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Specification
25194-3GS-GAW-002
Section A – Installation procedures covering temporary cathodic protection system for buried
piping
Section B – Installation procedures for Permanent impressed current cathodic protection system for
buried piping
Section D – Installation procedure for sacrificial system for internal surfaces of seawater carrying
carbon steel pipework
Section A
Contents
1. Introduction.............................................................................................................................. 5
3. Bill of Quantity......................................................................................................................... 6
4. Anode detail............................................................................................................................. 7
5. Design Notes............................................................................................................................ 8
6. Installation Guidelines............................................................................................................ 10
Appendix III – Site Installation Check List for Temporary Cathodic Protection.............................16
1. Introduction
Section A of this specification outlines the installation procedures for the temporary
cathodic protection system for buried piping to be installed at the Reliance
Petroleum Limited, Jamnagar Export Refinery Project,
Time period between the first pipe burial and the energisation of the permanent
impressed current system. The temporary cathodic protection is designed for a
18 month life.
The early material includes items such as test posts, pipe to cable connections
leading to test posts, bonding cables, permanent reference electrodes and negative
connections.
A unit wise breakdown of material and an installation check list has been included
with this document.
The underground services that would need temporary protection would in general
cover the following (all are carbon steel coated pipes);
Buried Seawater piping within the plant is assumed to be non metallic and hence no
cathodic protection needed for this service.
Buried vessels are excluded from temporary protection since these are installed
within concrete enclosures and bedded in washed and graded sand.
Appendix I to this document provides a listing (with unit numbers) of various units
within the JERP wherein the buried piping would require temporary cathodic
protection. Appendix II provides a unit wise breakdown of material while Appendix
III provides a check list for installation.
A total of 245 kms of buried piping has been estimated, ranging from 2 inch and
lower (0.75 and 1 inch) and up to 84 inches (in case of cooling tower pipe work).
(Attachment II of Specification 25194-3PS-GAW-036 (Section A) provides a unit
wise and a pipe size wise breakdown of the buried pipe work.)
3. Bill of Quantity
The estimated bill of Quantity for the temporary cathodic protection is as follows for
providing temporary protection for the above buried pipe work (Refer specification
25194-3PS-GAW-036 -Section A):
Unit of Total
Item Description Remarks
Measurement Quantity
Installation
nos 150
10 Negative lugs , welded to pipe contractor
*It is assumed that the firewater hydrants could serve as test posts and can be used
for potential monitoring based upon which quantity of test posts have been
accordingly reduced. It may be necessary to install temporary magnesium anodes on
a hydrant, Thermit welded on to the hydrant.
4. Anode detail
A temporary cathodic protection system has been provided , designed for an 18
month life using prepackaged 5 kg net sacrificial magnesium anodes , type AZ63
( Grade A or B), with a magnesium alloy having a potential of -1.5 volts versus a
copper/copper sulfate reference electrode (CSE)
5. Design Notes
The permanent impressed current cathodic protection system design shall be based
upon consideration that the buried piping is classed as a “complex structure” which
by definition (BS EN 14505) is defined as a structure to be protected and one or
more foreign electrodes such as earthing cannot be electrically separated from it and
universal electrical continuity will have to be considered while designing the
cathodic protection system and current drains to be suitably accounted for.
However, the design of the temporary cathodic protection system is based upon
achieving isolation of the pipework from all earthing and foreign electrodes. It is
preferable to not connect the pipework at above ground/underground interfaces in
the event there is no isolation at these interfaces. Besides, the following additional
considerations will assist in reduction of extraneous current drains.
(a) Isolation of puddle flanges within catch basins (isolation of rebars from
puddle flange as well as coating of the flange within concrete) to be
considered as these constitute a large current drain and would be beneficial
for the temporary cathodic protection system on the storm water drain
pipework.
(c) Isolation of oily water pipework(OWS) from drain funnels , as these again
constitute a large current drain and would be beneficial for the temporary
cathodic protection system
(g)A review of the ISBL piping layout shows that the storm water pipes are
located in the centre of each plot/unit compared to the other pipe work that may
be located in the periphery and it may be difficult to protect the storm water
pipes in its entirety using a distributed system of anodes. Sections of the storm
water pipe work that is remote from the periphery may be left unprotected. This
will be addressed in detail in the Section covering permanent design of the
buried piping.
Other Considerations
The test post may be used as a bonding connection point, if the situation
so demands.
(i) Bonding between pipes will be done via the bond box using a 16 mm 2
cable, thermit welded or pin brazed to the pipe, bonded via the busbar
inside the box.
(j) Pipe to soil potential measurement in paved areas adjacent to hydrants,
test posts and at above ground /underground interfaces and including
locations where permanent reference electrodes are installed shall be
provided through portable reference cell placed on soil pits (reference
electrode pits). Test points shall be minimum 0.75 meter deep and 89
mm dia PVC pipe to extend below the concrete cover to reach the soil
and shall be used and filled with natural soil. These pits shall be flush
with the paving.
6. Installation Guidelines
The following installation guide lines may be adopted for installation of all materials
that constitute the temporary cathodic protection system (Refer Appendix II of this
document):
1) From the above, the following inference can be made on anode
installation
3) Soil pits for measurement in paved areas could be located one per test
post as well as at every hydrant location and if possible inside every valve
pit as well as at every above ground/underground interface. An estimated
1500 soil pits have been considered.
Uni Abbreviatio
t Description Complex n
220 HNUU - General Refinery Aromatics ARR
221 HNUU 2 Refinery Aromatics ARR
230 Platforming - General Refinery Aromatics ARR
231 Platforming 2 Refinery Aromatics ARR
232 CCR Regen Refinery Aromatics ARR
233 Recovery plus system Refinery Aromatics ARR
234 Hydrogen purification system (PSA) Refinery Aromatics ARR
300 Crude Common Area Crude CRU
311 CDU and VDU Unit 3 Crude CRU
312 CDU and VDU Unit 4 Crude CRU
321 Sat Gas Conc 3 Crude CRU
322 Sat Gas Conc 4 Crude CRU
331 Sat LPG Merox 2 FCC/Olefins FCC
353 Clean Fuels CFP
354 Clean Fuels CFP
355 Clean Fuels CFP
357 Clean Fuels CFP
358 Clean Fuels CFP
361 VGO Unit 3 Hydrotreating HT
362 VGO Unit 4 Hydrotreating HT
371 Delayed Coker Coker COK
372 Gas Plant Coker COK
400 FCC/Olefines Common Area FCC/Olefins FCC
411 Fluidised Catalytic Cracker (FCC) 2 FCC/Olefins FCC
412 Power Recovery 2 FCC/Olefins FCC
413 FCC Unit (Main Column Section) 2 FCC/Olefins FCC
Unsaturated Gas Concentration
414 Section FCC/Olefins FCC
415 Unsaturated LPG Merox 2 FCC/Olefins FCC
425 Propylene Recovery 3 FCC/Olefins PRU
429 Alkylation ALK
430 Alkylation ALK
435 Alkylation ALK
431 Amine Treating Process Unit 5-8 Hydrotreating ATU
441 Sour Water Stripping Unit 5-8 Hydrotreating SWS
451 Sulphur Plant 4 Hydrotreating SUL
452 Sulphur Plant 5 Hydrotreating SUL
453 Sulphur Plant 6 Hydrotreating SUL
521 Hydrogen 4 Hydrotreating HYD
522 Hydrogen 5
523 Hydrogen 6
524 Hydrogen 7
25194-3GS-GAW-002 Rev 1 Page 12 of 32
Reliance Petroleum Limited
Jamnagar Export Refinery Project
Underground
No. of Test Two Part Monitoring Underground Bond/Negative
Pipe Posts Thermit Epoxy, 0.3 Cable,6 mm2, Ag/AgClRef Above Bond/Negative cable ,10/ 16 Other conn. 10/
Length, No. of 5 kg including Weld, litres / 15/20 m per Electrode (1 per groundNegative cable mm2, 20 m per 16 mm2, 10 m per Thermit weld , 25
Unit m mag anodes hydrants 15 gm Cadweld Test Post 400 m) cable lugs connections conn. comm. gms.
Fire Water (Units 713, 714) 80982 705 705 705 212 14100 176 40 20 400 200 20
Appendix III – Site Installation Check List for Temporary Cathodic Protection
SITE INSTALLATION CHECK LIST FOR TEMPORARY CATHODIC PROTECTION
Reliance
Project- JERP
Unit - Unit No -
Contractor
Layout drawing no- Attached As built sketch no -
NO. DESCRIPTION As Installed Acceptable Remarks
Pipe Details
A
Pipe diameter(s)
1
Single or multiple pipe
2
B Test post
1 Type , Fink with support or Fink with flange connector or hydrant GI test post /Flange connector type
2 Cable connections at terminal M = mag anode, P1 for pipe 1 , P2 for pipe 2 , R for
reference el, B for bonding
3 Test post identifcation Provide iunique dentification
C Magnesium anode
1 Has one been installed at this test post location
2 Has plastic cover ( if any) been removed from anode
3 Has Mag anode been wetted for atleast 10 minutes prior installation
4 Depth of installation, horizontal or vertical
5 Anode separation from( largest dia) pipe edge
1 Thermit welding
2 Thermit weld epoxy cover
3 Cable termination at test post
4 Link between cable and anode
5 cable identifiation at test post
6 cable size
E Reference Electrode
Reliance - Contractor-
Signature- Signature-
Name- Name-
Date Date
Reliance
Project- JERP
Unit - Unit No -
Contractor
Layout drawing no- Attached As built sketch no -
NO. DESCRIPTION As Installed Acceptable Remarks
F Bonding/negative cables
1 Thermit welding
2 Thermit weld epoxy cover
3 Cable termination at test post
4 cable identifiation at test post
5 cable size
G Potential checks
1 Are all terminations in order
2 Natural potential using reference elwectrode
3 Natural potential using soil pit and portable reference electrode
4 Pipe to soil potential after 24 hours after linking anode to pipe ( pipes)
H Other checks
1 Isolation beteween earth and pipe at nearest above ground/underground provide unique identification
2 Earthing to soil potential
3 Av. soil resistivity at anode installation ,
4 Is there a nearby hydrant
provide unique identification
5 Is there a buried valve nearby , is it continuous provide unique identification
6 Is the puddle flange at nearby Catch basin isolated
provide unique identification
7 Are pipes around nearby catch basin continuous
provide unique identification
8 Is there a negative lug provided at above ground/underground interface nearby
provide unique identification
9 Are nearby above ground OWS pipes isolated from drain funnel provide unique identification
Reliance - Contractor-
Signature- Signature-
Name- Name-
Date Date
Section B
Section C
Section D