Waha Oil Company: Installation of Cathodic Protection Systems
Waha Oil Company: Installation of Cathodic Protection Systems
INSTALLATION OF
CATHODIC PROTECTION SYSTEMS
Rev.
Issued Endorsed Appr’d
No. Date Description
By By By
Signature
Not Verified
ISSUED
Rev.0
Page 1 of 12 ENG-TS-X-SP-0016.doc
TABLE OF CONTENTS
1. SCOPE........................................................................................................................................... 3
2. GENERAL CONDITIONS.......................................................................................................... 3
3. CONTRACTOR REQUIREMENTS.......................................................................................... 3
4. MATERIALS ................................................................................................................................ 3
5. SHALLOW ANODE GROUNDBEDS ....................................................................................... 4
6. DEEP WELL ANODE GROUNDBEDS .................................................................................. 4
7. DC POWER SOURCE................................................................................................................. 6
8. DC, TEST AND BOND CABLES ............................................................................................... 7
9. BONDING STATIONS, TERMINAL AND JUNCTION BOXS............................................. 9
10. POTENTIAL TEST POSTS........................................................................................................ 9
11. PERMANENT REFERENCE ELECTRODES....................................................................... 10
12. TANK INTERNAL CATHODIC PROTECTION.................................................................. 10
13. ELECTRICAL ISOLATION REQUIREMENTS .................................................................. 11
14. CASED ROAD CROSSINGS.................................................................................................... 12
15. PLATFORMS AND FOUNDATIONS ..................................................................................... 12
16. FENCING BARRIERS .............................................................................................................. 12
17. CLEAN UP.................................................................................................................................. 12
18. RECORDS................................................................................................................................... 12
Page 2 of 12 ENG-TS-X-SP-0016.doc
1. SCOPE
This specification shall govern the installation of all materials and equipment related to
cathodic protection (CP) systems, which shall be provided to afford corrosion protection to
all buried and immersed facilities. The scope includes components associated with, but not
directly involved in, the provision of cathodic protection such as test leads, test stations,
insulating flanges, grounding cells and other electrical attachments.
2. GENERAL CONDITIONS
Heavy equipment and machinery may be used for loading, unloading, transport, excavation,
backfilling and all installation activities only where local conditions permit. Hand
excavation shall be employed in the vicinity of all buried pipelines, cables, etc., and where
so instructed by WOC.
3. CONTRACTOR REQUIREMENTS
The Contractor shall furnish all tools and equipment and perform all work necessary to:
install dc power supply units; install anodes and specified backfill material; lay cable;
remove any coating; clean the pipe/structure surface; re-coat the pipe/surface; mechanically
secure cable to the pipe (other than at the point of electrical attachment); bring the cable to
the surface and temporarily secure; install junction boxes, test and monitoring facilities with
related equipment; hook-up cables within junction boxes and test station enclosures; install
electrical isolation fittings and associated components; complete all other activities related
to the installation of the CP systems.
Contractor shall implement and maintain for all work, a quality system that meets all
requirements, as relevant to the scope of supply, of ISO 9002. Comparable
nationally/internationally recognised QA standards will be considered as an alternative. The
Contractor’s system shall be capable of operating with minimum intervention from WOC.
4. MATERIALS
The Contractor shall load and transport all WOC furnished equipment and materials from
the designated storage areas to the jobsite and work locations. Contractor shall be
responsible for all materials during loading operations and thereafter until completion of all
installation activities, as approved by WOC’s representative.
Page 3 of 12 ENG-TS-X-SP-0016.doc
5. SHALLOW ANODE GROUNDBEDS
Shallow anode groundbeds shall be installed in accordance with the approved project
drawings at the locations and depths determined from soil resistivity measurements and
specified on the project site layout drawing. Prior to the start of construction, WOC
Corrosion shall mark the exact location of anodes with wooden stakes and verify the proper
depth of burial. Should it be impractical for any anode hole to reach the specified depth, for
whatever reason, WOC’s representative shall determine whether such augured hole shall be
used.
All anodes shall be installed in sequential order. Cables shall be durably tagged to indicate
the anode number at the termination point inside the anode junction box. The number one
(1) anode shall be the farthest anode located on the right hand side of the anode junction
box, when facing the box.
Each anode shall be suspended in the centre of the augured hole, such that the lower end is
1.0 – 1.2 metres above the bottom of the hole. Loose dirt falling into a hole when the
drilling head is extracted shall be compacted before petroleum coke backfill is placed in the
hole. Petroleum coke backfill shall be added in small increments, and thoroughly
compacted by hand tamping equipment for each 12 inches of fill to ensure a void free
backfill, to provide a final depth of 0.75 metre (maximum) below grade. Care must be taken
not to damage or strain the anode cable during the process.
Individual anodes shall be provided with a vent/watering pipe unless otherwise instructed.
Pipes shall be 6” (nominal) diameter GRP material, installed such that the lower end of the
pipe contacts the top of the calcined petroleum coke backfill. Vent openings shall be above
grade to obviate blockage by debris and windblown sand.
Individual anode cables shall be routed to the anode junction box. Installation and
backfilling shall be in accordance with section 8.0 below.
Backfilling to grade shall be completed using sand free of rocks and other debris which
could damage cable insulation.
Deep well anode groundbeds (DWGBs) shall be one of the two following types:
1) Aquifer Penetrating Anode Groundbed Arrangement.
2) Non-Aquifer Penetrating Anode Groundbed Arrangement.
The type used shall be specified by WOC, dependent upon ground water depth and related
factors. Anode number one (1) shall be the anode located at the bottom of the hole.
Page 4 of 12 ENG-TS-X-SP-0016.doc
6.1 Aquifer Penetrating Anode Groundbed Arrangement
A borehole shall be drilled to the nominated depth. Steel surface casing shall be
installed to the depth of consolidated soil conditions to prevent collapse of the borehole
at the surface.
Non-metallic casing, resistant to the acid gases emitted from the anodes during
operation, shall be installed in the borehole to the nominated total depth. Slotted casing
lengths shall be used over the active anode groundbed length.
After completion of borehole casing and flushing a factory assembled anode chain is to
be lowered into the borehole in accordance with a detailed procedure and supported at
the surface within a wellhead enclosure (see clause 6.3 below), mounted onto a steel
platform.
Anode cables and suspension wires (where included) shall be secured to the support
bar and/or suspension clamp within the enclosure. Care shall be taken to ensure cables
are not damaged nor bent to less than their specified minimum bending radius. Cables
shall be routed out of the enclosure for termination into an anode junction box.
Installation of the anode junction box and steel platform is dealt with under sections 9.0
and 15.0 below.
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7. DC POWER SOURCE
AC power input to the T/R unit shall be through a fused disconnect switch or circuit
breaker, provided as an integral component of the unit. Input cable size, type and rating
shall be as specified for the particular unit and shall be terminated into the unit using
compression lugs.
DC positive and negative cables shall be terminated into the T/R unit by means of
either compression lugs or directly into the fitted terminals. DC cables shall be single
core type, unless otherwise approved by WOC representative, and of the specified size,
type and rating.
Input and output cables are to be neatly bundled, secured and protected.
Earthing of the T/R unit shall be provided as specified in the relevant project
specifications.
Paintwork shall be checked for any damage and repaired as necessary using compatible
touch-up paint materials.
Assembly and installation of the PPS unit shall be carried out in strict compliance with
the supplier’s documentation. All cables are to be neatly bundled, secured and
protected.
DC positive and negative cables shall be terminated into the PPS unit by means of
either compression lugs or directly into the fitted terminals. DC cables shall be single
core type, unless otherwise approved by WOC representative, and of the specified size,
type and rating.
Earthing of the PPS unit shall be provided as specified in the relevant project
specifications.
After completion of installation, paintwork shall be checked for any damage and
repaired as necessary using compatible touch-up paint materials.
Page 6 of 12 ENG-TS-X-SP-0016.doc
8. DC, TEST AND BOND CABLES
Colour codes, types and sizes of cables shall conform to Appendix 1 to this
specification, unless prior written approval is obtained from WOC’s representative.
When removing cable from a reel, the reel shall be supported at the centre so that the
cable will be removed in the same manner as originally reeled onto the cable spool.
This excludes the practice of laying the reel on its side and removing the cable by
spiraling from the reel. All exposed ends of the cable that are not covered by the
insulation shall be taped or sealed to prevent ingress of moisture and dirt.
Positive header cables for below grade usage shall be checked immediately prior to
installation with a pulse type holiday detector set at 18,000 Volts DC. Cable with
insulation holidays is to be rejected unless otherwise instructed by WOC’s
representative and approved in writing. Where repair of the insulation for below
grade positive cable is approved, splicing shall be performed in accordance with
clause 8.3.
Negative cables for below grade usage shall be visually checked for obvious
insulation holidays. Cable with visible insulation damage shall either be rejected, at
the sole discretion of WOC’s representative, or repaired in accordance with clause
8.3.
Sufficient slack shall be left in installed cable to prevent excessive tension in the
cable resulting from backfilling and subsequent earth settlement. Sufficient cable
from the groundbed or individual anodes shall be brought above ground at the anode
junction box location to ensure proper connection into the junction box without undue
tension in the cable.
Distances between test lead cables associated with each test station shall be accurately
measured and installed in accordance with applicable project drawings. Variations in
distance shall be specifically approved in writing by WOC’s representative.
Cables shall be clearly tagged and secured at the surface until installed and terminated
in the permanent enclosures. A minimum of 2 metres of cable shall be brought above
ground at T/R unit, junction box and test station locations.
Above grade cables shall be either installed on existing cable tray/ladders or routed
through steel conduit.
The Contractor at his expense shall replace any installed cables broken or damaged in
any way during construction activities.
Cables shall be terminated in an above grade power supply unit, junction box, test
station or bond box located as shown on the applicable project drawings. This work
shall include stripping back, glanding, ferruling and terminating cores using suitable
compression lugs and cable markers.
Page 7 of 12 ENG-TS-X-SP-0016.doc
8.2 Trenching
The Contractor may, at his option, utilize power trenching or plow-type trenching
equipment for cable placement, except that trenching across pipelines, and within
600mm of either side, or other buried facilities shall be accomplished by hand tool
excavation.
A minimum cover of 600mm shall be maintained over all cables except where
specifically stated otherwise on applicable drawings or approved by WOC’s
representative in writing. Cable marker tape shall be laid approximately 300mm above
all buried cables. Cables shall not be subjected to the direct impact of material during
backfilling operations. Cable trenches shall otherwise be constructed and completed as
specified for ac electrical cables.
All cable core splices shall be made with compression type connections using an
appropriate tool unless otherwise stated. The Contractor shall ensure that the length of
insulation removed from the cable to accommodate the splice is kept to a minimum.
Upon completion of the cable core splice, and immediately prior to repairing the
insulation, the cable insulation in the splice area shall be cleaned and the surface of the
insulation to be covered shall be roughened. WOC’s representative shall approve
preparation of the insulation surfaces before the insulation repair materials are applied.
Cable insulation repairs are to be made with 2 half-lapped layers of ¾” wide vinyl
plastic tape over 2 half-lapped layers of ¾” wide rubber tape.
Splices in above grade dc cables shall be minimised and shall only be performed after
receiving specific, individual approval from WOC’s representative.
Negative dc cables for below grade usage shall be visually checked for obvious
insulation holidays. Cable with insulation damage shall either be rejected, at the sole
discretion of WOC’s representative, or repaired as stated above.
Core splice of positive dc cables for below grade usage is not permitted. Such
connection should be made above grade in appropriate junction box.
Cable insulation repairs to buried dc positive cables shall be made with a two-part
epoxy compound and a splice cover mould unless otherwise approved by WOC’s
representative.
Page 8 of 12 ENG-TS-X-SP-0016.doc
WOC/Contractor personnel using pin brazing equipment and appropriate studs shall
make all negative cable connections to steel pipes and/or structures.
On completion of the cable connection to the pipe, the connection shall be coated as
required either with a proprietary cap or in accordance with the coating repair
procedure for the applicable coating system, as instructed by the WOC representative.
The coating repair shall be free of holidays and other defects at this location.
Posts are to be installed vertically, orientated to identify the cable route and secured in
place by means of concrete or steel footings.
Bonding stations, terminal and junction boxes shall be installed at the locations shown on
the project drawings or specified by WOC’s representative. The enclosures shall be
mounted on support frames, which are to be fixed to pre-fabricated steel or concrete
foundations using appropriately sized anchor bolts.
All enclosures are fitted with nameplates indicating their general type and, in some cases,
their specific application. Care shall be taken to ensure that all enclosures are installed at the
relevant locations.
Where provided, sunshades shall be assembled and fitted onto the enclosures using the
supplied fixings.
Single core cables shall be routed into the enclosures, through either the conduit or glands
provided with the units, and terminated onto the applicable studs by means of compression
lugs. All cables routed into and terminated within the enclosures shall be identified with
durable tags. The cable and the terminals shall be labeled to indicate the structures to which
they are connected.
Contractor shall install CP potential test posts at the nominated locations. In general, the
locations are at each cased crossing, each insulated flange, each crossing of any foreign
pipeline and at other locations specified by WOC. Test posts are to be secured in place by
means of concrete or steel footings, which will allow for cables to be routed into the base of
each post. Posts shall be installed vertical and to a finished height of 1.0 metre.
Potential test cables shall be attached to the adjacent structure by means of pin-brazed studs
and compression lugs, routed into each test post and terminated. Cable must be left with
sufficient slack to enable future re-termination within a replacement test post, if necessary.
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11. PERMANENT REFERENCE ELECTRODES
100mm diameter holes shall be cut in the tank roof; 1 no. in the centre for anode placement
and 1 no. nominally 500mm from the tank wall for reference electrode placement.
Removable caps should be fabricated for placement over the holes and which do not
prevent cable routing into the tank.
An anode junction box, complete with support frame, shall be installed at an appropriate
location that does not interfere with tank operations and maintenance. The support frame
should be fixed in place by means of either a steel or concrete foundation.
Galvanized steel conduit (typically ¾” or 1” diameter) or cable tray shall be attached to the
tank wall and roof to enable cables to be routed between the anodes and anode junction box.
Two anodes shall be installed such that the lower anode is located at 2/3 of the tank height
whilst the upper anode is located at 1/3 of the tank height (measured from the bottom). The
anode header cables shall then be installed within the conduit and terminated within the
anode junction box.
A transformer-rectifier unit is to be installed to provide dc power supply to the installed
anodes. T/R unit installation is detailed in clause 7.1 above.
A dc negative return cable shall be installed between the T/R unit and tank, either by
trenching or existing cable tray. Termination onto the tank shall be by pin brazed stud and
compression lug. A DC positive feeder cable shall also be run between the T/R unit and
anode junction box.
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13. ELECTRICAL ISOLATION REQUIREMENTS
Each I/F and I/J shall be tested by WOC’s representative and where continuity is
found to exist the joint shall be re-made, using the necessary replacement
components, at the Contractor’s expense.
The associated bonding cables shall be routed up to the insulated flange and
terminated onto the pipe, one cable to each side of the flange, by pin brazing (refer to
section 8.4). The cables shall be routed through 3” diameter galvanized steel or uPVC
(not PVC) conduit, which shall be adequately anchored by means of a concrete
foundation block, to within 150mm of the pipe surface. Termination onto the pipe
shall be carried out after backfilling of the Zinc grounding cell.
Prior to backfilling of the Zinc grounding cell, copious amounts of water shall be
poured over the cell to ensure that the cell package is thoroughly wetted.
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14. CASED ROAD CROSSINGS
Prior to installation of the casing sleeve pipe, casing insulators shall be installed around the
pipeline in accordance with the manufacturer’s instructions, supplied with the items, to
provide electrical isolation of the pipeline and casing pipe.
Test/bonding cables shall be attached to both the pipeline and casing sleeve by pin brazing
(refer to clause 8.4). All cables shall then be routed up to the nominated location for the
road crossing test facility for termination after backfilling.
Casing end seals shall be installed at both ends of the casing sleeve and around the pipeline
in accordance with the manufacturer’s instructions, supplied with the items, prior to
backfilling of the pipeline and casing sleeve.
Platforms for deep well anode groundbed (DWGB) wellheads and the support of the solar
generator, including the associated battery banks and module arrays, shall be welded
fabrications of steel plate, angles and sections.
Platforms and foundations for the support of transformer-rectifier units, anode junction
boxes (excepting at DWGB wellheads), negative current control boxes and all
test/monitoring facilities may be of either fabricated steel or cast concrete, at the discretion
of the Contractor.
Foundations may either be pre-cast and transported to the nominated installation location or
cast in-situ, at the discretion of the Contractor.
Transformer/rectifier units and photovoltaic power supplies sited in remote locations shall
be protected by barriers. The design of the barriers is to be proposed by the Contractor for
WOC’s approval and shall include for an entry gate that enables vehicular access for
equipment maintenance and replacement.
17. CLEAN UP
The Contractor shall clean up work and jobsite material storage and laydown areas on
completion of work in such a manner as to be acceptable to WOC’s representative.
Excess WOC furnished equipment and construction materials shall be returned to the
designated storage site.
18. RECORDS
All construction drawings shall be updated, for any field modifications to the original
design, to show the "as built" system. As-built drawings shall be issued to show the type
and location of all equipment and materials, including cable routing, cable-to-structure
termination points, insulating sleeves and flange sets.
Copies of the drawings shall be submitted to WOC for the attention of Engineering
Department, Corrosion Section, Tripoli within sixty (60) days of project completion.
Page 12 of 12 ENG-TS-X-SP-0016.doc