Approved Code B Sark Mecon Mpe TCP DD 01

DESIGN DOCUMENT Doc No. R.
FOR
SARK/MECON/MPE/TCP/DD/01 00
TEMPORARY CATHODIC
PROTECTION Page : 1 of 28
OWNER : PMC : CONTRACTOR :
Is MECON PMC for the Project NOW?
OWNER : M/s. GOA NATURAL GAS PVT LTD
PMC : M/s. MECON LIMITED
PIPELINE : M/s. M P ENGINEERING CONSTRUCTIONS (INDIA)

PVT. LTD
CONTRACTOR
CP CONTRACTOR : M/s. SARK EPC PROJECTS PVT LTD
DESIGN DOCUMENT
FOR
TEMPORARY CATHODIC PROTECTION SYSTEM

27/07/2020
Document No: SARK/MECON/MPE/TCP/DD/01
Issued for Review &

00 23.07.2020 DP KG MECON / GNGL
Approval
Prepared By Approved
Rev. Date Description Approved By
SARK By SARK
FOR
TEMPORARY CATHODIC
Table of Contents
1 INTRODUCTION ....................................................................................................... 4
1.1 SCOPE OF WORK .................................................................................................. 4

1.2 TEMPORARY CATHODIC PROTECTION SYSTEM OVERVIEW ......................................... 5
2 DESIGN APPROACH ................................................................................................. 5
2.1 INTRODUCTION ................................................................................................... 5

2.2 GENERAL PIPELINE DETAILS.................................................................................. 6
2.3 TEMPORARY CATHODIC PROTECTION SYSTEM DESIGN LIFE ...................................... 6
2.4 DEFINITIONS AND ABBREVIATIONS ....................................................................... 6
2.5 CODES AND STANDARDS ...................................................................................... 7
2.6 PHILOSOPHY OF TEMPORARY CATHODIC PROTECTION SYSTEM ................................. 8
2.7 TEMPORARY CATHODIC PROTECTION DESIGN CRITERIA ......................................... 10
2.8 TEMPORARY CATHODIC PROTECTION CURRENT DENSITIES..................................... 11
3 MATERIALS ............................................................................................................ 12
3.1 FORMAT AND ORGANIZATION OF THE DETAILED ENGINEERING PACKAGE ................. 12

3.2 SACRIFICIAL MAGNESIUM ANODES ...................................................................... 12
3.3 BACKFILL MATERIAL ........................................................................................... 13
3.4 SACRIFICIAL MAGNESIUM ................................................................................... 13
3.5 TEST STATION ................................................................................................... 14
3.6 CABLES ............................................................................................................ 15
3.7 CABLE LAYING ................................................................................................... 15
3.8 CABLE TO PIPE CONNECTION............................................................................... 17
3.8.1 SAFETY PRECAUTIONS ................................................................ 17
4 DESIGN CALCULATIONS ........................................................................................ 17
4.1 PIPELINE SURFACE AREA .................................................................................... 17

4.2 PIPELINE CURRENT REQUIREMENT ....................................................................... 18
4.3 NUMBER OF ANODES REQUIRED BY WEIGHT ......................................................... 18
4.4 TOTAL CIRCUIT RESISTANCE ............................................................................... 19
4.4.1 INDIVIDUAL ANODE TO BACKFILL RESISTANCE ................................ 19
4.4.2 INDIVIDUAL PREPACKAGED ANODE TO SOIL RESISTANCE .................. 20
4.4.3 TOTAL CABLE RESISTANCE .......................................................... 21
FOR
TEMPORARY CATHODIC
4.4.4 TOTAL CIRCUIT RESISTANCE ........................................................ 21

4.5 NUMBER OF ANODES REQUIRED BY CURRENT OUTPUT OF SINGLE ANODE ................. 21
4.5.1 INDIVIDUAL ANODE CURRENT OUTPUT ........................................... 21
4.5.2 NUMBER OF ANODES REQUIRED BY CURRENT OUTPUT ...................... 22
4.6 CONCLUSION .................................................................................................... 22
4.6.1 PIPELINE .................................................................................. 22
5 BILL OF MATERIALS .............................................................................................. 23
6 SCHEDULE OF TEST STATIONS ............................................................................... 23
ANNEXURE - A : DESIGN CALCULAITON ....................................................................... 24
ANNEXURE - B : BOM PIPELINE .................................................................................... 25
ANNEXURE - C : TLP SCHEDULE ................................................................................... 26
ANNEXURE - D : CP DRAWINGS .................................................................................... 27
ANNEXURE - E : SOIL RESISTIVITY REPORT ................................................................. 28

FOR
TEMPORARY CATHODIC
1 INTRODUCTION
M/s GOA NATURAL GAS PVT LTD has been intends for Survey, Design, detail engineering of
the temporary Cathodic protection (TCP) system using Mg / Zn galvanic anodes to protect the
external surface of 8”, 6", 4" dia, 3LPE Coated pipeline in the Geographical Area (GA) of Goa
against corrosion for a design life of as specified in specification enclosed with the tender for
temporary cathodic protection system, approved design document, data sheets & drawings
M/s MECON Limited has been for Survey, Design, detail engineering of the temporary
Cathodic protection (TCP) system using Mg / Zn galvanic anodes to protect the external surface
of 8”, 6", 4" dia, 3LPE Coated pipeline in the Geographical Area (GA) of Goa against corrosion
for a design life of as specified in specification enclosed with the tender for temporary cathodic
protection system, approved design document, data sheets & drawings.
M/s M P ENGINEERING CONSTRUCTIONS (INDIA) PVT. LTD have been awarded a

contract for Survey, Design, detail engineering of the temporary Cathodic protection (TCP)
system using Mg / Zn galvanic anodes to protect the external surface of 8”, 6", 4" dia, 3LPE
Coated pipeline in the Geographical Area (GA) of Goa against corrosion for a design life of as
specified in specification enclosed with the tender for temporary cathodic protection system,
approved design document, data sheets & drawings.
M/s SARK EPC Projects Pvt. Ltd., a Cathodic Protection Specialist Company, has been
awarded a sub-contract by M/s M P ENGINEERING CONSTRUCTIONS (INDIA) PVT. LTD
for Survey, Design, detail engineering of the temporary Cathodic protection (TCP) system using
Mg / Zn galvanic anodes to protect the external surface of 8”, 6", 4" dia, 3LPE Coated pipeline
in the Geographical Area (GA) of Goa against corrosion for a design life of as specified in
specification enclosed with the tender for temporary cathodic protection system, approved
design document, data sheets & drawings.
1.1 SCOPE OF WORK
This document covers the Design, Detailed Engineering, Procurement & supply of TCP materials,
Installation, Testing & Commissioning of Temporary Cathodic protection system for the corrosion
protection of external surface of the proposed pipeline for two years. The main purpose of the
Temporary Cathodic Protection (TCP) System is to deliver protection to the external surface of
the pipeline during the construction phase of the pipeline for 2 years or Permanent Cathodic
Protection System is commissioned whichever is later.
Pipeline details as below.
Sr. No. Pipeline DIA Length in KM Remarks

1 8’’ 4.5 Kundai IDC Junction T-
2 4” 5.5 Point To Mercy Circle
FOR
TEMPORARY CATHODIC
1.2 TEMPORARY CATHODIC PROTECTION SYSTEM OVERVIEW
The following design parameters have been used for the proposed Cathodic protection
system.
 Type of System: Temporary CP (TCP): Sacrificial /Galvanic anodes.

 Design life: 2 Years
 Current Density: 25 µA/Sq.- mtr (for more than 100 ohm-m resistivity) as per
Standard Technical document No: MEC/TS/05/E9/016A
 Type of anode: Magnesium (weight: 5kgs)
 Anode utilization factor: 0.6 for End connected.
 Anode potential: -1.75 V (High Potential anode for locations with resistivity more
than 30 ohm –meter to 50 ohm –meter w.r.t Cu/
 Anode consumption rate: 7.9 kg/ (A yr.) Max.
 Safety factor: 30%
 Pipeline Natural Potential : (-) 0.45 V w.r.t Cu/CuSO4 and protection criteria: Min
(-) 0.95 V (ON) , Max (-) 1.5 V ( ON) w.r.t Cu/CuSO4.
 Soil Resistivity consider in design: 2200 Ohm.meter (as per resistivity survey held
my M/s MP Engineering. Resistivity report attached in Annexure-E)
2 DESIGN APPROACH
2.1 INTRODUCTION
The tender specifications indicates the type of Cathodic Protection System and provide the
basic criteria and input parameters to be adopted for the detailed design of the Cathodic
Protection System.
The intent of this section is to propose design data and criteria for the Temporary Cathodic
Protection work for Kundai IDC Junction T-Point To Mercy Circle.
FOR
TEMPORARY CATHODIC
2.2 GENERAL PIPELINE DETAILS
The general pipeline details under our scope of work are summarized herein as under:
Sr. No. Pipeline Dia. (Inch) Pipeline Length (km) Type of Coating
1 8” 4.5 (Approx.) 3LPE
2 6” 5.5 (Approx.) 3LPE
2.3 TEMPORARY CATHODIC PROTECTION SYSTEM DESIGN LIFE
In accordance with the project technical specification, the Design life for Temporary
Cathodic Protection System shall be Two years (2) or till commissioning of PCP system
whichever is later.
2.4 DEFINITIONS AND ABBREVIATIONS
Terms Definition
A or Amps. Ampere.
AC Alternating Current.
DC Direct Current.
Anode The electrode through which current is discharged into the

electrolyte.
Cathode The electrode through which direct current leaves the electrolyte
or the structure receiving corrosion protection with installed CP.
Cathodic Protection Technique to protect metallic structure in contact with an

electrolyte by causing direct current to flow from electrolytic
environment to metal surface.
Electrolyte A liquid or liquid component in composite material like soil, in

which electric current flows by movement of ions.
FOR
TEMPORARY CATHODIC
Terms Definition
Groundbed System of buried or submerged anodes.
Protected potential The structure-to-electrolyte potential measured after application

of cathodic protection.
Protected Structure A structure to which cathodic protection is applied.
Protection Current The current made to flow into a metallic structure from electrolyte
in order to protect the metallic structure.
Reference Cell An electrode that serves as basis of comparison in the

measurement of other electrode potentials.
Structure/Electrolyte The difference in potential between a structure and a specified

Potential reference electrode in contact with the electrolyte.
2.5 CODES AND STANDARDS

The system design, performance and materials to be supplied shall generally conform to
the requirement of the latest revision of following Mecon Standard Specifications,
International Codes and standards:
Doc. No. Description
MEC/TS/05/E9/016A MECON Standard Technical Specification

Rev.1
NACE Standard RP- Standard Practice for Control of External Corrosion on

0169-2007 Underground or Submerged Metallic Piping systems.
NACE Publication Measurement technique related to criteria for CP of Underground

10A190 or Submerged Steel Piping System (as defined in NACE Standard
RPO169-83).
NACE Standard RP- Standard Practice Mitigation of Alternating Current and Lighting
0177 Effects on Metallic Structures and Corrosion Control Systems.
FOR
TEMPORARY CATHODIC
Doc. No. Description
NACE Standard RP- Standard Practice The Electrical isolation of Cathodically Protected
0286 Pipelines.
NACE Publication No. Cathodic Protection Monitoring for Buried Pipelines.

54276
NACE standard RP- Standard recommended practice Design, Installation and

0572 Operation of Impressed Current Deep well Groundbed.
BS 7361 Part I Code of Practice for Cathodic Protection for land and Marine
applications.
VDE 0150 Protection against Corrosion due to Stray Current from DC

Installations.
IS:7098 Part I XLPE insulated cables.
IS:1554 Part I PVC Insulated (Heavy Duty) cables
2.6 PHILOSOPHY OF TEMPORARY CATHODIC PROTECTION SYSTEM
Temporary cathodic protection system to pipeline shall be a Sacrificial Anodes system and
be designed using pre-packaged Sacrificial Magnesium. The pre-Packaged Magnesium shall
be installed in a horizontal configuration to earth and perpendicular to the Pipeline.
As per the Mecon technical specifications, along ROW where soil resistivity predominantly
remains low, ranges from 0-10 ohm – m and pH value is within 9, zinc anodes may be
provided. Anodes of type I as per ASTM-B 418 standard shall be used for seawater, brackish
water or saline electrolyte application and anode of type II as per ASTM-B 418 standard
shall be used for fresh water, back fill and soil applications.
Along ROW where soil resistivity predominantly in the range of 10 ohm – m to 30 ohm – m
low potential (-1.55V) magnesium anodes may be provided.
Along ROW where soil resistivity is predominantly in the range of 30 ohm – m to 50 ohm –
m high potential (-1.75V) magnesium anodes may be provided.
FOR
TEMPORARY CATHODIC
At high resistivity area where resistivity is of the order of 50 ohm – m and above magnesium
ribbon anodes may be provided.
Anodes shall be installed along the pipeline at suitable intervals as per pipeline protection
voltage attenuation calculations and ground bed resistance/current output of anode
installations.
Minimum one anode installation shall be provided for every 1 (one) km of the pipeline. At
high resistivity area the magnesium ribbon anodes shall be installed all along the pipeline
by the side of the pipeline in the pipeline trench.
Each Electrically continuous section of pipeline shall preferably be protected by single type
of anode to avoid inter-anode circulation currents as per Mecon technical specifications.
The anodes shall be installed at sufficient depth to reach moist soil and shall be separated
from the pipe as far as 5 meter as possible (as per space avaibility) line by at least 5m
respectively. The magnesium ribbon abode shall be separated from the pipeline by at least
½ meter. The anode connections to pipeline shall be routed through test stations.
For sacrificial anode ground bed which shall be integrated with permanent CP System the
leads of all the anodes shall be brought up to the test station and shall be terminated
individually.
Where Magnesium anode is used for protection of polyethylene coated pipeline, the anodes
shall be preferably of low potential type (-1.55V).
Monthly monitoring of TCP system including AC and DC voltages shall be carried out till
commissioning of PCP system.
Pipeline ends have to be sealed with proper end caps to avoid the entry of water / electrolyte
inside the pipeline.
FOR
TEMPORARY CATHODIC
The sacrificial anodes shall confirm to the requirements of ASTM-B 418 standard. The
potential and consumption rate of Magnesium anodes shall be as below:
Anode Open Circuit Potential (Theoretical) : -1.55 Volts (Low Potential)

: -1.75 Volts (High Potential)
Anode Consumption Rate : 7.9 kg / Amp – Year
Anode Utilization Factor : 0.88 for centre connected
0.6 for end connected
The potential and consumption rate of Zinc anodes shall be as below:
Anode Open Circuit Potential (Theoretical) : -1.10 Volts

Anode Consumption Rate : 11.24 kg / Amp – Year
Anode Utilization Factor : 0.85 for centre connected solid anodes
0.5 for end connected solid anodes
0.6 for ribbon anodes
Zinc anode Type – I shall be used for seawater, brackish water or saline electrolyte
application and Type - II shall be used for fresh water, back fill and soil applications.
2.7 TEMPORARY CATHODIC PROTECTION DESIGN CRITERIA
Criteria for determining the adequacy of protection to buried pipeline are defined in Mecon
technical speciation MEC/TS/05/E9/016ARev. 1 and the Cathodic Protection system shall be
designed to meet one of the following criteria:
“The pipe to electrolyte potential measurements shall be between (-) 0.95 V (ON) or more
negative as measured between pipe surface and saturated Cu-CuS04, reference electrode
contacting electrolyte when cathodic protection is applied but on potential measurement
shall not go more negative than (-)1.50 V (ON).“
“To prevent damage to the coating the limiting Pipe to Soil Potential should not be more
negative than (-) 1200 mV to avoid the detrimental effect of Hydrogen production and/or a
high pH at material surroundings.“
FOR
TEMPORARY CATHODIC
“The pipeline shall be considered protected when a minimum of (-) 300 millivolt potential
shift has been achieved from the initial native potential to the CP `ON’ potential.“
“In rare circumstances a minimum polarisation shift of (-) 100 millivolts shall indicate
adequate levels of cathodic protection for the pipeline. The formation of decay of this
polarisation shall be used in the criteria.“
Discretion to use any of the criteria listed above shall solely rest with the Owner / Owner’s
representative.
“A positive potential swing of 50-100 mV during TCP or more shall be considered as
sufficient to indicate the presence of an interference situation requiring investigation and
incorporation of mitigation measures.”
2.8 TEMPORARY CATHODIC PROTECTION CURRENT DENSITIES
The entire proposed pipeline are coated with Three Layer Polyethylene (3LPE) coating. The
current densities considered for the temporary cathodic protection system design as per
Mecon techhinical specification document no. MEC/TS/05/E9/016A (Rev. 1) are as follows:
Minimum Pipe Protection Current

Pipeline Surrounding
Density for TCP System (µA/m2)
Normal Soil ( 10-100 Ohm – m) 40
Marshy area/HDD ( < 10 Ohm – m) 75
High Resistivity area (more than 100 Ohm –

25
m)
Current density for marshy area/HDD (soil resistivity< 10 ohm.m) shall be considered for
design calculations.
A safety margin of 1.3 i.e. 30% shall be provided for the current requirement calculations
over and above the specified protective current densities.
FOR
TEMPORARY CATHODIC
3 MATERIALS
The preceding conceptual system design provides relevant references and criteria and
technical specifications for the major components of the temporary cathodic protection
equipments.
3.1 FORMAT AND ORGANIZATION OF THE DETAILED ENGINEERING PACKAGE
This part of the document is essentially devoted to the design and specifications of selected
materials and equipment based on the system design.
The specifications of the offered equipment and materials conform to the general
requirements outlined in the Enquiry specifications and the system design of this document.
Necessary inspection facilities for Customer’s representatives shall be organized at the

manufacturer’s/supplier’s premises.
Test Certificates shall be furnished, wherever applicable.
3.2 SACRIFICIAL MAGNESIUM ANODES
The anodes shall be of low potential type Magnesium alloy packed with special backfill. The
technical particulars of the Magnesium anodes are summarized herein under:
Sacrificial Magnesium Anode

Anode Type Magnesium anode (Low potential type)
Weight 5 kg (Approx.)
Length : 76 mm (+/- 2.5%)
Dimensions Width : 76 mm (+/- 5%)
Height : 500 mm (+/- 5%)
Pre packaged
200 mm (Dia.) x 1500 mm (Long)
dimensions
FOR
TEMPORARY CATHODIC
Sacrificial Magnesium Anode

Ref. Drawing No.: SARK-MECON-MPE-DWG-001
3.3 BACKFILL MATERIAL
All sacrificial anodes shall be packaged in a cotton bag and shall be surrounded by a low
resistivity chemical backfill of the following composition:
 Gypsum : 75%
 Bentonite : 20%
 Sodium Sulphate : 5%
3.4 SACRIFICIAL MAGNESIUM
The anodes shall be installed horizontally & perpendicular configuration to the pipeline at a
depth such that the top of anode is below the bottom level of pipleine and facing to the test
station to avoid excavation on or nearby to the buried pipeline. In rocky terrain anode shall
be installed at 1.0 m depth in horizontal configuration.Howerver the depth of anode bed
shall be as per specification.
If two or more anodes are to be installed at one location, the centre to centre spacing
between consecutive anodes shall be 5 m for Magnesium anode.
Buried junction box for sacrificial magnesim anodes shall be used when install more than
one anode at particular location. The lead cables from the each anode shall be terminated
and joined in a buried junction box filled with epoxy. A single cable from buried jucntion box
shall be terminated in the test station.
The anode shall be installed in a manner as above to avoid interference problem on the
existing pipeline in a common ROW. (i.e.) anode shall not be installed on existing pipeline
side (if any) / in rare condition at least 3 m distance shall be considered from the existing
protected pipeline.
FOR
TEMPORARY CATHODIC
3.5 TEST STATION
The test station shall be provided along the pipeline route (ROU) for monitoring the
performance of the cathodic protection at approx. every 500 meter interval in uncongested
& 250 meters in congested area and shall also be provided at the following locaitons :
 At the location of sacrificial anodes.

 At any other locations considered necessary by Owner/Owner's representative.
Test stations used for sacrificial anodes shall have shunt for measurement of anode current,
andprovision for variableresistance insertion to limit the anode current output & anode
disconnecting link.
Test stations with current measuring facility shall be provided at each intermidiate CP station
drainage point (to measure parameters from drainage point), interference prone areas, at
min. one for every 10 km (Max.) along the pipeline route (ROU).
All test stations shall have 20% spare terminals, weather proof enclosure, having degree of
protection IP55 with hinged lockable shutter. Enclosure shall be made of sheet steel of at
least 3 mm thickness and shall be suitable for MS post mounting. The inner and outer
surfaces of test stations shall be epoxy coated. The test stations shall be designed with
termianals required for both temporary and permanent CP system and shall be suitable for
total life of permanent C.P. System.
Test station connection schemes are as mentioned below:
Test station connection scheme

Purpose Type
Basic Schemes
POTENTIAL MEASRUMENT A
CURRENT MEASUREMENT B
Combined Schemes
POTENTIAL MEASUREMENT WITH GALVANIC ANODE AI
CURRENT MEASUREMENT ALONG WITH GALVANIC ANODE BI
FOR
TEMPORARY CATHODIC
Minimum two cables shall be provided from each pipeline at any test station.
The test stations shall be installed with the front of the test station facing the pipeline. The
name plate of test stations shall in minimum carry the following information.
 “Test station No.”

 “Chainage in km”
 “Test station connection scheme”
 “Distance from pipeline in meters”
 “Direction of product flow”
Test station installation Chainages & types are furnished in test station schedule at the end
of this document. All the chainages are approximate only.
3.6 CABLES
Cables shall be XLPE insulation type Single Core Copper, PVC sheathed 650/1100V Standard
Copper Conductor PVC sheathed confirming to IS1554 Part
Cable Type & Purpose along with size
Cable Specifications Purpose
1C x 6 mm2 cable
(Unarmoured)( outer sheath Tail cable for Magnesium anodes
Yellow Colour)
1C x 10 mm2 cable
Current measurement cable, Pipeline to test station for
(Armoured) (outer sheath Red
sacrificial anode connection
Colour)
3.7 CABLE LAYING

FOR
TEMPORARY CATHODIC
All cables shall be laid in accordance with approved layout drawings. No straight through
joint shall be permitted in a single run of cable. Cable route shall be carefully measured and
cables cut to required length. Half meter cable slack shall be provided near anodes, pipeline
and test station to account for any settling.
All cable inside plant / station area shall be laid at a depth of 0.75 m. cables outside
station/plant area shall area shall be laid at a depth of minimum 1.5 m and in rocky terrain
cable shall be laid at depth of 0.5 m. For cables laid outside the station/plant area,
polyethylene warning mats shall be placed at 60% of depth or 0.9 m of depth from the
finished ground level.
All cable shall be laid in sand under normal brick cover and back filled with normal soil. RCC
or PVC or GI pipes of proper size shall be provided for all underground unarmoured cables
at road crossings. All underground unarmoured cables for PCP including anode tail cables
shall run through PE/PVC sleeves of proper size.
Hume pipe of proper size shall be provided for all underground cables for road crossings.
Cables shall be neatly arranged in trenches in such a manner that crisscrossing is avoided
and final take-off to equipment is facilitated.
In case of above ground cable, all unarmoured CP cables shall be laid in GI conduits of
sufficiently large size, up to accessible height for protecting against the mechanical damage.
The armour of all the cables from pipeline to test station (potential measurement, reference
cell cables, cathode cables, etc.) and test station to ground bed (anode cable) shall be
earthed only at test station end of the cable to avoid armour carrying CP current. The cable
armour shall be insulated by cutting and taping with insulation tape.
In case of above ground cable installations, all un-armoured CP cables shall be laid in GI
conduits of sufficiently large size.
FOR
TEMPORARY CATHODIC
Where cable crossing with underground pipeline, all cables shall be placed above the
underground pipeline.
3.8 CABLE TO PIPE CONNECTION
All cable connections to the pipeline shall be made by exothermic Process (Thermit Weld)
for uncharge pipeline
Cable to pipe connection on foreign / charged charged pipeline shall be made by pin brazing.
The resistance of the cable to pipe at pin brazing/thermit weld connection point shall not
exceed 0.1 Ohm.
After the thermit welding / pin brazing has been done, the exposed area shall be completely
covered with plastic funnel and sealed with mastic/M-seal then the funnel is filled by two
part epoxy of make Dr. Beck & Beck. This method shall provide total encapsulation.
3.8.1 SAFETY PRECAUTIONS
Pipeline Material should not be damaged while removing the coating.The pipeline surface of
the weld/braze area should be prepared to white metal finish without any dust or grease.
The thermit weld mould should be kept up right on the pipeline without any tilting. Care
should be taken on that the cable shall not be connected at the seam of the pipeline.
Distance between two cables to pipe connections at a should be a minimum 300 mm.
Charge to be ignited with proper sparking gun. Personnel to keep his head as away as
possible from mould & should wear proper hand gloves. Upon completion immediately
remove the mould and check the connection after cooling.
4 DESIGN CALCULATIONS
4.1 PIPELINE SURFACE AREA

FOR
TEMPORARY CATHODIC
The sample calculation for surface area of pipeline having diameter of 8’’ (with 3 LPE
coating) at approx. 4.4 KM provided as below :
SA =  x D x L
SA =  x 0.203 x 4500
SA = 2872.67m2.
Where :
SA - Surface area of pipeline (m2)
D - Diameter of pipeline (m)
L - Length of pipeline(m)
4.2 PIPELINE CURRENT REQUIREMENT
The sample calculation for current requirement of pipeline having diameter of 8’’ (with 3
LPE coating) at approx. 4.4 Km provided as below :
It = (Sa x Id x Sm)
It = (2872.67x 0.025 x 1.3)

It = 93.362Amps
Where :
It - C.P. current requirement (m-Amps.)
SA - Surface area of pipeline (m2)
Id - C.P. protective current density (0.025mA/m2)
Sm - Safety Margin (1.3)
4.3 NUMBER OF ANODES REQUIRED BY WEIGHT
The sample calculation for Anode requirement by weight of pipeline having diameter of 8’’
(with 3 LPE coating) at approx. 4.5 Km provided as below :
FOR
TEMPORARY CATHODIC
W = (It x Ct x L) / Uf
W = ((93.362x 7.9 x 2) / 0.6)1000
W = 2.45kg.
Where :
W - Total anode weight requirement (kg.)
It - Total current requiremnt (Amps.)
Ct - Consumption rate of anode (7.9kg/Amp-year)
L - Design Life (2 years)
Uf - Utilization Factor (0.6)
NA = W/ WA
= 2.45/5
= 0.49Nos.
Where :
NA - Number of anodes required (Nos.)
W - Total Anode weight requirement (kg.)
WA - Weight of individual Mg. anode (5.00kg.)
4.4 TOTAL CIRCUIT RESISTANCE
The total circuit resistance of TCP system is included the sum of the following resistance :
 Individual anode to backfill resistance

 Individual pre-packaged anode to soil resistance
 Cable resistance
 Pipe to earth resistance (Assumed 0.1 Ohms)
Detailed calculation for total circuit resistance is summarized as below :
4.4.1 INDIVIDUAL ANODE TO BACKFILL RESISTANCE

FOR
TEMPORARY CATHODIC
The calculation for individual anode to backfill resistance is provided as below :
0.159ρ  8L 
R  b  Ln a  1 
b L  D 
a  a 
Rb = (0.159 x 0.5 / 0.5) x (Ln (8 x 0.5 / 0.097) – 1)

Rb = 0.43 Ohms.
Where :
Rb - Individual anode to backfill resistance (Ohms)
pb - Backfill Resistivity (0.5 Ohm – m)
La - Length of bare anode (0.500m)
Da - Diameter of bare anode(0.097m)
4.4.2 INDIVIDUAL PREPACKAGED ANODE TO SOIL RESISTANCE
As per site soil resistivity survey, the average soil resistivity of readings for this line at 4
meter depth (twice) 2200 Ohm meter shall be considered for design calculations.:
RGB 
 2 2
0.159ρ  4L  4L S  L
Ln
2 S
 
 S 2  L2


 1
L 
 DS L L 
 
RGB = (0.159 x 2200) / 1.5) x (Ln ((4 x 1.5 x 1.5 + 4 x 1.5 x (4 x 4 + 1.5 x 1.5)1/2) /
(0.2 x 4)) + (4 / 1.5) – ((4 x 4 + 1.5 x 1.5)1/2 / 1.5) – 1)
RGB = 603.19 Ohms.
Where :
RGB - Prepacked anode to soil resistance (Ohms)
p - Soil Resistivity (2200 Ohm – m)
L - Length of prepacked anode (1.5 m)
S - Twice depth of anode installaiton (4 m)
D - Diameter of prepacked anode(0.2 m)
FOR
TEMPORARY CATHODIC
4.4.3 TOTAL CABLE RESISTANCE

The calculation for total cable resistance having complete anode current flow circuit with
pipe connection cable is provided as below :
RC = (Rtc x Ltc ) + (Rcc x Lcc)
RC = (0.00308 x 10) + (0.00183 x 10)
RC = 0.049 Ohms.
Where :
RC - Total Cable Resistance (Ohms)
Rtc - Anode tail cable (6 mm2) resistance per meter cable (0.00308
Ohms)
Ltc - Maximum anode tail cable length (10 m)
Rtc - Cathode cable (10 mm2) resistance per meter cable (0.00183
Ohms)
Ltc - Maximum cathode cable length (10 m)
4.4.4 TOTAL CIRCUIT RESISTANCE
The calculation for total circuit resistance is provided as below :
RT = Rb + RGB + RC + RP
RT = 0.43 + 603.19 + 0.049 + 0.1
RT = 603.77 Ohms.
Where :
RT - Total Circuit Resistance (Ohms)
Rb - Individual anode to backfill resistance (Ohms)
RGB - Prepacked anode to soil resistance (Ohms)
RC - Total Cable Resistance (Ohms)
RP - Pipe resistance (0.1 Ohms)
4.5 NUMBER OF ANODES REQUIRED BY CURRENT OUTPUT OF SINGLE ANODE
4.5.1 INDIVIDUAL ANODE CURRENT OUTPUT

FOR
TEMPORARY CATHODIC
The sample calculation for individual anode current output for the above calculated total
circuit resistance is provided as below :
Ic = Vd / RT
Ic = (1.75 – 0.45) /603.77

Ic = 2.15 Amps
Where :
IC - Individual anode current output (mAmps.)
Vd - Driving voltage (Volts) (Anode OCP – Protective potential of
steel)
RT - Total circuit resistance (Ohms)
4.5.2 NUMBER OF ANODES REQUIRED BY CURRENT OUTPUT
N = It / Ic
N = 93.36 / 2.15
N = 43.36 Nos.
Where :
N - Number of anode required by current output (Nos.)
It - Total current requirement (Amps.)
Ic - Individual anode current output (Amps.)
4.6 CONCLUSION
4.6.1 PIPELINE
From the calculation carried out above, the total anode required for the protection of pipeline
is given in below table.
FOR
TEMPORARY CATHODIC
Magnesium Anode Required By Weight
PIPELINE (8” & 6”)
No of anode requried by Weight as per design 1
Number of Anodes Required by Current as per design 83
Praposed anode by Current 84
We propose to install four Magnesium anode 5 Kg each (Total :84 nos) at approximately
every km interval along the pipeline route and ensure complete protection to pipeline.
However, if adequate protection is not achieved at any of the location then additional anodes
shall be provided to ensure complete protection in that particular portion as per instructions
of Engineer In - charge at site.
The tentative location of anode to be installed is shown in test station schedule furnished at
the end of this document.
5 BILL OF MATERIALS
Attached in Annexure-B
The quantity mentioned in Annexure- B is tentative only. If additional quantity is required

for the effective protection of pipeline, shall be provided.
6 SCHEDULE OF TEST STATIONS
The test station schedule provided in Annexure : C is tentative only. The test station & Mg
anode locations can be changed as per actual site conditions. (i.e.) actual installation
locations shall be decided on site taking into consideration accessibility.
FOR
TEMPORARY CATHODIC
ANNEXURE - A : DESIGN CALCULAITON

TCP CALCULATION
Magnesium Anode Required By Weight
Pipeline section 8" 6"
Soil Resistivity Range (Ohm - m) average average

Soil Resistivity Considered (Ohm - m) 2200 2200
Pipeline Dia. (Inch) 8 6
Pipeline Dia. (m) 0.203 0.152
Pipeline Length (m) 4500 5500
Pipeline Surface Area (m2) 2872.67 2633.28
Protective Current Density (mA/m2) 0.025 0.025
Utilization factor 0.6 0.6
Safety Margin 1.3 1.3
Current Required (mAmps.) 93.362 85.582
Total Anodes Required by Weight (kg.) 2.45853 2.25365
Individual Magnesium Anode Weight (kg.) 5.00 5.00
Number of Anodes Required (Nos.) 0.49 0.45

Magnesium Anode Required By Current Output
Length of Pre-Packaged Anode Lpa (m) 1.5 1.5
Dia. of Pre-Packaged Anode Dpa (m) 0.2 0.2
Twice Depth of Anode Axis 4 4
Resistance of Pre-Packaged anode in
603.19 603.19
Horizontal Configaration (Ohms)
Resistivity of Backfill Material (Ohms) 0.5 0.5
Length of Bare Anode (m) 0.5 0.5
Dia. of Bare Anode (m) 0.097 0.097
Resistance of Bare Anode to Backfill Material (Ohms) 0.43 0.43
Resistance of Anode Tail Cable (Ohms) per meter 0.00308 0.00308
Maximum Anode Tail Cable Length (m) 10 10
Pipe (Cathode) Cable Resistance (Ohms) per meter 0.00183 0.00183
Maximum Pipe (Cathode) Cable Length (m) 10 10
Total Cable Resistance (Ohms) 0.049 0.049
Total Circuit Resistance (Ohms) 603.77 603.77
Anode OCP (Volts) 1.75 1.75 High Potential Magnesium
Potential of Steel-Pipe (Volts) 0.45 0.45 Anodes to be used
Driving Voltage (Volts) 1.3 1.3
Current Output per Anode (mA) 2.15 2.15
Number of Anodes Required by Current Output 43.36 39.75

Praposed anode 84.00 At least 84 Anodes shall be
installed.
27/07/2020
FOR
TEMPORARY CATHODIC
ANNEXURE - B : BOM PIPELINE

ANNEXURE-B (BILL OF MATERIALS)
Sr.
DESCRIPTION UOM Design Qty
No.
1 Prepacked Magnesium anodes for Carrier/Casing Pipe protection (Min 5.0 Kg Each) Nos. 84
2 Supply, laying, termination, Glanding and ferruling TCP-Cables--The Cables shall be annealed high
conductivity, stranded copper conductor, 650/1100V grade, XLPE Insulated & PVC Sheathed in
new/existing test stations and junction boxes.
3 1c x 6 mm2 - Anode tail cable - unarmoured Mtr 840
4 1 core x 10 mm2 - current measurement cable & Pipeline to Test station- armoured Mtr 560
5 New test stations Normal Size-(Weather Proof with IP-55) as per tender drawings with name plate
Nos. 21
6 All Cable to pipe connections by Exothermic Process or Pin Brazing for all sizes (Upto 1C x 25mm2)
LS 44
Note :
The quantity mentioned above is tentative only. If additional quantity is required for the effective protection of pipeline, shall be
provided.
High Potential Magnesium Anodes to be used.

Cables sizes for various connections shall be as specified in the Bid Documents
27/07/2020
Page 1
FOR
TEMPORARY CATHODIC
ANNEXURE - C : TLP SCHEDULE

ANNEXURE-D (TEST STATION SCHEDULE)
TLP CABLES LENGTH IN METER

Mg Anode
1C X 6
Chainage Chainage (5 kg) for Cable to Pipe
Sr. No TLP Type sqmm 1C X 10
in KM (km) Normal Carier Connections
Unarmour sqmm
Size Protection
ed Anode armoured
tail Cable
1 0.500 AI 1 4 40 20 2
2 1.000 AI 1 4 40 20 2
3 1.500 AI 1 4 40 20 2
4 2.000 AI 1 4 40 20 2
5 2.500 AI 1 4 40 20 2
6 3.000 AI 1 4 40 20 2
7 3.500 AI 1 4 40 20 2
8 4.000 AI 1 4 40 20 2
9 4.500 AI 1 4 40 20 2
10 5.000 AI 1 4 40 20 2
11 5.500 BI 1 4 40 160 4
12 6.000 AI 1 4 40 20 2
13 6.500 AI 1 4 40 20 2
14 7.000 AI 1 4 40 20 2
15 7.500 AI 1 4 40 20 2
16 8.000 AI 1 4 40 20 2
17 8.500 AI 1 4 40 20 2
18 9.000 AI 1 4 40 20 2
19 9.500 AI 1 4 40 20 2
20 10.000 AI 1 4 40 20 2
21 10.500 AI 1 4 40 20 2
Total 21 84 840 560 44

The test station schedule provided above is tentative only. The locations of the above mentioned items can be
1). changed as per actual site conditions. (i.e.) actual installation locations shall be decided on site taking into
consideration accessibility.
The quantities mentioned above is for estimation purpose only. The above mentioned quantity may decrease or
2)
increase as per the site requirement.
PAGE 1
FOR
TEMPORARY CATHODIC
ANNEXURE - D : CP DRAWINGS
1 2 3 4 5 6 7 8 9 10
NOTE :
1. ALL DIMENSIONS ARE IN MM UNLESS OTHERWISE SPECIFIED.
1500
A
A
500
CABLE TO ANODE CONNECTION A

( NUT BOLT)
B
B
EPOXY FILLING
76 200
DETAIL 'X'
C
C
1C x 10 Sq.MM XLPE/PVC
UNARMOURED ANODE TAIL CABLE
A
COTTON BAG MS IRON

BACK FILL MG ANODE
(FLAT 18x5)
MATERIAL ASTM B843
D
D
TWO PART M-SEAL MS IRON
76
(FLAT 18x5)
CABLE TO ANODE CONNECTION
(NUT BOLT)
EPOXY HARDENER MS IRON

(FLAT 18x5)
E
E
76
1C x 10 Sq.MM XLPE/PVC
UNARMOURED ANODE TAIL CABLE
PVC PIPE MG ANODE

00 24.07.2020 ISSUED FOR REVIEW RV KD KG
F
F
REV. DATE DESCRIPTION PRED. CHKD. APPRD.
CABLE TO MG ANODE CONNECTION PROJECT :

DETAILED ROUTE SURVEY FOR PROPOSED
DETAIL-X SECTION A-A GNGPL’s STEEL & MDPE PIPELINE ROUTES IN
NORTH GOA
OWNER :
CHEMICAL COMPOSITION OF MG ANODE GOA NATURAL GAS PVT LTD,

HIGH POTENTIAL TYPE
PMC :
BACK FILL COMPOSITION TOLERANCE (As per DNV RP B401)
(%) WEIGHT CONTENT GYPSUM : 75% MECON LIMITED
ELEMENTS COMPOSITION :
G
G
LENGTH : ±5%
0.50 - 1.30 % BENTONITE : 20%
MANGANESE : WIDTH : ±5% PIPELINE CONTRACTOR:
COPPER : 0.02 % MAX. SODIUM SULPHATE : 5% M P ENGINEERING

HEIGHT : ±5%
SILICON : 0.05 % MAX. CONSTRUCTIONS INDIA PVT LTD
WEIGHT : ±5%
ALUMINIUM : 0.01 % DIMENSION OF BARE ANODE CP CONTRACTOR :
IRON : 0.03 % MAX. PREPACKAGED ANODE :
HEIGHT : 76
NICKEL : 0.001%MAX SARK
SARK EPC PROJECTS PVT. LTD.
MAGNESIUM (MG) WIDTH/DIA : 76 DIM : 1500MM LONG x 200MM DIA
: BALANCE
>= (-VE)1.75 V W.R.T. LENGTH : 500
ANODE OPEN CIRCUIT : DRAWING TITLE:
: Cu-CuSO4 REFERENCE WEIGHT : 5 KG. FABRICATION OF SACRIFICIAL MAGNESIUM ANODE (5KG) HIGH
POTENTIAL (THEORETICAL) POTENTIAL
H
H
CELL
GNGPL Document No.
---
SCALE SARK Document No. SHEET
NTS SARK-MECON-MPE-DWG-001 01 OF 01
1 2 3 4 5 6 7 8 9 10
420 MM X 297 MM - SIZE A3
1 2 3 4 5 6 7 8 9 10
NOTE :
1. ALL DIMENSIONS ARE IN MM UNLESS OTHERWISE SPECIFIED.
2. ALL CABLES WILL BE REQUIRED TO BE LAID AT A DEPTH OF
0.75 M INSIDE STATION / PLANT AREA AND 1.5 M DEPTH
OUTSIDE PLANT / STATION AREA IN 100 MM THICK SAND
UNDER BRICK COVER BACKFILLED WITH NORMAL SOIL AND IN
A
A
ROCKY TERRAIN AREA CABLE SHALL BE LAID AT 0.5 M DEPTH.
OUTER OR INSIDE PLANT THE ROUTE SHALL BE MARKED WITH
POLYTHENE CABLE WARNING MATS PLACED AT 60% OF
DEPTH OR 0.9 M OF DEPTH FROM FINISHED GROUND LEVEL.
HOWEVER, ALL ANODE TAILS FROM ANODE JUNCTION BOX TO
ANODE WILL BE 1.5 M DEEP APPROX.
3. CABLE ROUTE SHALL BE CAREFULLY MEASURED AND CABLES
TO BE CUT FOR REQUIRED LENGTH INCLUDING REQUIRED
GL GL LOOPS AT EITHER END. MINIMUM ONE METER SLACK/LOOP
SHALL BE PROVIDED NEAR ANODES, PIPELINE AND TEST
STATIONS TO ACCOUNT FOR ANY ADJUSTMENT.
4. CABLE LAYING FOR CURRENT MEASUREMENT TEST STATION,
B
B
REFERENCE ELECTRODE CABLES AND OTHER LENGTHY
CABLES SHALL BE CARRIED OUT ALONG THE TOP OF THE PIPE
BY SECURELY STRAPPING IT WITH ADHESIVE TAPE / NYLON
ROPE OR EQUIVALENT AS REQUIRED.
NORMAL SOIL
900
C
C
PE/PVC CABLE WARNING MATS
1500
ORDINARY BRICKS LAYER COVER
100
D
D
CABLE O.D SAND FILL
CABLES
100 100
100
SAND BED(100 MM)
600
E
E
CABLE TRENCH DETAILS
CONCRETE COVER CP CABLE 00 24.07.2020 ISSUED FOR REVIEW RV KD KG

F
F
2" Ø GI/PVC CONDUIT CEMENT GROUT PROJECT :
GNGPL’s STEEL & MDPE PIPELINE ROUTES IN
F.G.L F.G.L NORTH GOA
OWNER :
150
GOA NATURAL GAS PVT LTD,
VARIES
PMC :
MECON LIMITED
G
G
PIPELINE CONTRACTOR:
M P ENGINEERING
CONSTRUCTIONS INDIA PVT LTD
150
PER CABLE CP CONTRACTOR :
SARK
CABLE INSTALLATION IN CONCRETE DRAWING TITLE:
CABLE LAYING DETAILS

H
H
GNGPL Document No.
---
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
250 NOTE :
300 1) ALL DIMENSIONS ARE IN MM UNLESS STATED.
2) EVERY CABLE COMING TO THE TEST STATION IS TO BE LABELED ON BOTH ENDS WITH
250 NOTIFICATION NUMBER AS PER CONNECTION SCHEME USING PVC PERRULES
9 11 8 3) ANODIZE ALUMINUM NAME PLATE (120 X 120 X 1.5 MM) TO BE FIXED IN INNER SIDE OF
1 25 50
40
THE INNER SIDE OF DOOR
4) THE NUMBER OF ALL TEST STATION SHALL BE WRITTEN WITH BLACK PANT USING
A
A
100MM STENCILS ON THE OUTER SIDE OF THE FRONT SHUTTER IN UNIFORM MANNER.
19 5) THE TERMINAL PLATE TO BE SCREW FASTENED WITH MS ANGLES HAVING INTERNAL
175
THREADS
3 40 6) THE SHUTTER SHALL BE HINGED TYPED WITH CONCEALED LOCK AND IT SHALL HAVE
200
DOOR GASKET TO MAKE TEST STATION WEATHER PROOF (IP55) TYPE
4 7) LIGHT GRAY AND POWER COATED (PAINT SHADE 631 OF IS - 5, THICKNESS - 80 MICRON)
A 22 A
275
SHALL BE APPLIED TO THE INTERNAL AND EXTERNAL OF THE ENCLOSURE & MS ANGLES.
21 21
250
275
FO
4 FIX
8) CABLE ENTRY SHALL BE SEALED WITH SEALING COMPOUND AFTER INSTALLATION TO
IN
7
C NG
PREVENT WATER ENTRY INSIDE PIPE.
H
H PIP
CONNECTION SCHEME OF RELEVANT
9) RCC SHALL BE DONE AFTER TEST STATION INSTALLATION
I
TEST STATION TO BE PRODUCED HERE
O
6
LE E
TEST STATION NO.
CHAINAGE IN KM
TEST STN CONN. SCHEME TYPE
10) TEST STATION INSTALLATION SHALL BE DONE 1.2 M OR AS PER SITE CONDITION ON
DISTANCE FROM PIPE IN MTR
DIRECTION OF MAINLINE FLOW 2 NARROW SIDE OF ROW
11) LUGS FOR CABLE CONNECTIONS TO THE TEST STATION SHALL BE DOUBLE CRIMPED
ON THE CABLE CONDUCTOR.
25
TO BE WELDED 150 12) TEST STATION SHALL BE SO ERECTED AS TO SERVE AS A PIPELINE MARKER. ALSO
200 THEIR SHUTTERS SHALL BE PARALLEL TO THE PIPELINE.
5
B
B
175 25 18
13) THE NUMBER OF TERMINALS SHALL BE SAME FOR ALL THE TEST STATIONS. THE
12 INTERNAL THREADED BUSH SECTION A-A TERMINALS USED FOR ONE TEST STATION DEPENDS UPON THE REQUI-REMENT OF
SUITABLE FOR ALLEN BOLT THE CONNECTION AT THE PARTICULAR LOCATION.
13 WELDED
DOOR
NON THREADED BUSH
SUITABLE FOR ALLEN BOLT
18
1000
13 DOOR FIXING DETAILS
250
C
C
B B
50
75
15 RCC FOUNDATION 20
16 BILL OF MATERIAL
14
ITEM
DESCRIPTION QTY
NO.
1 TOP PLATE 300 x 250 x 3 mm THK. M.S. 1
250
150
2 SIDE PLATE 175 x 275 x 250 x 3 mm THK. M.S. 2
17 17
200
3 REAR PLATE 250 x 250 x 3 mm THK. M.S. 1

4 FRONT DOOR 3 mm THK. M.S. 1
24 160 5 BOTTOM PLATE 250 x 175 x 3 mm THK. M.S. 1
D
D
25 CONCEALED LOCK WITH 2 KEY(HINGED TYPE)
20 6 1
FGL FGL GL GL 7 HINGE FOR DOOR 2
8 PHENOLIC LAMINATED SHEET TERMINAL PLATE 200x 160 x 6 mm THK. 1
40 4 HOLES FOR FIXING
9 M.S. ANGLE FOR FIXING TERMINAL PLATE 40x40x5 THK. 20 mm LONG 4
TERMINAL PLATE
BRASS NICKEL PLATED BOLT M 6 DIA X 40 mm LONG WITH 2 Nos. M6
30 10 12 SET
WELD POINT NUT & 2 Nos. WASHER FOR EACH TERMINAL
SS316 CROSS HEAD SCREW FOR FIXING TERMINAL PLATE M 6 DIA 20
11 4
ELBOW mm LONG
FRONT VIEW SECTION
600
23 12 M.S. COUPLING PLATE TOP 200 x 150 x 5 THK. 1

20 WITHOUT SHUTTER AND TERMINAL PLATE 4"Ø MS PIPE 1000mm LONG SCH 40 (4.5 mm THK. MIN. )
13 1 SET
14 M.S. FOUNDATION PLATE 400 x 400 x 5 mm THK. 1 SET
15 M.S. STIFFNER PLATE 6 mm THK. 4
200
16 M.S. GALVANIZED HEXAGONAL BOLT M12 DIA X 50 MM LONG 4
17 RCC FOUNDATION M-20 GRADE(1:5:10 ) 600 mm x 600 mm x 800 mm 1
125
40 40 40 40 40
E
E
50 18
NEOPRANE (10% MIN) & BALANCE RUBBER 30 X 6 MM THICK AS
RECTANGULAR CROSS SECTION GASKET. REQUIRED
50
25 19 M8 ALLEN BOLT FOR DOOR LOCK NON DETACHABLE FROM DOOR 2
30
20 RUBBER BUSH 1
600 600 21 M.S HANDLE DIMENSION 25 mm X 100 mm X 3 mm 1
22 NAME PLATE DIMENSION 120 mm X 120 mm X 1.5 mm 1
700 700
8
23 4"Ø ELBOW M.S SCH 40 90 Deg. (4.5 mm THK. MIN. ) 1
50
AS
FRONT VIEW 10
24 10 MM DIA ROD 200 CIC BOTH WAYS
REQUIRED
SIDE VIEW 25 PCC FOUNDATION M-20 GRADE(1:5:10 ) 700 mm x 700 mm x 50 mm 1
160
50
F
F
11
30
DETAIL 'X' PROJECT :
NORTH GOA
8 TERMINAL PLATE (TYP) OWNER :
6
WASHER GOA NATURAL GAS PVT LTD,
26
NUT 120
14
400 400 PMC :

BOLT
Ø12 50 300 50 50 300 50
16 MECON LIMITED
22
G
G
50
50
50
50
CONNECTION SCHEME OF RELEVANT PIPELINE CONTRACTOR:

TEST STATION TO BE PRODUCED HERE M P ENGINEERING
6 CONSTRUCTIONS INDIA PVT LTD
400
400
300
300
300
300
120
10
TEST STATION NO. CP CONTRACTOR :
CHAINAGE IN KM
36
SARK
TEST STN CONN. SCHEME TYPE
50
50
50
50
40 Ø12 DISTANCE FROM PIPE IN MTR

DRAWING TITLE:
50 300 50 50 300 50 FABRICATION & INSTALLATION DETAILS OF TEST STATION
(NORMAL SIZE)
H
H
DIRECTION OF MAINLINE FLOW
DETAIL 'X' OF TEST TERMINAL 10
HING DETAILS GNGPL Document No.
7 TOP PLATE BOTTOM PLATE ---
TEST STATION IDENTIFICATION DETAIL
SECTION B-B SCALE SARK Document No. SHEET
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
NOTE :
1) ALL DIMENSIONS ARE IN MM UNLESS OTHERWISE SPECIFIED.

2) AT LOCATION OF THERMIT WELD CONNECTION REMOVE 50mm x 50mm
SQUARE OF PIPELINE COATING . EXPOSED AREA OF PIPELINE SHALL BE
FILLED WITH A COARSE FILE TO PREPARE SHINING METAL AND BE FREE
OF RUST, PAINT, DIRT, GREASE & MOISTURE.
A
A
3) POSITION MOLD OVER THE EXPOSED AND CLEANED AREA OF PIPELINE.
STARTING POWDER
MOLD POSITION THE CLEANED CONDUCTOR IN THE MOLD AFTER ENSURING
THE MOLD IS DRY BY PRE-HEATING OR MAKING A TEST JOINT.
4) REMOVE APPROXIMATE 40mm OF INSULATION FROM END OF CABLE .
INSERT COPPER SLEEVE FOR #14 AWG. TO #10 AWG. CABLE SIZES.
5) LOCK THE MOLD WITH THE HANDLE CLAMP; IF THE MOLD DOES NOT
CLOSE PROPERLY ADJUST THE TENSION OF THE MOLD AND INSERT
STEEL DISC AT THE BOTTOM OF THE MOLD CRUCIBLE.
PLASTIC CONTAINER 6) POUR THE WELDING POWDER INTO THE MOLD. THE WELDING POWDER
IS RETAINED IN THE UNDERSIDE OF THE CARTRIDGE. SPREAD THE
STARTING POWDER EVENLY OVER THE WELDING POWDER, PLACING A
SMALL AMOUNT ON THE TOP EDGE OF THE MOLD FOR EASY IGNITION.
WELDING POWDER 7) POSITION WELDER OVER EXPOSED AREA OF PIPELINE AND INSERT
B
B
CABLE UNDER MOLD , PACK CABLE AND MOLD WITH PACKING MATERIAL
(IF NECESSARY) TO SEAL MOLD AND CABLE OPENING .
8) COVER THE MOLD, PLACE IGNITER AT OPENING OF THE MOLD AND
APPLY SPARK WHICH WILL IGNITE STARTING POWDER AND THEN
WITHDRAW IGNITER QUICKLY TO PREVENT FOULING / BURNS . AFTER
CA-15/32 COVER STARTING POWDER HAS IGNITE HOLD MOLD IN PLACE FOR 30 SECONDS
FIRMLY . THEN REMOVE MOLD.
9) LIGHTLY TAP WELDER WITH HAMMER TO REMOVE SLAG.
WELDING POWDER 10) THE RESISTANCE OF THE CABLE TO PIPE AT THERMIT WELD
CONNECTION POINT SHALL NOT EXCEED 0.1 OHM.
11) THE CONNECTION SHALL BE TESTED BY STRIKING 0.5 KG HAMMER
DIRECTLY OVER THE CONNECTION. AND IF CONNECTION FAILS, THE
STARTING ABOVE PROCEDURE SHALL BE REPEATED AFTER WAITING TIME OF
APPROX 10 MIN FOR THE PIPELINE SURFACE TO COOL DOWN.
C
C
12) SEALING THE COMPLETED JOINT SEAL WITH EPOXY RESIN
POWDER FORMULATION ENSURING THAT EVERY METALLIC PART OF THE JOINT
IS COMPLETELY INSULATED. M-SEAL SHALL BE APPLIED AT THE POINT
OF CABLE EXIT & AROUND FUNNEL.
13) FUNNEL SHALL BE MINIMUM 15MM OVERLAPPING ON PIPE COATING ON
WELDING EACH SIDE.
POWDER CABLE 14) DISTANCE BETWEEN TWO CABLES TO PIPE CONNECTIONS (THERMIT
WELD) SHOULD BE A MINIMUM 300 MM.
15) A LOOP OF APPROX 1.0 MTR OF CABLE SHALL BE KEPT AT BOTH
DISC 16)
PIPELINE AND TEST STATION END.
THERMIT WELD PORTION OF THE PIPELINE SHALL BE CHECKED FOR ANY
HOLIDAY
PIPELINE
D
D
THERMIT WELDING CONNECTION
CABLE SIZE WELD METAL SIZE

E
E
2
UPTO 10 mm CA-15
16 TO 352 mm CA-32
TESTING VERIFICATION FOR

1MM THK.PVC FUNNEL EPOXY-HARDENER (10:1) CABLE POST ATTACHMENT.
(NOTE-12) MAKE -(DR. BECK) 1. HOLIDAY TEST.

2. HAMMER TEST.
THERMIT WELDING
CONNECTION
F
F
M-SEAL REV.
PROJECT :
DATE DESCRIPTION PRED. CHKD. APPRD.
CABLE DETAILED ROUTE SURVEY FOR PROPOSED

NORTH GOA
COATING OWNER :
M-SEAL
PMC :
PIPELINE MECON LIMITED

G
G
M P ENGINEERING
15MM 50MM 15MM CP CONTRACTOR :
SARK
DRAWING TITLE:
80MM CABLE TO PIPE CONNECTION BY THERMIT WELD
H
H
GNGPL Document No.
COATING CROSS SECTION OF FINISHED THERMIT WELDING CONNECTION ---
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
NOTE :
1. CABLE TO PIPE RESISTANCE AT BRAZING CONNECTION POINT

SHALL NOT EXCEEED 0.1 OHM.
2. ALL TRACES OF OIL, GREASE,MILL SCALE AND ANY OTHER
FLUX CONTAMINATIONS SHALL BE REMOVED ON THE COATING OR
STEEL BEFORE ANY FILING OR GRINDING.
A
A
BLAZING ALLOY 3. THE COATING SHALL BE REMOVED OVER AN AREA OF OF
APPROXIMATELY 50X50 MM USING A COARSE FILE OR SMALL
(FINE/MEDIUM) HAND GRINDING WHEEL. THE STEEL SHALL THEN
PIN BODY BE CLEANED TO BRIGHT METAL USING A NON-METALIC COARSE
GRINDER.
4. PIN BRAZING SHALL ONLY BE CARRIED OUT BY VENDOR USING
THE APPROVED PROCEDURE AND USING OPERATORS WHICH
BRAZING GUN BRASS THREADED BRAZING PIN HAVE BEEN QUALIFIED.
5. THE CONNECTION SHALL BE TESTED BY STRIKING 0.5 KG
HAMMER DIRECTLY OVER THE CONNECTION. AND IF CONNECTION
M8 X 30 MM LONG FAILS, THE ABOVE PROCEDURE SHALL BE REPEATED AFTER
WAITING TIME OF APPROX 10 MIN FOR THE PIPELINE SURFACE TO
B
B
COOL DOWN.
6. FUNNEL SHALL BE MINIMUM 15MM OVERLAPPING ON PIPE
COATING ON EACH SIDE.
DETAIL 'A' CUT SECTION OF PIN BRAZING STUD 7. SEALING THE COMPLETED JOINT SEAL WITH EPOXY RESIN
FORMULATION ENSURING THAT EVERY METALIC PART OF THE
DETAIL 'A' BRAZING PIN JOINT IS COMPLETELY INSULATED. M-SEAL SHALL BE APPLIED
AT THE POINT OF CABLE EXIT & AROUND FUNNEL.
8. DISTANCE BETWEEN TWO CABLES TO PIPE CONNECTIONS (PIN
COATING REMOVED M8 CERAMIC FERRULE BRAZING) SHOULD BE A MINIMUM 300 MM.
(50x50 APPROX.) PIPE WALL 9. A LOOP OF APPROX 1.0 MTR OF CABLE SHALL BE KEPT AT BOTH
PIPELINE AND TEST STATION END.
10.PIN BRAZED PORTION OF THE PIPELINE SHALL BE CHECKED FOR
C
C
ANY HOLIDAY.
11.PIN BRAZING SHALL BE CARRIED OUT ON CHARGED PIPELINE
ONLY.
PIPE WALL
PIN BRAZING TO THE PIPE SURFACE
D
D
PIN BRAZING SET UP COPPER CRIMP LUG (TABLE -1)
LUG SIZE CABLE SIZE
9 x 6 mm UPTO 10 mm²
8 x 12 mm 25 mm²
E
E
EPOXY-HARDENER (10:1) TESTING VERIFICATION FOR
1MM THK.PVC FUNNEL CABLE POST ATTACHMENT.
MAKE -(DR. BECK)
(NOTE-6) 1. HOLIDAY TEST.
2. HAMMER TEST.
BRASS THREADED BRAZING PIN M8 BRASS NUT
M8 X 30 MM LONG
COPPER CRIMP LUG 00 24.07.2020 ISSUED FOR REVIEW RV KD KG
BRASS WASHERS
F
F
(REFER TABLE 1) REV.
PROJECT :
DATE DESCRIPTION PRED. CHKD. APPRD.
PIN BRAZING M-SEAL CABLE DETAILED ROUTE SURVEY FOR PROPOSED

CONNECTION NORTH GOA
COATING OWNER :
M-SEAL
PMC :
PIPELINE MECON LIMITED

G
G
M P ENGINEERING
15MM 12MM 15MM CP CONTRACTOR :
SARK
50MM
DRAWING TITLE:
80MM CABLE TO PIPE CONNECTION BY PIN BRAZING
H
H
CABLE TO PIPE CONNECTION BY PIN BRAZING WITH THREADED STUD GNGPL Document No.
---
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
NOTE :
TEST STATION TEST STATION 1. ALL DIMENSIONS ARE IN MM. OR OTHERWISE MENTIONED GENERALLY 1
OR 4 MG ANODE SHALL BE INSTALLED PER TEST STATION AS PER
DESIGN.
[275(H) X250(W)X175(D)] [275(H) X250(W)X175(D)] 2. IF REQUIRED MORE NUMBER OF ANODE SHALL BE CONNECTED AS PER
CALCULATION.
A
A
3. CABLE LOOP OF 1M SPARE IS TO BE PROVIDED AT EACH ANODE AND
TEST STATION END.
4. THE PRE-PACKAGED MAGNESIUM ANODES SHALL BE INSTALLED IN A
HORIZONTAL CONFIGURATION TO EARTH AND PERPENDICULAR TO THE
PIPELINE AT A DEPTH SUCH THAT THE TOP OF ANODE IS BELOW THE
BOTTOM LEVEL OF PIPELINE AND FACING TO THE TEST STATION TO
AVOID EXCAVATION ON OR NEARBY TO THE BURIED PIPELINE.
5. PIPELINE DEPTH ARE AS PER PROVIDED DATA FROM CLIENT.
INSTALLATION OF SACRIFICIAL ANODE SHALL BE DONE AS PER DESIGN
1C X 6 Sq.MM XLPE,PVC OR AS PER SITE CONDITION.
1C X 6 Sq.MM XLPE,PVC UNARMOURED ,CU CABLE

UNARMOURED ,CU CABLE 1C X 10 Sq.MM XLPE,PVC
B
B
ARMOURED ,CU CABLE
1C X 10 Sq.MM XLPE,PVC
ARMOURED ,CU CABLE
GL GL GL GL
PIPELINE
DEPTH
C
C
1.5M PREPACKED
1.5M ANODE
UNARMOURED ,CU CABLE
UG .PIPELINE CLOTH BAG WITH
PREPACKED BACKFILL
ANODE MATERIAL
CLOTH BAG WITH 1C X 6 Sq.MM XLPE,PVC
D
D
BACKFILL MATERIAL UNARMOURED ,CU CABLE
ELEVATION 5M FOR MG ANODE
UG PIPELINE
ALL CABLE SIZE TO BE AS PER BID DOCUMENT/SPECIFICATIONS
E
E
ARMOURED ,CU CABLE
2M 1C X 10 Sq.MM XLPE,PVC
ARMOURED ,CU CABLE
TEST
RV KD KG
5M STATION 00 24.07.2020 ISSUED FOR REVIEW

F
F
PROJECT :
1C X 6 Sq.MM XLPE,PVC GNGPL’s STEEL & MDPE PIPELINE ROUTES IN
NORTH GOA
OWNER :
PMC :
MECON LIMITED
G
G
CLOTH BAG WITH M P ENGINEERING
BACKFILL CONSTRUCTIONS INDIA PVT LTD
27/07/2020
MATERIAL CP CONTRACTOR :
PREPACKED SARK
ANODE DRAWING TITLE:
5M FOR MG ANODE ANODE INSTALLATION DETAILS

H
H
PLAN FOR SACRIFICIAL ANODE INSTALLATION GNGPL Document No.
---
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
NOTE :
1. ALL DIMENSIONS ARE IN MM. OR OTHERWISE MENTIONED
2. TEST STATION SIZE SHALL DEPEND ON THE TYPE OF
CONNECTION SCHEME AND THE NUMBER OF TERMINAL
REQUIRED.
A
A
TEST STATION
[275(H) X250(W)X175(D)]
ALL CABLE SIZE TO BE AS PER BID DOCUMENT/SPECIFICATION
VARIABLE
TERMINALS RESISTOR
B
B
LINK
SHUNT
(0.5A/50mv)
ARMOURED ,CU CABLE
ARMOURED ,CU CABLE
C
C
MG ANODE
PIN BRAZING/
300mm THERMIT WELD
POTENTIAL MEASUREMENT WITH GALVANIC ANODE

CONNECTION SCHEME-AI
D
D
TEST STATION
[275(H) X250(W)X175(D)]
E
E
LINK
27/07/2020
F
F
PROJECT :
ARMOURED ,CU CABLE DETAILED ROUTE SURVEY FOR PROPOSED
1C X 10 Sq.MM XLPE,PVC NORTH GOA
ARMOURED ,CU CABLE OWNER :
MG ANODE
PIN BRAZING/ 300mm 60000MM(TYP) 300mm PIN BRAZING/
THERMIT WELD THERMIT WELD GOA NATURAL GAS PVT LTD,
PMC :
MECON LIMITED
G
G
CURRENT MEASUREMENT WITH GALVANIC ANODE
M P ENGINEERING
CONNECTION SCHEME-BI CONSTRUCTIONS INDIA PVT LTD
CP CONTRACTOR :
SARK
DRAWING TITLE:
TEST STATION CONNECTION SCHEME

H
H
GNGPL Document No.
---
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
NOTE :
1. ALL CHAINAGE IN METER UNLESS OTHERWISE SPECIFIED
TLP TYPE DESCRIPTION

AI POTENTIAL MEASUREMENT WITH GALVANIC ANODE
A
A
BI CURRENT MEASUREMENT WITH GALVANIC ANODE
4000
4500
2000
2500
3000
3500
5000
1000
1500
500
B
B
MATCH LINE WITH 'A'
AI AI AI AI AI AI AI AI AI AI
Mg Mg Mg Mg Mg Mg Mg Mg Mg Mg Mg Mg Mg Mg Mg Mg Mg Mg Mg Mg
LEGEND:
START
Mg Mg Mg Mg Mg Mg Mg Mg Mg Mg Mg Mg Mg Mg Mg Mg Mg Mg Mg Mg PIPE LINE
TEST STATION (NORMAL SIZE)

C
C
AI
AI
AI
AI
AI
AI
AI
AI
AI
AI
Mg MG ANODE (5 Kg)
D
D
10000
6000
6500
8000
8500
5500
7000
7500
9000
9500
MATCH LINE WITH 'A'
MATCH LINE WITH 'B'

BI AI AI AI AI AI AI AI AI AI
E
E
BI
AI
AI
AI
AI
AI
AI
AI
AI
AI
F
F
PROJECT :
NORTH GOA
OWNER :
PMC :
MECON LIMITED
G
G
10500
M P ENGINEERING
MATCH LINE WITH 'B'
AI
CP CONTRACTOR :
Mg Mg
SARK
FINISH
Mg Mg
DRAWING TITLE:
OVERALL TCP LAYOUT

AI
H
H
GAIL Document No.
---
1 2 3 4 5 6 7 8 9 10
FOR
TEMPORARY CATHODIC
ANNEXURE - E : SOIL RESISTIVITY REPORT

(A Joint Venture of GAIL Gas Limited and BPCL)
DETAILED ROUTE SURVEY FOR PROPOSED GNGPL’s

STEEL & MDPE PIPELINE ROUTES IN NORTH GOA
SOIL RESISTIVITY SURVEY REPORT FOR FOUR
SECTIONS
1.SV5-G TO KUNDAI IDC JUNCTION

2.KUNDAI IDC JUNCTION TO MERCY CIRCLE
3.KUNDAI IDC JUNCTION TO PONDA
4.MERCY CIRCLE TO GMC
SECON PRIVATE LIMITED

405, TANISHKA, OPP. GUNDECHA INDUSTRIAL COMPLEX
AKURLI ROAD, KANDIVALI EAST, MUMBAI – 400 101.
PH: (022) 28870000, FAX 022-28870000,
E-mail: secon.mumbai@secon.in, Website: http:// www.secon.in
Pipeline Network in North Goa Corrosion Survey Report
ABBREVIATIONS
BH No. Bore Hole Number

TP Trial Pit
Ch. Chainage
Cl Chloride
DS Disturbed Samples
EGL Existing Ground Level
I Current
Ep Oxygen activity
R Resistance
Eh Redox potential
a Electrode seperation
ρf Resistivity of formation
ρw Resistivity of water contained in the formation
Ft Factor dependent on the texture of the formation
Fw Factor dependent on the saturation.
Km Kilo meter
m Meter
GNGPL SECON
TABLE OF CONTENTS
1.0 PREAMBLE .......................................................................................................................... 1

2.0 INTRODUCTION ................................................................................................................... 1
3.0 SCOPE OF WORK ................................................................................................................ 1
4.0 LOCATION DETAILS FOR CORROSION SURVEY ................................................................... 2
5.0 METHODOLOGY FIELD INVESTIGATIONS ............................................................................. 2
5.1 Electrical Resistivity Survey .................................................................................................... 2
5.2 Principle and Methodology of Resistivity Survey by Wenner's 4-pin method ................................... 2
5.3 Effect of Resistivity on Corrosion ............................................................................................. 3
6.0 CHEMICAL ANALYSIS OF SOIL AND WATER SAMPLES ......................................................... 4
6.1 Laboratory Testing Procedures for Soil ..................................................................................... 5
6.1.1 Preparation of Aqueous extract ............................................................................................... 5
6.1.2 Moisture Content ................................................................................................................... 5
6.1.3 Measurement of pH along with Oxygen activity and Redox Potential............................................. 5
6.1.4 Determination of Chloride in Soil .............................................................................................. 5
6.1.5 Determination of Sulphate in Soil ............................................................................................. 6
6.1.6 Determination of Carbonate & Bicarbonate in Soil ...................................................................... 6
6.1.7 Determination of Hardness, Calcium & Magnesium in Soil ........................................................... 7
6.1.8 Determination of Nitrate in Soil ................................................................................................. 8
6.1.9 Determination of Sodium & Potassium in Soil ............................................................................. 8
6.2 Determination of Sulphide in Soil .............................................................................................. 9
6.2.1 Determination of Phosphate in Soil ........................................................................................... 9
6.2.2 Determination of Nitrite in Soil .................................................................................................. 9
6.2.3 Determination of Total Soluble Solids (TSS) in Soil ................................................................... 10
6.2.4 Determination of Organic matter in Soil ................................................................................... 10
6.2.5 Determination of Aerobic & Anaerobic bacteria in Soil ................................................................ 11
6.3 Laboratory Testing Procedures for Water ................................................................................ 11
6.3.1 Measurement of pH along with Oxygen activity and Redox Potential........................................... 11
6.3.2 Chloride Test for Water ........................................................................................................ 11
6.3.3 Sulphate Test for Water........................................................................................................ 12
6.3.4 Determination of Carbonate & Bicarbonate in Water ................................................................. 12
6.3.5 Determination of Calcium & Magnesium in Water ..................................................................... 13
6.3.6 Determination of Nitrate in Water ........................................................................................... 13
6.3.7 Determination of Sodium & Potassium in Water ....................................................................... 14
GNGPL SECON
7.0 ANALYSIS OF TEST RESULTS ............................................................................................ 15

7.1 Corrosion Behaviour of Soil based on Resistivity Test Results ................................................... 15
8.0 CONCLUSION .................................................................................................................... 23
9.0 REFERENCES ................................................................................................................... 23
GNGPL SECON
DETAILED ROUTE SURVEY FOR GNGPL’S NATURAL GAS PIPELINE IN NORTH GOA
CORROSION SURVEY REPORT
1.0 PREAMBLE
M/s Goa Natural Gas Private Limited (GNGPL), a joint venture of GAIL Gas and BPCL has been
authorized by PNGRB to set up a CGD network in North Goa and Mecon Limited (MECON) has been
appointed as EPMC Consultants for the said work.
To meet the above objective, M/s Goa Natural Gas Private Limited (GNGPL) proposes to lay a Steel &
MDPE Gas Pipeline network for supply of Natural Gas to various consumers in the cities of Panjim,
Mapusa, Porvorim and other cities in North Goa.
2.0 INTRODUCTION
M/s Goa Natural Gas Private Limited (GNGPL) has awarded the job of carrying out detailed route survey
for Natural Gas pipeline to M/s. SECON Private Limited vide FOA No: GNGPL/2016-17/03 dated
15.03.17.
As per scope of services, detailed engineering survey, soil stratification survey, soil resistivity survey
along the pipeline alignment shall be carried out.
The present report covers the details of Soil Stratification survey comprising of auger boring with visual
observations along the pipeline alignment and pipeline route.
As per scope of services, detailed engineering survey, soil stratification survey, soil resistivity survey
along the pipeline alignment shall be carried out.
The present corrosion survey report covers the details of electrical resistivity tests carried out along the
alignment and its inference on corrosion behavior of soil. In addition, chemical analysis of soil and water
samples also carried out.
3.0 SCOPE OF WORK

The brief scope of work includes the following:
• Carrying out Soil Resistivity Measurements at an intervals of approximately 500 m along the
pipeline route up to 3 m depth below EGL by using Wenner’s 4-pin method
• The resistivity measurements shall be carried out at 1.0 m, 2.0 m & 3.0 m depth below existing
ground level by using Wenner’s 4-pin method.
• Collection of Soil / Water samples at an intervals of approximately 10km along the pipeline route at
1.0 m and 2.0 m depth below EGL for chemical testing.
• Conducting Chemical Tests on Soil / Water samples to determine the chemical contents.
• Preparation and submission of report including soil resistivity values and graphs showing variation
of resistivity values along the pipeline routes. The report also include classification of corrosion
behavior of soil based on resistivity values.
GNGPL 1 SECON
4.0 LOCATION DETAILS FOR CORROSION SURVEY
The detail of alignment of proposed pipeline network in North Goa District is as under;
Sl. No Description of Section Length in km

1 GAIL’s SV-5G To Kundai IDC Junction 5.00
2 Kundai IDC Junction T-Point To Mercy Circle 17.98
3 Kundai IDC Junction To Ponda 8.66
4 Mercy Circle to Goa Medical College (GMC) 3.46
Total 35.10
5.0 METHODOLOGY FIELD INVESTIGATIONS

5.1 Electrical Resistivity Survey
Electrical Resistivity Tests have been carried out along the pipeline route approximately at every 500 m
intervals by using CRM 20 Electrical Resistivity Meter. The resistivity measurements are measured up to
1.0 m / 2.0 m / 3.0 m depth at each test location. At locations where multi-layer soil with large variation in
resistivity / corrosiveness is expected, measurements at additional depth were taken.
In general, the resistivity of soil, which shall be surrounding the pipe, is measured. In general electrodes
spacing is approximately equal to the depth of the measurement. The observations were made along the
pipeline route alignment. All measurements were taken at right angles to the right of way. All
measurements were made and recorded in metric units. While recording the data, reference to the
nearest TP /IP was made before arriving at the pipeline chainages.
5.2 Principle and Methodology of Resistivity Survey by Wenner's 4-pin method
Electrical Resistivity method is a highly popular geophysical technique used in Geo-technical studies. In
this method, a known current is sent into the ground through a pair of electrodes viz. “Current
electrodes” and the resulting potentials (voltage) developed across the ground surface is measured
through another pair of electrodes known as “potential electrodes”. The ratio between the potential (∆V)
developed and the current (I) sent gives the resistance “R” and is measured with the help of
Resistivity meter. There are a number of electrode arrangements (configuration), namely Wenner and
Schlumberger. Wenner‘s configuration is commonly used. In Wenner’s configuration, all the four
electrodes are kept equidistant (known as “electrode separation” ‘a’) along a straight line symmetrically
over the measuring point.
The resistance (R) values measured for each separation is multiplied by the configuration factor 2πa to
get apparent resistivity (ρa) i.e., ρa = 2πaR. The apparent resistivity (ρa) in ohm- m is considered as the
average resistivity of the formation from the surface up to a depth of ‘a’ (i.e., electrode separation in m).
Resistivity measurements give the values at the time of measurement under prevailing conditions.
The apparent resistivity ρa is considered as the average resistivity of the formation from the surface up
to a depth of ‘a’ (i.e., electrode separation). The resistivity sounding interpretation assumes horizontal
homogeneous layering. However, in nature, this is not always the case and wherever there is lateral in-
homogeneity, the resistivity results get distorted. In some such cases the resistivity reading may even
give negative values, which are to be considered as highly resistive layers with lateral in-homogeneity in
stratification.
While recording readings, care was taken to ensure that measurement at the spot was not influenced by
any foreign underground structures, presence of overhead lines and earth current.
GNGPL 2 SECON
5.3 Effect of Resistivity on Corrosion

In resistivity survey, the important physical parameter of estimating the apparent resistivity of subsoil at
various depths is carried out from measurements made on the ground.
Resistivity of formation (ρ f) can be expressed as,
ρf = ρw
Ft x Fw
Where,
ρ w = Resistivity of water contained in the formation
Ft = Factor dependent on the texture of the formation
Fw = Factor dependent on the saturation.
From above equation it can be inferred that the resistivity of the water / moisture content has a major
effect on the resistivity of formation. The resistivity of the water / moisture contained in the formation is, in
turn, dependent on the ion forming salts present, which are responsible for the corrosion activities. The
factor Ft is mostly dependent on the porosity of the formation. The effect of saturation on the resistivity is
asymptotic. About 15 to 20% of saturation, which is water, retaining capacity of most of the soils is
sufficient to change the value substantially and any further saturation may have only negligible effect on
the soil resistivity. Hence the measurement of resistivity (ρf) of the formation will help in estimating the
corrosion properties of the sub-surface formation. Uniform subsoil conditions are not generally found in
long pipelines. Different types of soils with varying permeability, different moisture content, porosity and
chemical composition cause different diffusion velocities of oxidising agents to the iron surface. These
result in locally separated anodic and cathodic areas (i.e.) macro cells. The soil resistivity generally
measures the degree of aeration of the soil and along with it the chances of forming oxygen type
electrochemical cells. The relationship between specific soil resistivity and corrosion behavior has been
well established. As the electrical resistance of soil reduces, the electrochemical process takes place
more efficiently. Based on the resistivity values, their effect on the corrosion behavior has been
evaluated. Extensive investigation has been carried out regarding effect of various ranges of resistivities
on steel sections.
The different ranges of values and classification are summarized below:
Resistivity (ohm-m) Degrees of Corrosivity Category
<10 Very highly aggressive A
10-25 Highly aggressive B
25-50 Medium aggressive C
50-100 Low corrosive D
> 100 Very low corrosive E
It has been observed that correct measurement of resistivity in soils is a fairly reliable method in
evaluating the type of corrosion protection necessary for buried pipelines.
GNGPL 3 SECON
6.0 CHEMICAL ANALYSIS OF SOIL AND WATER SAMPLES

The following tests have been conducted as per relevant standards on soil and water samples to
determine the chemical contents:
− pH
− Redox Potential,
− Chloride,
− Sulphates
− Sulphide,
− Carbonate & Bicarbonate
− Calcium, Magnesium, Nitrate, Sodium, Potassium, Phosphate & Nitrite
− Total Soluble Solids
− Organic Matter
− Anaerobic & Aerobic bacteria,
− Moisture Content
To get an idea of the effect of various chemical parameters and corrosivity, the following shall be
generally considered.
For Soil
Sl. No. Parameters Allowable Limits
1. Moisture content shall be Less than 20%
2. pH shall be More than 5
More than 400 mV, However between 200 – 400 mV is
3. Redox Potential at pH 7 shall be
Considered as moderate
Less than 0.01%, However between 0.02 – 0.05% is
4. Chloride shall be
5. Sulphate shall be
For Water
Sl. No. Parameters Allowable Limits
1. pH shall be Not less than 6
More than 400 mV, However between 200 – 400 mV is
2. Redox Potential at pH 7 shall be
3. Chloride shall be
4. Sulphate shall be
GNGPL 4 SECON
6.1 Laboratory Testing Procedures for Soil

6.1.1 Preparation of Aqueous extract
Calculated quantity of field soil sample is mixed with distilled water in the ratio of 1:5 & 1.10 Soil and
Water ratio. The suspension is mixed thoroughly and allowed to stand overnight and the extract obtained
by filtering with the help of a vacuum pump, final extract is filtered again and used for chemical tests
parameters by using standard procedure.
6.1.2 Moisture Content
The empty weight of the container (W1) is measured;
About 20 Gms of field sample is taken in a moisture cup and weighed (W2)
Sample is dried in a thermostatically controlled oven at 110°C for about 24 hours and the cup with the
dry sample is weighed (W3).
Calculation:
Natural Moisture Content (%) = (W2 - W3) X 100
(W3 - W1)
6.1.3 Measurement of pH along with Oxygen activity and Redox Potential
Calibrate the pH meter with pH 4 and pH 7 with standard NIST solution. Rinse the electrode with distilled
water shake off excess water. 75 ml of distilled water is added to 30 grams of soil sample. The
suspension is stirred for few seconds and allowed to stand for 1 hour with occasional stirring. It is stirred
again, immediately before testing. The pH value is recorded directly from the display after it stabilizes.
The same sample, which is prepared for pH measurement, is used for the measurement of oxygen
activity. Platinum electrode and the Calomel reference electrode are introduced into the soil suspension
and the Oxygen activity (Ep) value is recorded directly from the display after it stabilizes.
The Redox Potential (Eh), at pH 7, of the soil suspension is calculated as shown below.
Calculation:
Redox potential (mV), Eh = Ep + Er + 60 (pH-7)
Where,
Ep = Redox potential measured with reference to Calomel having a potential of Er (mV)
Er = +250mV for Calomel reference electrode
pH = pH of the soil
6.1.4 Determination of Chloride in Soil
40 Gms of oven dried and 2 mm sieved soil is taken & 200 ml of distilled water is added to it and shake
the suspension with the help of mechanical shaker or allow the soil suspension to stand overnight, filter
the suspension and filtrate is used for estimation of Chloride.
Titrate the known volume of aliquot from the above suspension in the pH range 7.0 to 10.0. Adjust
sample pH between 7 and 10 with sulphuric acid or sodium hydroxide if it is not in the range. Add 1 ml
Potassium Chromate indicator. Titrate with Standard Silver Nitrate titrant to brick red end point.
Standardize silver nitrate solution and establish reagent blank value.
Calculation:
Chloride (%) = BR (V1 – V2) X N (AgNO3) X 35.45 X V3 X 100
Wd X S X 1000
GNGPL 5 SECON
Where,
V1 = Volume of silver nitrate used for the sample
V2 = Volume of silver nitrate used for the blank
N = Normality of AgNO3
S = Volume of aliquot taken for titration (ml)
Wd = Weight of dry soil taken for filtration (Gms)
V3 = Total volume made for extraction
6.1.5 Determination of Sulphate in Soil
Weigh 20 Gms air dry specimen in a 250-ml conical flask. Add 100 ml of Morgan’s extraction. Shake the
suspension for one-half hour or keep it for overnight and filter through Whatman’s No. 42 filter paper or
equivalent. Take 25 ml aliquot and transfer to a 50 ml volumetric flask, add 20 ml of 10% Barium
Chloride and shake for 1 minute, then add 1 or 2 ml of 0.25 % gum acatia make up the solution to 50 ml
mark with distilled water and shake for a minute. Precipitate the suspension and take the reading
between 5 to 30 minutes i.e. after 20 minutes by using Nephelometer, before taking reading calibrate the
instrument with standard sulphate solution after warm up for a period of 15 minutes.
Calculation:
Sulphate (%) = Concentration X Volume made for extraction X Volume made for test X DF
Weight of soil in Gms X Aliquot taken for test X 10000
Where,
DF is the dilution factor if applicable
Sulphate as SO4, (PPM) = Sulphate as SO4 (%) X 10000
Sulphate as SO3 = Sulphate as SO4 x 0.8333
6.1.6 Determination of Carbonate & Bicarbonate in Soil
the suspension and filtrate is used for estimation of Carbonate & Bicarbonate.
Titrate the known volume of aliquot from the above suspension with the help of standard Hydrochloric
acid by using Phenolphthalein & Bromocresol green indicator.
Add 2 to 3 drops of Phenolphthalein indicator to 20 ml of aliquot
If pink colour appears (pH over 8.3), titrate the solution against standard Hydrochloric acid (0.02N)
End Point: Pink Colourless
Add 2 to 3 drops of Bromocresol green indicator to the above solution continue titrating against HCl (0.02
N)
End Point: Dark green Light pink (pH of 4.5)
Record volume of HCl used for both titrations
Calculation:
Phenolphthalein Alkalinity = A X N (HCl) X 50 X V3 X 100
Wd X S X 1000
GNGPL 6 SECON
Total Alkalinity = (A+B) X N (HCl) X 50 X V3 X 100

Wd X S X 1000
Where,
A = Volume of HCl used for titration to pH 8.3
B = Volume of HCl used for titration from pH 8.3 to pH 4.5
N = Normality of HCl
Use the following table as a guide to calculate bi-carbonate and carbonate concentrations
Results of Hydroxide Alkalinity as Carbonate Bicarbonate Alkalinity
Titration CaCO3 as CaCO3
Alkalinity as CaCO3
P=0 0 0 T
P<½T 0 2P T-2P
P=½T 0 2P 0
P>½T 2P-T 2(T - P) 0
P=T T 0 0
Where; P= Phenolphthalein alkalinity and T= Total alkalinity
6.1.7 Determination of Hardness, Calcium & Magnesium in Soil
the suspension and filtrate is used for estimation of Hardness & Calcium. Burette reading of Hardness is
used for the Calculation of Magnesium in soil.
Procedure for Hardness: Take 50 ml volume of aliquot from the above suspension. Add 2ml of Ammonia
buffer, and then add 1 or 2 drops of Erichrome black–T indicator titrate against EDTA (0.01M). The end
point of the titration is pink to blue.
Procedure for Calcium: Take 50 ml volume of aliquot from the above suspension. Add 2ml of 4% NaOH
and pinch of Murexide indicator. Titrate this solution against EDTA solution until the pink colour changes
to purple colour.
Procedure for Magnesium: Estimation of Calcium and Hardness has to be conducted earlier. Magnesium
may be estimated as the difference between Hardness and Calcium.
Calculation:
Hardness, % = BR X 0.01 X 100 X V1 X 100
Wd X S X 1000
Calcium, % = BR X 0.01 X 40.08 X V1 X 100

Wd X S X 1000
GNGPL 7 SECON
Magnesium, % = BR X 0.01 X 24.305 X V1 X 100

Wd X S X 1000
Where,
BR = Volume of EDTA used for sample
6.1.8 Determination of Nitrate in Soil
the suspension and filtrate is used for estimation of Nitrate in soil.
Take 20 ml of aliquot in a porcelain evaporating dish and add a pinch of Calcium carbonate powder to
each evaporating dish. Then evaporate the contents to dryness on a water bath. Cool and add 2 ml of
Phenoldisulphonic acid and rotate the porcelain evaporating dish so that all the residual salts come in
contact with phenoldisulphonic acid and allow the reagent to act for 10 minutes. After 10 minutes, add 15
ml of distilled water to each evaporating dish. Allow to cool and then add 10 ml of Sodium Hydroxide-
EDTA Solution. Transfer all the content of the basin to 100 ml volumetric flask and dilute the solution to
100 ml mark with distilled water. Stopper and mix the contents by turning the flask upside down holding
the stopper firmly. Allow Ten minutes time for the maximum development of the colour complex.
Switch on the Spectrophotometer and allow 10 minutes for the instrument to warm up before taking
absorbance of the coloured complex calibrate the instrument. Read absorbance at 420 nm, and then
calculate the concentration of nitrate directly from the standard graph. Similarly run blank without sample.
Calculation:
Nitrite (%) = Concentration X Volume made for extraction X Volume made for test X DF
Where,
6.1.9 Determination of Sodium & Potassium in Soil
the suspension and filtrate is used for estimation of Sodium & Potassium in soil.
Switch on the Flame Photometer and allow 10 minutes for the instrument to warm up before taking
readings calibrate the instrument, feed distilled water to the atomizer, wait at least for 30 seconds and
adjust meter reading to Zero, and then feed the filtrate samples to the atomizer & calculate the
concentration of Sodium & Potassium directly from the standard graph.
Calculation:
Concentration X Volume made for extraction X Volume made for test X DF
Sodium & Potassium (%) = Weight of soil in Gms X Aliquot taken for test X 10000
Where, DF is the dilution factor if applicable
GNGPL 8 SECON
6.2 Determination of Sulphide in Soil

the suspension and filtrate is used for estimation of Sulphide.
Take 50 ml of soil - water extract in conical flask. Add 2ml of Zinc acetate solution, shake it thoroughly.
Leave the solution for few minutes for precipitate formation. Filter the sample using glass fiber filter
paper. Transfer the precipitate along with filter paper to iodine flask. Add about 50 ml of distilled water.
Add 10 ml 0.025N iodine solution + 2 ml of 6N HCl. Shake it vigorously. If iodine colour disappears add
more iodine until colour persists. Titrate against standard sodium thiosulfate (0.025N) solution using
starch as indicator. End point is blue to colourless. Note down the burette reading. Follow the above
steps in the procedure for blank without sample, using distilled water. Iodine solution volume must be the
same for both blank and sample.
Calculation:
Sulphide (%) = (V1-V2) X N X 16 X V3 X 100
Wd X S X 1000
Where,
V1 = Volume of Sodium thiosulphate used for the blank
V2 = Volume of Sodium thiosulphate used for the sample
N = Normality of Sodium thiosulphate
6.2.1 Determination of Phosphate in Soil
the suspension and filtrate is used for estimation of Phosphate.
Take 50 ml of aliquot from the above suspension in the volumetric flask. Add 2ml of ammonium
molybdate reagent and mix thoroughly. Add 0.2 ml of stannous chloride (approximately 5 drops)
reagent. Prepare reagent blank by taking 50 ml D W along with reagents. Measure the intensity of blue
color in absorbance mode at 690nm, for standards as well as samples, by setting the spectrophotometer
to “ZERO” absorbance with a blank. Take readings within 10 to 12 minutes. Plot the graph of
concentration in ppm against OD. Find out concentration factor from the graph.
Calculation:
Phosphate (%) = Concentration X Volume made for extraction X Volume made for test X DF
6.2.2 Determination of Nitrite in Soil
the suspension and filtrate is used for estimation of Nitrite.
To 50 ml of clear aliquot neutralized to pH 7 or to apportion diluted to 50 ml, add 1 ml of sulphanilamide
reagent. Let the reagent react for 2 to 8 minutes. Add 1 ml of NED dihydrochloride solution and mix
GNGPL 9 SECON
immediately. Let stand for at least 10 minutes. Measure absorbance at 540 nm. Prepare a standard
curve by adding suitable volumes of standard nitrite solutions and diluting to 50 ml with distilled water.
Develop colour as described in above procedure and measure absorbance at 540 nm.
Calculation:
Nitrite (%) = Concentration X Volume made for extraction X Volume made for test X DF
6.2.3 Determination of Total Soluble Solids (TSS) in Soil
the suspension and filtrate is used for estimation of Total Soluble Solids.
Take 50-ml of the clear filtrate in pre-weighed porcelain dish, or glass dish and concentrate by
evaporating in the water bath before finally drying in the oven at 110°C. The dish shall then be cooled to
room temperature in desiccators and weighed to get the weight of the residue. The percentage of total
soluble solids in the soil shall then be calculated on the basic of the soil taken for analysis.
Calculation:
Total Soluble Solids (%) = (W2-W1) X Volume of distilled water added X 100
Weight of soil X Aliquot taken for the test
Where,
W2 = Weight of dish after evaporation in Gms
W1 = Weight of dish before evaporation in Gms
6.2.4 Determination of Organic matter in Soil
Take 0.25 gm to 5.0 gm of oven dried (105°C) sample thoroughly ground and sieved through 2 mm
sieve. Transfer the weighed sample to a 500-ml. conical flask and add 10 ml. 1N Potassium Dichromate
(K2Cr2O7) solutions. Then add 20 ml. Conc. Sulphuric acid (H2 SO4) and mix gently by rotation to
ensure complete contact. Allow the mixture to stand for 30 minutes. Add 200 ml distilled water, 10 ml of
Ortho phosphoric acid (H3 PO4, 85%), 0.2 gm of Sodium fluoride and 1 ml of diphenylamine indicator.
Titrate the solution with 0.5 N Ferrous Sulphate (FeSO4.7H2O) solution. The color is dull green at the
beginning and then shifts to turbid blue as the titration proceeds at the end point the colour sharply turns
to brilliant green. Keep a blank titration without sample and follow the same procedure.
Calculation:
Organic matter (%) = BR (V1 – V2) X N of Ferrous Sulphate X 0.003 X 100 X 1.724 X 1.3
Weight of sample in Gms
Where,
i) V1 = ml of 1.0 N Ferrous sulphate solution used for blank titration.
ii) V2 = ml of 1.0 N Ferrous Sulphate solution used for sample titration.
iii) 0.003 = 1 ml of 1 N Potassium Dichromate = 0.003 g of organic carbon
iv) Factor 1.724 is called Van Bemmeler factor with the assumption of 58% of Carbon in soil organic
matter. Therefore Organic carbon (%) is multiplied by 1.724.
GNGPL 10 SECON
v) 1.3 = The use of heat of dilution don’t give complete oxidation of organic compound in soil. Walkely &
Black (1934) observed about 60-80 % of the soil organic carbon was oxidized by the heat of dilution and
the correction factor has to be considered to give an approximate estimate of soil.
6.2.5 Determination of Aerobic & Anaerobic bacteria in Soil
Take about 25 ml of sterilized mixture of 5 g yeast extract, 10 g Triptone and 5 g Sodium chloride in 1000
ml of distilled water in two test tubes. One test tube is airtight and the other having free air supply. Add
about 5 g of soil in each of the test tubes and allow the suspension to stand still for about two days.
Increased turbidity in the airtight test tube indicates the presence of anaerobic bacteria and the same in
the second test tube indicates the presence of aerobic bacteria.
6.3 Laboratory Testing Procedures for Water
Representative samples are filtered to remove any unwanted particles present, if any and used for
chemical testing.
6.3.1 Measurement of pH along with Oxygen activity and Redox Potential
100 ml of water sample is taken and stirred thoroughly before testing, the pH meter is calibrated with
standard NIST solution and pH of the water sample is measured.
To measure oxygen activity (Ep) and Redox potential (Eh).
The same sample, which is prepared for pH measurement, is used for the measurement of oxygen
activity. Platinum electrode and the Calomel reference electrode are introduced into the water sample as
per specifications. The Oxygen activity (Ep) value is recorded directly from the display. The Redox
Potential (Eh), at pH 7, of the soil suspension is calculated as shown below.
Calculation:
Redox potential (mV), Eh = Ep + Er+ 60 (pH-7)
Where,
Eh = Standard Redox Potential of soil suspension, in mV.
Ep = Oxygen activity measured with reference to Calomel reference electrode having a potential of Er,
in mV.
Er = + 250 mV for Calomel reference electrode
pH = pH of the water.
6.3.2 Chloride Test for Water
Titrate the known volume of sample (25 ml), in the pH range 7.0 to 10.0. Adjust sample pH between 7
and 10 with sulphuric acid or sodium hydroxide if it is not in the range. Add 1 ml Potassium Chromate
indicator. Titrate with Standard Silver Nitrate titrant to brick red end point. Standardize silver nitrate
solution and establish reagent blank value.
End point: Yellow Brick Red colour.
Calculation:
Chloride (mg/l) = BR (V1 – V2) X 0.0141 X 35.45 X 1000
ml of sample taken for the test
Where,
V1 = Volume of silver nitrate used for the sample
GNGPL 11 SECON
V2 = Volume of silver nitrate used for the blank

6.3.3 Sulphate Test for Water
Filter the sample, if there is any turbidity. Take 25ml of clear aliquot of the water sample or suitable
amount diluted to 25ml in100ml standard flask, add 1.0ml of 1:9 Hydrochloric acid and 1.0ml of
conditioning reagent (2) and mix well for 30 seconds. Read the absorbance on spectrophotometer after
10 minutes at 420 nm or read the turbidity occurred on turbidity meter. Prepare a calibration curve of
standards mg/l vs. absorbance. Read the sulphate concentration of sample directly from calibration
curve.
Calculation:
Sulphate (mg/l) = Concentration X Volume made for the test X DF
Volume of sample taken for the test
Where,
6.3.4 Determination of Carbonate & Bicarbonate in Water
Titrate the known volume of water sample with the help of standard Hydrochloric acid by using
Phenolphthalein & Bromocresol green indicator.
Add 2 to 3 drops of Phenolphthalein indicator to 20 ml of aliquot
If pink colour appears (pH over 8.3), titrate the solution against standard Hydrochloric acid (0.02N)
End Point: Pink Colourless
Add 2 to 3 drops of Bromocresol green indicator to the above solution continue titrating against HCl (0.02
N)
End Point: Dark green Light pink (pH of 4.5)
Record volume of HCl used for both titrations
Calculation:
Phenolphthalein Alkalinity = A X N (HCl) X 50 X 1000
S
Total Alkalinity = (A+B) X N (HCl) X 50 X 1000
S
Where,
A = Volume of HCl used for titration to pH 8.3
B = Volume of HCl used for titration from pH 8.3 to pH 4.5
N = Normality of HCl
Use the following table as a guide to calculate bi-carbonate and carbonate concentrations
Alkalinity as CaCO3
P=0 0 0 T
P<½T 0 2P T - 2P
GNGPL 12 SECON

Alkalinity as CaCO3
P=½T 0 2P 0
P>½T 2P-T 2(T - P) 0
P=T T 0 0
Where,
P= Phenolphthalein alkalinity and T= Total alkalinity
6.3.5 Determination of Calcium & Magnesium in Water
Procedure for Hardness: Take 50 ml of water sample. Add 2ml of Ammonia buffer, and then add 1 or 2
drops of Erichrome black–T indicator titrate against EDTA (0.01M). The end point of the titration is pink
to blue.
Procedure for Calcium: Take 50 ml of water sample. Add 2ml of 4% NaOH and pinch of Murexide
indicator. Titrate this solution against EDTA solution until the pink colour changes to purple colour.
Procedure for Magnesium: Estimation of Calcium and Hardness has to be conducted earlier. Magnesium
may be estimated as the difference between Hardness and Calcium.
Calculation:
Hardness, mg/l = BR X 0.01 X 100 X 1000
S
Calcium, mg/l = BR X 0.01 X 40.08 X 1000
S
Magnesium, mg/l = BR X 0.01 X 24.305 X 1000
S
Where,
BR = Volume of EDTA consumed during titration of water sample
6.3.6 Determination of Nitrate in Water
If large amount of suspended matter is present, filter suitably.
Pipette 2.0 ml portions of sample and blank into volumetric flasks (preferably 10ml), to each flask add 1
drop of sulphite-urea reagent. Place in a cold tray of water (10 to 20 °C) and add 2ml of antimony
reagent. Swirl flasks during the addition of each reagent. After about 4 minutes in the bath, add 1 ml of
Chromotropic acid reagent, swirl, and allow to cooling for a further 3 minutes, add concentrated sulphuric
acid to bring volume near the 10ml mark. Stopper flasks and mix by inverting. Allow to stand at room
temperature for 45 minutes and adjust volume to 10 ml with concentrated sulphuric acid. Perform the
final mixing very carefully, taking care to avoid the formation of air bubbles. Read absorbance at 410 nm
after final volume adjustment.
Use distilled water in reference cell of the spectrophotometer. Compare absorbance to calibration curve
and determine the concentration of nitrate in water sample.
Calculation:
Nitrate, mg/l = Concentration X 10 X DF
GNGPL 13 SECON
2
Where,
DF= Dilution Factor
6.3.7 Determination of Sodium & Potassium in Water
Switch on the Flame Photometer and allow 10 minutes for the instrument to warm up before taking
readings calibrate the instrument, feed distilled water to the atomizer, wait at least for 30 seconds and
adjust meter reading to Zero, and then feed the water samples to the atomizer & calculate the
concentration of Sodium & Potassium directly from the standard graph.
Calculation:
Sodium & Potassium, mg/l = Concentration from the graph x DF
Where,
DF= Dilution factor.
6.3.8 Determination of Sulphide in Water
Take 50 ml of water sample in conical flask. Add 2ml of Zinc acetate solution, shake it thoroughly. Leave
the solution for few minutes for precipitate formation. Filter the sample using glass fiber filter paper.
Transfer the precipitate along with filter paper to iodine flask. Add about 50 ml of distilled water. Add 10
ml 0.025N iodine solution + 2 ml of 6N HCl. Shake it vigorously. If iodine colour disappears add more
iodine until colour persists. Titrate against standard sodium thiosulfate (0.025N) solution using starch as
indicator. End point is blue to colourless. Note down the burette reading. Follow the above steps in the
procedure for blank without sample, using distilled water. Iodine solution volume must be the same for
both blank and sample.
Calculation:
Sulphide, mg/l = (V1-V2) X N X 16 X 1000
S
Where,
V1 = Volume of Sodium thiosulphate used for the blank
V2 = Volume of Sodium thiosulphate used for the sample
N = Normality of Sodium thiosulphate
S = Volume of water sample taken for titration (ml)
6.3.9 Determination of Phosphate in Water
Take 50 ml of water sample in the volumetric flask. Add 2ml of ammonium molybdate reagent and mix
thoroughly. Add 0.2 ml of stannous chloride (approximately 5 drops) reagent. Prepare reagent blank by
taking 50 ml D W along with reagents. Measure the intensity of blue color in absorbance mode at 690nm,
for standards as well as samples, by setting the spectrophotometer to “ZERO” absorbance with a blank.
Take readings within 10 to 12 minutes. Plot the graph of concentration in ppm against OD. Find out
concentration factor from the graph.
Calculation:
Phosphate, mg/l = Concentration X 100 X DF
50
Where,
DF= Dilution factor
GNGPL 14 SECON
6.4 Determination of Nitrite in Water

To 50 ml of clear water sample neutralized to pH 7 or to apportion diluted to 50 ml, add 1 ml of
sulphanilamide reagent. Let the reagent react for 2 to 8 minutes. Add 1 ml of NED dihydrochloride
solution and mix immediately. Let stand for at least 10 minutes. Measure absorbance at 540 nm.
Prepare a standard curve by adding suitable volumes of standard nitrite solutions and diluting to 50 ml
with distilled water. Develop colour as described in above procedure and measure absorbance at 540
nm.
Calculation:
Nitrite, mg/l = Concentration X 100 X DF
50
Where,
DF= Dilution factor
6.4.1 Determination of Total Dissolved Solids (TDS) in Water
Heat clean dish to 180 ± 2°C for 1 hour in an oven. Keep in desiccators for cooling. Weigh immediately
before use. Filter the aliquot quantity of a well mixed sample diluted to 50 ml by applying suction. Filtered
water sample is transferred to a pre-weighed dish. Wash the filtration assembly with 3 successive 10 ml
volumes of reagent grade water allowing for complete drainage between washings. Transfer all the
filtrate portions to evaporation dish. Evaporate to dryness on a water bath at 100°C. Dry evaporated
sample at least for 1 hour in an oven at 180 ± 2°C. Remove the dish from oven, cool in desiccators and
weigh. Repeat this drying, cooling desiccating cycle until a constant weight is obtained.
Calculation:
TDS, mg/l = W2-W1) X 1000 X 1000
Volume of sample taken for the test
Where,
W2 = Weight of dish after evaporation in Gms
W1 = Weight of dish before evaporation in Gms
7.0 ANALYSIS OF TEST RESULTS
7.1 Corrosion Behaviour of Soil based on Resistivity Test Results
The degree of corrosivity of soil based on resistivity values measured at proposed Pipeline location is
summarized as under:
a) GAIL’s SV-5G To Kundai IDC Junction
Chainage Pin Spacing Resistance Resistivity Degree Of

Sl.No Remark
(M) (M) (Ohm) (Ohm - M) Corosivity
1 0 1.0 152.00 955.04 E
2 0 2.0 78.00 980.18 E
3 0 3.0 40.00 753.98 E
4 30 1.0 634.00 3983.54 E
5 30 2.0 217.00 2726.90 E
6 30 3.0 126.00 2375.04 E
7 500 1.0 1645.00 10335.84 E
8 500 2.0 1464.00 18397.17 E
GNGPL 15 SECON

Sl.No Remark
9 500 3.0 916.00 17266.19 E
10 902 1.0 196.00 1231.50 E
11 902 2.0 107.00 1344.60 E
12 902 3.0 76.00 1432.57 E
13 1000 1.0 123.00 772.83 E
14 1000 2.0 113.00 1420.00 E
15 1000 3.0 72.00 1357.17 E
16 1500 1.0 505.00 3173.01 E
17 1500 2.0 257.00 3229.56 E
18 1500 3.0 207.00 3901.86 E
19 2000 1.0 297.00 1866.11 E
20 2000 2.0 203.00 2550.97 E
21 2000 3.0 200.00 3769.91 E
22 2500 1.0 1023.00 6427.70 E
23 2500 2.0 394.00 4951.15 E
24 2500 3.0 27.00 508.94 E
25 3000 1.0 142.00 892.21 E
26 3000 2.0 7.00 87.96 D
27 3000 3.0 51.00 961.33 E
28 3500 1.0 330.00 2073.45 E
29 3500 2.0 159.00 1998.05 E
30 3500 3.0 86.00 1621.06 E
31 4000 1.0 611.00 3839.03 E
32 4000 2.0 316.00 3970.97 E
33 4000 3.0 174.00 3279.82 E
34 4500 1.0 253.00 1589.65 E
35 4500 2.0 101.00 1269.20 E
36 4500 3.0 58.00 1093.27 E
37 5000 1.0 109.00 684.87 E
38 5000 2.0 56.00 703.72 E
39 5000 3.0 41.00 772.83 E
b) Kundai IDC Junction T-Point To Mercy Circle

Sl.No. Remark
1 0 1.0 217.00 1363.45 E
2 0 2.0 36.30 456.16 E
3 0 3.0 14.93 281.42 E
4 500 1.0 274.00 1721.59 E
5 500 2.0 121.90 1531.84 E
6 500 3.0 93.90 1769.97 E
GNGPL 16 SECON

Sl.No. Remark
7 1000 1.0 131.00 823.10 E
8 1000 2.0 34.00 427.26 E
9 1000 3.0 17.00 320.44 E
10 1500 1.0 133.20 836.92 E
11 1500 2.0 71.20 894.73 E
12 1500 3.0 27.00 508.94 E
13 2000 1.0 102.20 642.14 E
14 2000 2.0 20.70 260.12 E
15 2000 3.0 3.34 62.96 D
16 2110 1.0 318.00 1998.05 E
17 2110 2.0 19.10 240.02 E
18 2110 3.0 1.01 19.04 B
19 2110 4.0 0.33 8.29 A
20 2110 5.0 0.06 1.88 A
21 2500 1.0 143.00 898.50 E
22 2500 2.0 87.00 1093.27 E
23 2500 3.0 38.00 716.28 E
24 3000 1.0 241.00 1514.25 E
25 3000 2.0 91.00 1143.54 E
26 3000 3.0 55.00 1036.73 E
27 3500 1.0 278.00 1746.73 E
28 3500 2.0 112.00 1407.43 E
29 3500 3.0 65.00 1225.22 E
30 4000 1.0 227.00 1426.28 E
31 4000 2.0 89.00 1118.41 E
32 4000 3.0 44.00 829.38 E
33 4500 1.0 929.00 5837.08 E
34 4500 2.0 590.00 7414.16 E
35 4500 3.0 500.00 9424.78 E
36 5000 1.0 135.00 848.23 E
37 5000 2.0 79.00 992.74 E
38 5000 3.0 40.00 753.98 E
39 5250 1.0 200.00 1256.64 E
40 5250 2.0 103.00 1294.34 E
41 5250 3.0 42.00 791.68 E
42 5500 1.0 168.00 1055.58 E
43 5500 2.0 52.00 653.45 E
44 5500 3.0 21.00 395.84 E
45 6000 1.0 240.00 1507.96 E
46 6000 2.0 238.00 2990.80 E
47 6000 3.0 161.00 3034.78 E
GNGPL 17 SECON

Sl.No. Remark
48 6500 1.0 792.00 4976.28 E
49 6500 2.0 484.00 6082.12 E
50 6500 3.0 387.00 7294.78 E
51 7000 1.0 138.00 867.08 E
52 7000 2.0 94.00 1181.24 E
53 7000 3.0 55.00 1036.73 E
54 7500 1.0 122.00 766.55 E
55 7500 2.0 50.00 628.32 E
56 7500 3.0 31.00 584.34 E
57 8000 1.0 127.00 797.96 E
58 8000 2.0 82.00 1030.44 E
59 8000 3.0 56.00 1055.58 E
60 8500 1.0 630.00 3958.41 E
61 8500 2.0 400.00 5026.55 E
62 8500 3.0 247.00 4655.84 E
63 9000 1.0 1187.00 7458.14 E
64 9000 2.0 679.00 8532.57 E
65 9000 3.0 358.00 6748.14 E
66 9500 1.0 358.00 2249.38 E
67 9500 2.0 133.50 1677.61 E
68 9500 3.0 81.10 1528.70 E
69 10045 1.0 62.00 389.56 E
70 10045 2.0 415.00 5215.04 E
71 10045 3.0 253.00 4768.94 E
72 10045 4.0 183.00 4599.29 E
73 10045 5.0 142.00 4461.06 E
74 10000 1.0 1164.00 7313.63 E
75 10000 2.0 690.00 8670.80 E
76 10000 3.0 445.00 8388.05 E
77 10500 1.0 324.00 2035.75 E
78 10500 2.0 187.20 2352.42 E
79 10500 3.0 122.60 2310.96 E
80 11000 1.0 7670.00 48192.03 E
81 11000 2.0 40.30 506.42 E
82 11000 3.0 24.80 467.47 E
83 11500 1.0 739.00 4643.27 E
84 11500 2.0 409.00 5139.65 E
85 11500 3.0 245.00 4618.14 E
86 12000 1.0 624.00 3920.71 E
87 12000 2.0 394.00 4951.15 E
88 12000 3.0 221.00 4165.75 E
GNGPL 18 SECON

Sl.No. Remark
89 12500 1.0 315.00 1979.20 E
90 12500 2.0 176.00 2211.68 E
91 12500 3.0 94.40 1779.40 E
92 13000 1.0 671.00 4216.02 E
93 13000 2.0 330.00 4146.90 E
94 13000 3.0 218.00 4109.20 E
95 13181 1.0 3.71 23.31 B
96 13181 2.0 3.14 39.46 C
97 13181 3.0 1.12 21.11 B
98 13181 4.0 0.48 12.06 B
99 13181 5.0 0.30 9.42 A
100 13500 1.0 617.00 3876.73 E
101 13500 2.0 574.00 7213.10 E
102 13500 3.0 532.00 10027.96 E
103 14000 1.0 143.00 898.50 E
104 14000 2.0 41.00 515.22 E
105 14000 3.0 22.00 414.69 E
106 14500 1.0 164.00 1030.44 E
107 14500 2.0 24.00 301.59 E
108 14500 3.0 8.00 150.80 E
109 15000 1.0 145.00 911.06 E
110 15000 2.0 79.00 992.74 E
111 15000 3.0 52.00 980.18 E
112 15500 1.0 136.00 854.51 E
113 15500 2.0 62.00 779.11 E
114 15500 3.0 31.00 584.34 E
115 16000 1.0 943.00 5925.04 E
116 16000 2.0 580.00 7288.49 E
117 16000 3.0 365.00 6880.09 E
118 16500 1.0 339.00 2130.00 E
119 16500 2.0 224.00 2814.87 E
120 16500 3.0 148.20 2793.50 E
121 17000 1.0 650.00 4084.07 E
122 17000 2.0 149.10 1873.65 E
123 17000 3.0 91.70 1728.50 E
124 17500 1.0 886.00 5566.90 E
125 17500 2.0 578.00 7263.36 E
126 17500 3.0 466.00 8783.89 E
GNGPL 19 SECON
c) Kundai IDC Junction To Ponda

Sl.No. Remark
(M) (M) (Ohm) (Ohm-M) Corosivity
1 0 1.0 741.00 4655.84 E
2 0 2.0 381.00 4787.79 E
3 0 3.0 245.00 4618.14 E
4 500 1.0 166.00 1043.01 E
5 500 2.0 53.00 666.02 E
6 500 3.0 30.00 565.49 E
7 1000 1.0 773.00 4856.90 E
8 1000 2.0 519.00 6521.95 E
9 1000 3.0 423.00 7973.36 E
10 1500 1.0 11.02 69.24 D
11 1500 2.0 57.00 716.28 E
12 1500 3.0 186.10 3507.90 E
13 2000 1.0 141.00 885.93 E
14 2000 2.0 60.00 753.98 E
15 2000 3.0 48.00 904.78 E
16 2500 1.0 121.00 760.27 E
17 2500 2.0 59.00 741.42 E
18 2500 3.0 44.00 829.38 E
19 3000 1.0 107.00 672.30 E
20 3000 2.0 46.00 578.05 E
21 3000 3.0 34.00 640.88 E
22 3500 1.0 143.00 898.50 E
23 3500 2.0 79.00 992.74 E
24 3500 3.0 66.00 1244.07 E
25 4000 1.0 78.00 490.09 E
26 4000 2.0 41.00 515.22 E
27 4000 3.0 32.00 603.19 E
28 4500 1.0 4040.00 25384.07 E
29 4500 2.0 2000.00 25132.74 E
30 4500 3.0 1128.00 21262.30 E
31 5000 1.0 102.00 640.88 E
32 5000 2.0 69.00 867.08 E
33 5000 3.0 59.00 1112.12 E
34 5500 1.0 2470.00 15519.47 E
35 5500 2.0 379.00 4762.65 E
36 5500 3.0 255.00 4806.64 E
37 6000 1.0 119.00 747.70 E
38 6000 2.0 66.00 829.38 E
GNGPL 20 SECON

Sl.No. Remark
39 6000 3.0 47.00 885.93 E
40 6500 1.0 50.00 314.16 E
41 6500 2.0 38.00 477.52 E
42 6500 3.0 35.00 659.73 E
43 7000 1.0 92.00 578.05 E
44 7000 2.0 25.00 314.16 E
45 7000 3.0 12.00 226.19 E
46 7500 1.0 2059.00 12937.08 E
47 7500 2.0 31.00 389.56 E
48 7500 3.0 22.00 414.69 E
49 8000 1.0 104.00 653.45 E
50 8000 2.0 56.00 703.72 E
51 8000 3.0 37.00 697.43 E
52 8500 1.0 91.00 571.77 E
53 8500 2.0 28.00 351.86 E
54 8500 3.0 16.00 301.59 E
55 8725 1.0 49.00 307.88 E
56 8725 2.0 22.00 276.46 E
57 8725 3.0 15.00 282.74 E
d) Mercy Circle to Goa Medical College (GMC)

Sl.No Remark
1 0 1.0 192.30 1208.26 E
2 0 2.0 141.00 1771.86 E
3 0 3.0 117.30 2211.05 E
4 142 1.0 261.00 1639.91 E
5 142 2.0 94.80 1191.29 E
6 142 3.0 54.40 1025.42 E
7 142 4.0 27.00 678.58 E
8 142 5.0 19.00 596.90 E
9 157 1.0 720.00 4523.89 E
10 157 2.0 379.00 4762.65 E
11 157 3.0 308.00 5805.66 E
12 157 4.0 187.20 4704.85 E
13 157 5.0 122.60 3851.59 E
14 411 1.0 322.00 2023.19 E
15 411 2.0 226.00 2840.00 E
16 411 3.0 206.00 3883.01 E
17 500 1.0 1157.00 7269.65 E
GNGPL 21 SECON

Sl.No Remark
18 500 2.0 885.00 11121.24 E
19 500 3.0 622.00 11724.42 E
20 713 1.0 167.00 1049.29 E
21 713 2.0 105.00 1319.47 E
22 713 3.0 68.00 1281.77 E
23 1000 1.0 1171.00 7357.61 E
24 1000 2.0 1098.00 13797.87 E
25 1000 3.0 711.00 13402.03 E
26 1312 1.0 164.00 1030.44 E
27 1312 2.0 59.00 741.42 E
28 1312 3.0 31.00 584.34 E
29 1312 4.0 22.00 552.92 E
30 1312 5.0 15.00 471.24 E
31 1500 1.0 970.00 6094.69 E
32 1500 2.0 431.00 5416.11 E
33 1500 3.0 166.60 3140.34 E
34 2000 1.0 354.00 2224.25 E
35 2000 2.0 149.20 1874.90 E
36 2000 3.0 93.00 1753.01 E
37 2488 1.0 792.00 4976.28 E
38 2488 2.0 494.00 6207.79 E
39 2488 3.0 387.00 7294.78 E
40 2488 4.0 224.00 5629.73 E
41 2488 5.0 148.20 4655.84 E
42 3000 1.0 660.00 4146.90 E
43 3000 2.0 194.50 2444.16 E
44 3000 3.0 81.20 1530.58 E
45 3950 1.0 40.40 253.84 E
46 3950 2.0 20.00 251.33 E
47 3950 3.0 11.28 212.62 E
48 3950 4.0 0.69 17.34 B
49 3950 5.0 0.59 18.54 B
50 4000 1.0 67.20 422.23 E
51 4000 2.0 22.60 284.00 E
52 4000 3.0 20.10 378.88 E
53 4000 4.0 7.63 191.76 E
54 4000 5.0 6.01 188.81 E
GNGPL 22 SECON
8.0 CONCLUSION
• Soil resistivity survey has been carried out at proposed pipeline alignment and the detailed
explanation is given in sec 5.1 above
• The degree of corrosivity of soil based on resistivity test results along the pipeline alignment are
presented in the table sec 7.1 above.
• Based on the degree of corrosivity along the pipeline alignment, necessary corrosion protective
measures shall be adopted at the locations wherever the soil encountered is of medium to very
highly aggressive nature.
9.0 REFERENCES
IS 1892 - Code of Practice for Sub Surface Investigations for Foundations, Bureau of Indian Standards,
New Delhi
IS 2720 (Part 2) - 1973 Method of test for soils, Part II - Determination of Water Content, Bureau of
Indian Standards, New Delhi
IS 2720 (Part 26) - 1987 Methods of test of soils, Part XXVI - Determination of pH value, Bureau of Indian
Standards, New Delhi
IS 2720 (Part 27) - 1987 Methods of test of soils, Part XXVII - Determination of Total Soluble Sulphates,
Bureau of Indian Standards, New Delhi
IS 3043 - 1987, Code of Practice for Earthing, Bureau of Indian Standards, New Delhi
A Text Book of Soil Chemical Analysis by P.R.Hesse
SECON
GNGPL 23 SECON

Approved Code B Sark Mecon Mpe TCP DD 01

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DESIGN DOCUMENT Doc No. R.

Is MECON PMC for the Project NOW?

OWNER : M/s. GOA NATURAL GAS PVT LTD

PMC : M/s. MECON LIMITED

PIPELINE : M/s. M P ENGINEERING CONSTRUCTIONS (INDIA)

CP CONTRACTOR : M/s. SARK EPC PROJECTS PVT LTD

TEMPORARY CATHODIC PROTECTION SYSTEM

Document No: SARK/MECON/MPE/TCP/DD/01

Issued for Review &

1.1 SCOPE OF WORK .................................................................................................. 4

2 DESIGN APPROACH ................................................................................................. 5

2.1 INTRODUCTION ................................................................................................... 5

3.1 FORMAT AND ORGANIZATION OF THE DETAILED ENGINEERING PACKAGE ................. 12

4 DESIGN CALCULATIONS ........................................................................................ 17

4.1 PIPELINE SURFACE AREA .................................................................................... 17

4.4.4 TOTAL CIRCUIT RESISTANCE ........................................................ 21

5 BILL OF MATERIALS .............................................................................................. 23

6 SCHEDULE OF TEST STATIONS ............................................................................... 23

ANNEXURE - A : DESIGN CALCULAITON ....................................................................... 24

ANNEXURE - B : BOM PIPELINE .................................................................................... 25

ANNEXURE - C : TLP SCHEDULE ................................................................................... 26

ANNEXURE - D : CP DRAWINGS .................................................................................... 27

ANNEXURE - E : SOIL RESISTIVITY REPORT ................................................................. 28

M/s M P ENGINEERING CONSTRUCTIONS (INDIA) PVT. LTD have been awarded a

1.1 SCOPE OF WORK

Pipeline details as below.

Sr. No. Pipeline DIA Length in KM Remarks

1.2 TEMPORARY CATHODIC PROTECTION SYSTEM OVERVIEW

 Type of System: Temporary CP (TCP): Sacrificial /Galvanic anodes.

2.2 GENERAL PIPELINE DETAILS

1 8” 4.5 (Approx.) 3LPE

2 6” 5.5 (Approx.) 3LPE

2.3 TEMPORARY CATHODIC PROTECTION SYSTEM DESIGN LIFE

2.4 DEFINITIONS AND ABBREVIATIONS

Anode The electrode through which current is discharged into the

Cathodic Protection Technique to protect metallic structure in contact with an

Electrolyte A liquid or liquid component in composite material like soil, in

Groundbed System of buried or submerged anodes.

Protected potential The structure-to-electrolyte potential measured after application

Protected Structure A structure to which cathodic protection is applied.

Reference Cell An electrode that serves as basis of comparison in the

Structure/Electrolyte The difference in potential between a structure and a specified

2.5 CODES AND STANDARDS

Doc. No. Description

MEC/TS/05/E9/016A MECON Standard Technical Specification

NACE Standard RP- Standard Practice for Control of External Corrosion on

NACE Publication Measurement technique related to criteria for CP of Underground

Doc. No. Description

NACE Publication No. Cathodic Protection Monitoring for Buried Pipelines.

NACE standard RP- Standard recommended practice Design, Installation and

VDE 0150 Protection against Corrosion due to Stray Current from DC

IS:7098 Part I XLPE insulated cables.

IS:1554 Part I PVC Insulated (Heavy Duty) cables

2.6 PHILOSOPHY OF TEMPORARY CATHODIC PROTECTION SYSTEM

Anode Open Circuit Potential (Theoretical) : -1.55 Volts (Low Potential)

The potential and consumption rate of Zinc anodes shall be as below:

Anode Open Circuit Potential (Theoretical) : -1.10 Volts

2.7 TEMPORARY CATHODIC PROTECTION DESIGN CRITERIA

2.8 TEMPORARY CATHODIC PROTECTION CURRENT DENSITIES

Minimum Pipe Protection Current

Normal Soil ( 10-100 Ohm – m) 40

Marshy area/HDD ( < 10 Ohm – m) 75