINITIONS

Engineering, Procurement & Construction Lawe – Lawe Faciities RDMP RU V

PROJECT
– Balikpapan
OWNER PT. Kilang Pertamina Balikpapan
Integrated Project Management Team consists of a combination of OWNER
personnel and PMC. Communication between OWNER and CONTRACTOR to
IPMT
be executed through IPMT as representative of OWNER. The PMC is
represented by Worley
Joint operation of China Petroleum Pipeline Co.Ltd and
CONTRACTOR
PT. Hutama Karya
Means any person named in this EPC contract as a SUB-CONTRACTOR or any
SUBCONTRACTOR person as appointed as a SUBCONTRACTOR (of any tier), for a part of the
works and the legal sucessors in the title to each of these persons
A company providing specific materials or services required for the
VENDOR
construction of the facility.

3 ABBREVIATIONS

MMO Mixed Metal Oxide Anode

ICCP Impressed Current Cathodic Protection
PPE Personal Protective Equipment
CP Cathodic Protection
IEC International Electrotechnical Commission
DNV-RP Det Norske Veritas-Recommended Practices
National Association of Corossion Engineer – Recommended
NACE-RP
Practices
ISO International Standard Organization
SPM Single Point Mooring
PLEM Pipeline End Manifold
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4 STANDARD & CODES

International Code :

DNVGL-RP-B401 Cathodic Protection Design

DNVGL-RP-F103 Cathodic Protection of Submarine Pipeline
Control of External Corrosion on Underground or Submerged Metallic
NACE-RP-0169
Piping System
Mitigation of Alternating Current and Lightning Effects on Metallic
NACE-RP-0177
Structures and Corrosion Control System
NACE-SP-0286 The Electrical Isolation of Cathodically Protected Pipeline
Design, Installation, Operation and Maintenance of impressed Current
NACE-SP-0572
Deep ground Beds
IEC 61643 Low Voltage Surge Protective Device
IEC 60079 Electrical apporiate for explosive gas atmospheres
IEC 60529 Degree of Protection Provide by enclosures IP (code)
IEC 60416 Semiconductor Converters
IEC 60269 Low Voltages Fuses
Petroleum and Natural Gas and Industries-Cathodic Protections of
ISO 15589-1
Pipeline Transportation System-part 1: on Land Pipeline
Petroleum, petrochemical and Natural Gas Industries-Cathodic
ISO 15589-2 Protections of Pipeline Transportation System-part 2: Offshores
Pipeline
ISO 9001-2000 Quality Management Systems Requirements
ISO 9004-2000 Quality Management Gudelines for Performance Improvement
Field Measurement of Soil Resistivity Using the Wenner-Electrode
ASTM G57
Method
ASTM B4 18 Cast and Wrouht Galvanic Zinc Anodes

Project Document :

26076-110-EQ-400-L0005 Installation Drawing of Test Post (Onshore Facilities)

26076-110-EQ-400-L0006 Wiring Diagram of Transformer Rectifier (Onshore Facilities)

26076-110-EQ-400-L0007 Structure and Installation Diagram for Junction box (Onshore

Facilities)
26076-110-EQ-400-L0008 Cable Welding and Coating Drawing (Onshore Facilities)

26076-110-EQ-400-L0009 Cable Layout diagram (Onshore Facilities)

26076-110-EQ-400-L0010 MMO Anode Connection Diagram (Onshore Facilities)

26076-110-EQ-400-L0011 Cathodic Protection System Layout Diagram for Tank Bottom


Doc. No. : 26076-110-GPP-GCX-00060
Job No. : 26076
26076-110-EQ-400-L0012
26076-110-EQD-400-L0001
26076-110-EQD-400-L0002
26076-110-EQD-400-L0003
26076-110-EQD-400-L0004
26076-110-EQD-400-L0005
26076-110-EQD-400-L0006
26076-210-EQ-420-L0002
26076-210-EQ-420-L0003
26076-850-EQD-422-L0001
26076-850-EQD-422-L0002
26076-850-EQD-422-L0003
26076-850-EQD-422-L0004
26076-850-EQD-422-L0005
26076-850-EQD-422-L0006
26076-850-EQD-422-L0007
26076-850-EQ-422-L0001
26076-850-EQ-422-L0002
26076-850-EQJ-422-L0003
26076-850-EQ-422-L0004
26076-850-EQJ-422-L0005
26076-850-EQJ-422-L0006
26076-850-EQJ-422-L0007
EPC OF LAWE-LAWE FACILITIES RDMP
RU-V BALIKPAPAN
CATHODIC PROTECTION Rev No. : 002
INSTALLATION PROCEDURE Page No. :7 / 20
(Onshore Facilities)
Sacrificial Anode Installation Drawing for Internal Surface of Tank
Bottom (Onshore Facilities)
Data Sheet for Transformer Rectifier (Onshore Facilities)
Data Sheet for Test Post (Onshore Facilities)
Data Sheets for Sacrificial Anode (Onshore Facilities)
Data Sheets for MMO Anode (Onshore Facilities)
Data Sheets for Reference Electrode (Onshore Facilities)
Data Sheets for Junction Box (Onshore Facilities)
MMO Anode Net Layout Diagram for Tank Bottom (Onshore
Facilities)
Reference Electrode Layout Diagram for Tank Bottom (Onshore
Facilities)
Data Sheet for Transformer Rectifier (Unloading Facilities)
Data Sheet for Test Post (Unloading Facilities)
Data Sheet for Junction Box (Unloading Facilities)
Data Sheet for Reference Electrode (Unloading Facilities)
Data Sheet for Auxiliary Anode of Impressed Current Cathodic
Protection (Unloading Facilities)
Data Sheet for Sacrificial Anode (Unloading Facilities)
Data Sheet for Accessories of Impressed Current Cathodic
Protection (Unloading Facilities)
Layout Drawing of Cathodic Protection Facilities Along Pipeline
Route (Unloading Facilities)
Cathodic Protection System Block Diagram (Unloading Facilities)
Test Post Installation Details (Unloading Facilities)
Temporary Cathodic Protection Installation Drawing (Unloading
Facilities)
Cable Welding and Coating Details (Unloading Facilities)
Transformer Rectifier Installation Details (Unloading Facilities)
Drain Point Installation Details (Unloading Facilities)
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26076-850-EQ-422-L0008 Cathodic Protection Cable Laying Drawing (Unloading Facilities)

Auxiliary Anode Groundbeds Installation Details (Unloading

26076-850-EQJ-422-L0009
Facilities)

26076-850-EQB-422-L0001 MTO for Cathodic Protection System (Unloading Facilities)

26076-850-N3D-422-L0001 Data Sheet for Bracelet Anode for Unloading Line

26076-850-R4-422-L0007 Unloading Pipeline, Bracelet Anode Details

26076-850-R4-422-L0008 Unloading Pipeline, Bracelet Anode General Arrangement

26076-910-N3D-422-L0003 Data Sheet for Bracelet Anode for Transfer Line

26076-910-R4-422-L0005 Transfer Pipeline, Bracelet Anode Details

26076-910-R4-422-L0006 Transfer Pipeline, Bracelet Anode General Arrangement

26076-210-3PS-EQ00-L0005 Specification of Cathodic Protection for Tanks

26076-210-EQC-420-L0002 Cathodic Protection Calculation for Crude Oil Tanks

26076-210-EQ-420-L0023 Sacrificial Anode Installation Drawing for Internal Surface of Tank

Bottom (Crude Oil Tanks)

26076-210-E0D-420-L0007 Data Sheet for Transformer Rectifier (Crude Oil Tanks)

26076-210-E0D-420-L0008 Data Sheet for Test Post (Crude Oil Tanks)

26076-210-E0D-420-L0009 Data Sheets for Sacrificial Anode (Crude Oil Tanks)

26076-210-E0D-420-L0010 Data Sheets for MMO Anode (Crude Oil Tanks)

26076-210-E0D-420-L0011 Data Sheets for Reference Electrode (Crude Oil Tanks)

26076-210-EQ-420-L0013 MMO Anode Net Layout Diagram for Tank Bottom (Crude Oil Tanks)

26076-210-EQ-420-L0014 Reference Electrode Layout Diagram for Tank Bottom (Crude Oil
Tanks)

26076-210-EQ-420-L0016 Installation Drawing of Test Post (Crude Oil Tanks)

26076-210-EQ-420-L0017 Wiring Diagram of Transformer Rectifier (Crude Oil Tanks)

26076-210-EQ-420-L0018 Structure and Installation Diagram for Junction box (Crude Oil
Tanks)

26076-210-EQ-420-L0019 Cable Welding and Coating Drawing (Crude Oil Tanks)

26076-210-EQ-420-L0020 Cable Layout diagram (Crude Oil Tanks)

26076-210-EQJ-420-L0021 MMO Anode Connection Diagram (Crude Oil Tanks)

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26076-210-E0D-420-L0012 Data Sheets for Junction Box (Crude Oil Tanks)

26076-910-EQ-422-L0001 Layout Drawing of Cathodic Protection Facilities Along Pipeline

Route (Transfer Lines Facilities)
26076-910-EQ-422-L0002 Cathodic Protection System Block Diagram (Transfer Lines Facilities)

26076-910-EQ-422-L0003 Test Post Installation Details (Transfer Lines Facilities)

26076-910-EQ-422-L0004 Temporary Cathodic Protection Installation Drawing (Transfer Lines

Facilities)
26076-910-EQ-422-L0005 Cable Welding and Coating Details (Transfer Lines Facilities)

26076-910-EQ-422-L0006 Transformer Rectifier Installation Details (Transfer Lines Facilities)

26076-910-EQ-422-L0007 Drain Point Installation Details (Transfer Lines Facilities)

26076-910-EQ-422-L0008 Cathodic Protection Cable Laying Drawing (Transfer Lines Facilities)

26076-910-EQ-422-L0009 Cathodic Protection Cable Laying Drawing (Transfer Lines Facilities)

26076-910-EQ-422-L0010 Layout Drawing of Cathodic Protection Station (Transfer Lines

Facilities)

5 HSSE (Health, Safety , Security and Environment)

5.1 Health and Safety

x All personnel shall attend safety induction prior to entering site

x All HSE issues in every work location will be coordinated by the Safety Officer assisted by
safety representatives. CONTRACTOR shall comply with HSSE Project Procedures.
x All tools and equipment shall be checked daily by qualified person prior to usage.
x A job Safety Analysis (JSA) shall be prepared by supervisor and be attached to the permit to
work (PTW) for approval by approving Authority (Area Authority). JSA shall be developed in
accordance with risk Assessment and together with method statement (MS) for the specific
work.
x The JSA shall be clearly explained to all worker by the supervisor during the tool box meeting.
Supervisor shall make sure that all personnel understand all the risk and hazard identified in
the JSA.
x All personnel shall be made familiar with the emergency Response Procedure (ERP), see
document number 26076-110-GPP-GHX-00006 Emergency Response Procedure.
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x Any operations carried out where there is public access or a thoroughfare such as road, shall
be closely monitored by safetyman.
x First Aid Kit always be at site and ready to use. Administered by trained first aid person at
location
x The work shall be suspended during heavy rains or thunderstorms unless suitable rain and
lightning cover is provided.

5.2 Security

x Security will be provided at all items when equipment, tools and material are left on site
without any working activity. Security shall patrol the job site regularly to keep the working
area free from non-authorized persons and local community, and to prevent property loss
and to prevent the public to enter the open excavations.
x Site security shall be report to safety officer if any incident.

5.3 Environment

x Worker shall keep the working area clean and tidy. Wastes shall be disposed of in disposal
bins.
x While filling equipment with fuel, manual hydraulic pump shall be used. Plastic sheet and
drip pan shall be placed under the equipment to manage fuel spill.
x Smoking at work site is strictly prohibited. Designated smoking area shall be provided for
each work site and shown on safety notice board and with proper signage.

6 MANPOWER

CONTRACTOR will be mobilize the manpower to perform CP Installation activities . The

manpower list will be described and part of method statement.

Skilled and non-skilled workers are required for routine work.

Non-skilled manpower or workers (helper) will be recruited from local community. Skilled
workers will be recruited from local source as a primary source, and out of local district skilled
workers recruitment may be developed when necessary. All workers shall be given a safety
induction by the safety officer and shall be educated abourt working hazards and risks prior to
being assigned to working area.
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7 ROLES AND RESPONSIBILITIES

7.1 Supervisor

The Supervisor will be responsible for the overall coordination and supervision of the install CP
installation activities. Supervisor will provide the necessary information and liaise with PTW
Coordinator and shall be responsible for applying the correct work permits and LOTO prior to
commencement of works.

7.2 Technician

The Technician will be responsible for all technical problems such as installation and testing
activities.

7.3 Certified Welder

The Welder is responsible to perform the safe welding operation following cable welding &
coating drawing .

7.4 Helper

The Helpers are responsible for performing all work ordered by supervisor correctly and safely.
Work will consist of unskilled activities such as: preparing the hand tool, perform manual handling,
etc.
7.5 Security

Security personnel shall regularly patrol the work areas to keep it safe from non-authorized
persons, local community and avoid property loss.

7.6 Driver

The Drivers are responsible for driving the vehicle safely. Drivers shall have valid driving license.
The Drivers are also responsible for the state of the vehicle that they drive.

8 EQUIPMENT

CONTRACTOR will mobilize the equipment to perform CP Installation activities. The equipment
list will described and part of work method statement. The equipment performing CP installation
work must pass inspection according to the inpection procedure.
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9 WORKING TIME

Working times shall follow project working hours as per Construction Execution Plan No. 26076-
110-G01-GCX-00001. Prior to leave the working area, all equipment and tools shall be tidied up
and the working area shall be cleaned. Supervisor shall inform the safety officer and OWNER site
representative when overtime is required, in a timely manner. No work during lightning. Work at
night shall follow Work at Night Procedure No. 26076-110-GPP-GHX-00048.

10 QUALITY

CONTRACTOR shall identify in documents to its manufacturers, supplier, vendors and

SUBCONTRACTOR all applicable A=QA/QC requirements imposed by the COMPANY and shall
ensure compliance.

CONTRACTOR shall follow specifications and minimum requirements. ITP shall be followed.

Every product will be reviewed by QA/QC plan. The reviewer should be experienced in QA/QC
review for minimizes errors and creates a quality CP installation. QA/QC is responsible for
checking CP installation and checking drawing.

QC shall only As per ITP.

11 INSTALLATION PROCEDURE
11.1 Impressed Current Cathodic Protection (ICCP)

Impressed Current Cathodic Protection (ICCP) shall be installed for onshore pipeline section
in accordance with Specification of Cathodic Protection for Onshore Buried Pipeline
(Amandement), 26076-850-3PS-EQ00-L0001.

Temporary cathodic protection sacrificial anode will be provided during installation stage
until ICCP is operational.

11.1.1 Installation of negative cable to pipe by means thermit welding

See appendix 1 for detail process of thermit welding

1) Check all Personal Protective Equipment (PPE) Worker Safety Team CP. Construction
and convinced that all has been put completely and correctly according to standards
suggested.
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2) Check all equipment Employment and make sure that all is in good condition and
ready for use or function as the function of the work equipment.
3) Perform Safety Induction / explanation would work safety before carrying out the
work and ensure that all employees understand and know the danger area.
4) Welding negative cable for monitoring pipeline protection potential in Negative
Junction Box to the pipe can be carried out before or after the pipe lowered into the
trench . But should be done after the process is completed and the pipe joint
coating ready to be lowered. For existing pipeline, we have to be careful during
excavation and do not damage the coating of pipes, excavation must be in addition
to the pipe.
5) Prepare Thermit welding equipment (thermowelding mold, cadweld powder, metal
disk, and flint gun) and safety equipment (special heat resistance gloves, fire
extinguisher, goggles,masks and helmets).
6) Clean the surface of the iron / pipe that will be the point of connection. Peel the
coating layer on the top of the pipe with a size of about 6 x 6 cm. The part is then
cleaned with sandpaper until the condition of "white metal". Iron surfaces must be
dry and clean of all dirt, oil and water.
7) Cut the cable insulation type CU/XLPE/AWA/PVC size 1c x 25 mm2 (black) along
required (estimated in the field, according pipeline depth and should be sufficient to
achieve the Negative Junction Box, including the spare)

8) Peel the end of the cable insulation type CU/XLPE/AWA/PVC along the ± 2.5 cm.
Make rough the cable core surface with sandpaper, clean and dry. Close the end of
the cable to the cable connector 25 sqmm and pressed with cable crimping tool.
9) Install the "disk" (small and round metal plate) on the inside of the mold. This disc
only serves to hold the powder inside the mold so as not to spill.
10) Pour "powder" into the mold (ensure the mold dry before pouring powder and
consider to pre heat hot gun before use to avoid moisture existence). Make sure all
the powder entered and the last part is a powder that is poured at the bottom of
the capsule which is a powder triggers fire gun powder.
11) Put the mold which already contain powder and wires on the surface of the pipe.
Make sure the proper mold position in as pipes and stable. If necessary, right-left
side of the mold can be propped up with mastic / neogum sealer (especially for
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small pipe).
12) Shoot powder (powder) with use flint gun T - 120 Erico. Powder will react
(exothermic), occurs flame (in the mold) and the powder will melt into a molten
copper that unites Core Cable with an iron surface. It is imperative that during the
exothermic reaction mold should remain stable and should not be rocking.
13) After the reaction, hold the mold position about 10 seconds, and then mold can be
removed and be careful to put it because of the condition of the hot mold.
14) The connection established should try his strength with a knock-tap using light
hammer (or a rubber hammer) and slightly pulled. Connections are less powerful or
doubtful strength should be repeated.
15) Mould allowed to cool and cleaned with a scrapper and a cloth, before being used
for the next connection.
16) Once the cable connection to the pipe is formed, the surface of the pipe at the joint
and surrounding areas (about 20 x 20 cm) painted with a coating Primer Polyken flat.
17) After the primer paint coating Polyken rather dry, open mat layer Royston Handy
Caps and paste Royston Handycap right on the wired connection-pipe. The next part
of the edges around Royston Handycap strengthened by being hit with a hammer.
18) Cable is already connected neatly into the pipe, the cable should be fastened using
plastic straps (Cable Ties), to reduce the possibility of damage caused by the pull of
the pipe when lowered or when backfilling.
19) Before cable terminated in Negative Junction Box, cable ends should be covered
with insulation tape 3M Products and combined with cable tie (do not forget to give
marking / mark the end of the cable)
11.1.2 Installation of MMO Anode in Groundbed Hole

SUBCONTRACTOR shall develop method statement prior to MMO anode installation

1) Check all Personal Protective Equipment (PPE) Worker Safety Team CP. Construction
and convinced that all has been put completely and correctly according to standards
suggested.
2) Check all equipment Employment and make sure that all is in good condition and
ready for use or function as the function of the work equipment.
3) Perform Safety Induction / explanation would work safety before carrying out the
Conduits for cables from outside dyke wall (cathodic protection panel, AJB, NJBs) to tank area inside dyke wall shall be laid in
underground Conduits as per layouts. Same shall be mentioned in cable installation procedure.
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work and ensure that all employees understand and know the danger area.
4) Conduct Pit Test / digging soil with a size of 1 m2 before drilling begins so that you
can know the position and safe location of the cable planting line.
5) Water injection drilling method will be used, water tank shall be placed for easy
access and free obstacle for drilling process.,mud excess after drilling process shall
be streamed to safe place. Drilling starts by using a 2 inch diameter drill bit first and
continuing with a large diameter drill bit which is a 10 inch diameter.
6) After the drilling depth is reached (the depth is accordance with the design of the
deep ground bed ICCP System) new drilling mud is given evenly and allowed to
settle completely (± 1 hour). The drill bit is slowly lifted and the drill bit lever pipe
continues to rotate until the hole is perfect.
7) Assembling all MMO Anodes into 8” CS Deep Well Ground bed Casing Pipe.

8) Set the MMO Anodes correctly and don’t forget to install the anode rubber
centralizer in the 8” CS Deep Well Ground bed Casing Pipe.
9) Trim and tie all MMO Anodes feeder cable in red 1c x 16 mm2 stranded copper
conductor, type of insulation cable CU/XLPE/HMWPE grade 0.6 / 1 kV with strong
cable ties fastener and straighten all the MMO Anode cables and ventilation pipe are
ensured installed correctly.
10) Insert 8” CS Deep Well Ground bed Casing Pipe that has MMO Anode installed into
the Deep Well Ground bed hole. Heavy equipment lifting For ground bed casing more
than 3 meters length shall be considered.
11) Insert the special SC-3 Metallurgical Coke Breeze into Deep Well Ground bed Case
slowly and make sure that it is evenly covered the anode.
12) Trim all MMO Anode cables that have been marked or sequential and enter them
immediately into the Positive Junction Box to be installed.
13) Install CS Pipe Caps 8” diameter to the casing pipe and make sure that it is in a
strong condition and ready to be casted.
14) Install the mold to make a solid concrete foundation so that casing pipe does not
change position, after the result is dry, immediately paint with yellow
11.1.3 Installation of Junction Box (Positive & Negative)

1) Check all Personal Protective Equipment (PPE) Worker Safety Team CP.
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Construction and convinced that all has been put completely and correctly
according to standards suggested.
2) Check all equipment Employment and make sure that all is in good condition and
ready for use or function as the function of the work equipment.
3) Perform Safety Induction / explanation would work safety before carrying out the
work and ensure that all employees understand and know the danger area.
4) Prepare all Junction Box materials including and tag numbers.

5) Dig the ground beside the Ground bed Anode for Positive Junction Box and beside
the pipe for Negative Junction Box concrete foundation with a size of 600 mm x 600
mm x 500 mm deep (according to the reference image).
6) Install the mold for making the concrete foundation Junction Box type K-250 with a
concrete foundation size of 550 mm x 550 mm x 500 mm in accordance with
Engineering Specification Concrete Work (Amandement) 26076-110-3PS-GES-
00001-002
7) Concrete foundry and installation of Junction Box iron support complete with
anchor bolts, nuts-bolts, cable connection terminals and PVC conduits, after the
concrete conditions are dry, immediately terminate cable (both from MMO anodes
or from pipes) and attach tag number.
8) After terminating the cable and the header cable (Positive and Negative) Junction
Box include Permanent Reference Electrode is complete, immediately paint the
support and concrete foundation to be durable in accordance with the desire
design.
9) Pull the main cable / header cable size of 1c x 25 mm2 stranded copper conductor
CU/XLPE/AWA/PVC type insulation cable planting, grade 0.6 / 1 kV of Positive and
Negative Junction Box to the TR unit through the dug hole and PVC conduit that has
been prepared. After the main cable has been inserted into the PVC conduit, the
sand is evenly covered with sand ± 10 cm thick. Don’t forget to give a warning tape
on top of PVC Conduit which contains the main cable buried in sand ± 10 cm and
back with soil as before. Junction Box installation is complete.
11.1.4 Installation of Transformer Rectifier

1) Check all Personal Protective Equipment (PPE) Worker Safety Team CP.
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Construction and convinced that all has been put completely and correctly
according to standards suggested.
2) Check all equipment Employment and make sure that all is in good condition and
ready for use or function as the function of the work equipment.
3) Perform Safety Induction / explanation would work safety before carrying out the
work and ensure that all employees understand and know the danger area.
4) If the concrete foundation is ready and strong, install TR unit be carefully and
precisely, pull the positive and negative header and the power cable that has been
provided through PVC conduit and tie with cable ties.
5) Make a complete termination with the tag number, tighten all terminations, enter
the Oil Shell Diala S2 ZU-1 slowly to the point of Oil Level (avoid splashing water or
dust).
6) Transformer Rectifier units are ready to be tested / internal commissioning.
11.2 Barcelet Anode Cathodic Protection

Anodes shall be clamped around the anti-corrosion coated pipe. Electrical continuity between
the anode and the pipe shall be facilitated by anode bonding cables in accordance with
Specification for Bracelet Anode and Installation (Amandement) 26076-110-3PS-EQA1-L0030.
1) Prior to bracelet anode assembly on the pipe joint, all internal anode surfaces shall be
inspected for any dirt, foreign material, grit or metallic protrusions that could damage the
anti-corrosion coating. Any such deleterious material shall be removed.
2) Bracelet anodes shall be positioned in the approximate center of the pipe and with the gaps
between anode halves approximately at ninety degrees (90o) to the pipe longitudinal seam
(if present).
3) The anode halves shall be clamped tightly to the pipe using ratchet webbing straps or
OWNER-approved equivalent and the steel tabs fillet welded together. Anti-corrosion
coating shall be protected with heat resistant material when tabs are welded. Welders
performing the fillet weld shall be qualified in accordance with DNVGL-ST-F101.
4) During fit-up, CONTRACTOR shall visually inspect for cracks in accordance with NACE RP-
0492-99, Section 3, Clause 3.10.
5) Bonding cable connection areas on the pipe shall be selected so that the connected cable
lies flat against the pipe and near the center of the anode gap. The connection area shall be
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completely cleaned of anti-corrosion coating over an area of approximately 50 mm x 50 mm,

and the bare steel shall be bright, clean and dry. Anode steel tab connection areas shall be
bare and cleaned in a similar manner.
6) Bonding cable insulation shall be removed, to provide bare conductor surfaces, over a
minimum 50 mm from both cable ends.
7) The pipe surface preparation shall conform SSPC SP-3 requirement. Bonding cables shall be
connected to the pipe via doubler plate and anode using Thermit welding. Thermit welds
shall be made using manufacturer's recommended procedures, however, no exothermic
welding charge greater than 15 gram is permitted, and care shall be taken to keep weld
areas and weld molds dry. Slag shall be removed from weld molds prior to each weld and
molds shall be fully cleaned every six (6) welds.
8) Each of the two half shell bonding cables at each anode assembly shall be connected
separately to the pipeline.
9) Technicians that are to apply Thermit welding shall be qualified by making at least three
attachments to similar pipe. The welds will be destructively tested and sectioned in
accordance with BS 4515. Hardness values shall not exceed 270 HV10. Welding shall not be
performed at pipe welds.
10) External anode faces shall be cleaned of all materials, including anti-corrosion coating
11) Anode numbers shall be identified against the pipe numbers in CONTRACTOR records.
CONTRACTOR tally system shall separate anode from plain pipe.
12) The gap between bracelet anode and CWC shall be sealed flush with epoxy mastic or similar
compound.

11.3 Crude Oil Tank Cathodic Protection Installation

11.3.1 Installation preparation for cathodic protection

Be familiar with drawings before the construction, find out problems and solve them, check the
equipment and materials after their arriving in according to the design documents. Collaborate
with constructors to pre-bury pipe for cable protection.
During construction these principles should be followed: first grouting inside foundation and
then outside foundation; first prefabrication and then installation; first installation and then test.
Pay attention to cooperation with builder and erector.
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11.3.2 Construction procedure of cathodic protection of crude oil tank

After the crude oil tank foundation installation civil work is satisfied, then start the cathodic
protection installation work

1) Check and acceptance of arrived materials and equipment.

2) Laying of grid anode.
3) Installation of reference ectrode and anode cable.
4) Reference electrode installation.
5) Anode cable installation.
6) Aluminium Anode Installation.
7) Cable Installation.
8) Rectifier installation.

11.3.3 Tank cathode Protect system test

The cathode protect system should be tested after all installation work were finished, rectifier
test must meet the demands, reference electrode should be fully polarized.
Before the cathode protecting system was powered on, the voltage value of each cathode
protect point in the storage tank should be measured by the digital multimeter and then write
down the records as the reference date for the over voltage protection testing.
The voltage should be given continuously by the power supply equipment from low to high
during the cathode protect testing with impressed current.
Rectifier setting: power supply equipment rate voltage 5V. Protecting voltage value of the
storage tank cathode protection at each point should be measured on the test stake clip and
recorded. The given voltage value of power supply equipment should be raised or reduced
according to the protecting voltage value of the storage tank cathode protection at each point.
11.4 SPM & PLEM Bracelet Anode Cathodic Protection Installation

The anode installation work of SPM & PLEM will be carried out in the manufacturing yard of
VENDOR. Before anode installation, SUBCONTRACTOR will ensure that the technical
requirements comply with the approved specifications and drawings. During the installation
process, SUBCONTRACTOR will perform installation and protection work according to design
requirements and third-party requirements.
There was no anode installation work during on-site installation.
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12 PRECOMMISSIONING, TESTING AND INSPECTION

Each anode and bonding cable attachment shall be inspected for electrical continuity and
mechanical strength before re-coating, as directed by OWNER. Unsatisfactory bonding cable
attachments shall be removed and remade by re-cleaning and re-attaching in a new location.

1) Anode conductor attachment electrical continuity shall be tested with an ohmmeter.

Electrical resistance between anode segments and the pipe joint shall show close to zero (0)
ohm resistance.
2) Mechanical strength of the anode cable shall be checked by a firm side blow from a 1-kg
hammer, and then checked visually for any sign of inadequate bonding.
3) CONTRACTOR shall submit document the results of all tests for inclusion in the
commissioning manual.
13 DOCUMENTATION

CONTRACTOR shall submit to OWNER for approval the following documents:

a. Description of anode application equipment

b. Anode application procedures

c. Material technical data sheets

CONTRACTOR shall submit to OWNER , at data book comprising:

a. Inspection reports

b. Physical test reports

c. Tally record of anode pipes

d. Material certificates, All certificates shall be in the English language and use metric units of
measure.

The data book and all associated original documentation shall be approved and signed by the
CONTRACTOR and OWNER Representatives. All documentation shall be supplied in hard copy
and electronic format.
APPENDIX -1 DETAIL PROCESS OF THERMIT WELDING
APPENDIX - 2 EXAMPLE OF QC REPORT
Date
QC-EL-028
ENGINEERING, PROCUREMENT & CONSTRUCTION LAWE-
LAWE RDMP RU V - BALIKPAPAN Doc. No Page
of

Subject : CATHODIC PROTECTION TEST DATA Project No. : 26076

Area : Test Instrument

Type of material : Type :
Location : Range :
Reference drawing : Serial No. :
Temperature : Manufacture :
Weather :

No. Point No. Input Voltage to DC Output Voltage Rate Output Current Potential Continuity test Insulating Resistance Remarks
TR. Rectifier (V) Rectifier (V) Rectifier (%) Level (M-ohm)

Prepared by : Reviewed/Witness by : Reviewed/Witness by : Reviewed/Certified by :

QC CONSTRUCTION CONTRACTOR COMPANY THIRD PARTY

SUBCONTRACTOR

NAME : NAME : NAME : NAME :

SIGN : SIGN : SIGN : SIGN :

DATE : DATE : DATE : DATE :