CALABAR NIPP POWER PLANT O&M PROJECT

GAS METERING STATION

O. T. OTIS ENGINEERING
_____________________________________________________________________________________
REPORT ON REACTIVATION OF TRANSFORMER RECTIFIER FOR THE 21KM GAS PIPELINE
CATHODIC PROTECTION SYSTEM IN CALABAR GMS.

Summary

Subsequent to being awarded the contract in respect of the above job, a kick-off meeting was
held between The Contractor, the COO, the GMS O&M Manager and GMS Electrical Maintenance
Representative. Actual works commenced on 4th February, 2023 and the contractor completed
most of the tasks in the scope of work on 11th February, 2023 as highlighted below:

1. Restored the Transformer Rectifier (T/R) DC output.

2. Inspected and tested the anodes.
3. Replaced faulty indicating meters for correct readings.
4. Changed old transformer oil.
5. Replaced and changed silica gel bottle.
6. Supplied one (1no.) CuCuSO4 probe for CP measuring along the 24” x 24 km gas pipeline at designated
test points (TPs)
7. Checked the entire system and ensured all components supplied and installed conformed to
international best practice.

8. Prepare T/R test sheet (report) and CP readings for the entire pipeline. **
9. Carry out the CP measurement on the designated TPs and river/road crossings. **
(Please Note: Items 8** & 9 ** could not be concluded as would be explained later.)

Investigations Carried Out

S/N Component Investigations

1 The Ground Bed Opened and inspected. There are 6 anodes with the connection cable
(anode pit) connected to copper bar and the output to the NJB. The resistances of the six
(6nos) anode were tested and found to be satisfactory.
2 AC supply 405Vac, Ok
3 DC output volt Depleted and was insufficient to inject the required cathodic protection to the
gas pipeline. After the reactivation, this was corrected.
4 Fuses Ok.
5 Indicating Meters Ok.
6 Transformer Oil Quite old, discolored with poor viscosity. This was emptied out and 2 drums of
new transformer oil refilled to the required level (see fig. 1).
7 Thyristors All were bad and have been replaced.
8 Silica Gel/Bottle Found to have expired and was replaced.
9 Switching Relays OK.

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 10 Negative Junction One resistor had corroded. This was shunted with a cable.
Box
11 Electronic cards All tested ok.
12 Electrical and All electrical joints were retightened same with mechanical bolts and supports.
Mechanical
connections

Test and Commissioning

The T/R was powered (405 Vac) and the outputs were observed on the panel (see fig. 2). Data
was also read off on the 24” gas inlet pipeline using fluke ammeter and Cu-CuSO4 probes (see fig.
3). The first test point (TP) at the back of the GMS was tested and voltage obtained was
satisfactory (see fig. 4).

Further upstream, a major challenge presented. The Right of Way (RoW) was completely
overgrown with thick vegetation which made access impossible. Therefore no other test points
were found. A trip to the tie in point of the 21km pipeline was made in order to test the
effectiveness of the cathodic protection voltage. Also, no test posts were obvious.

Recorded Data

After reactivation, the readings recorded on the indicating meters of the transformer rectifier
and also at the drain point (see fig.3) have been confirmed to meet standard cathodic protection
range for steel pipes (-1.054V, where the standard range is between -0.85V to -1.10V). Please see
Table 1 below.

S/N Test Reading Data Before Reactivation Data After Reactivation

1 TR Output Voltage 0.1 - 14.0 V
2 TR Output Current 0.00 -08.5 A
3 TR Potential Measurement 527 -1.054V
4 TR Cathodic Reading 608 -2.047V
5 Potential Measurement at Drain Point 634 -1.054V

Table 1: Table Comparing Data Obtained Before and After the Reactivation of the Transformer Rectifier System.

Survey and Measurements of 24” x 21km Gas Pipeline from Creek Town to GMS

The contractor Messers Machobs Global Links Ltd in company of GMS Electrical Maintenance
embarked on the pipeline survey through the ROW and measurement of the 21km pipeline
starting from the GMS end (downstream). Reasons for the survey of the pipeline RoW are but
not limited to:

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 a. Assessing the effectiveness of the CP on the buried pipes.
b. Check for possible damage to the line e.g. dents, cracks or gorges.
c. Encroachment on the RoW.
d. Erosion on the RoW.
e. Leaks.
f. Any potential hazards in the pipeline.

The pipeline was created and commissioned about 9 years ago and has been in operation without
clearing the RoW, maintenance of the cathodic protection i.e. pipe – to –soil which is mandatory
and statutory requirements of an operating gas pipeline system.

During the survey, after about 1 .5km from the GMS through the thick bush/swamp, no trace of
TP or pipeline marker posts were spotted. The assessment was later taken to the tie – in station
at Creek Town and after about 2.5km, no trace of TP or marker post was seen. Also at the road
crossing at creek town, none was seen.

The pipeline ridge was barely seen as stumps, palm trees, bamboo trees, thick bushes, ant hills
and community farms had taken over the ROW. Swamps were impassable and the river crossing
banks could not be viewed.

Subsequently, the GMS team decided to embark on another survey at a village called Mkpara,
this time unaccompanied by the contractor. After a long search, one test point was finally found
on the right of way closest to an area people lived (see fig. 5). The pipe-to-soil potential was
measured and found to be -0.737V which is not ideal for pipe protection (see fig. 6). Ideal Pipe-
to-Soil voltage potential readings for buried steel pipe should be -0.85V or higher. By contrast,
lower reading as obtained on the only test post found at Mkpara Village which is approximately
3km away from the GMS were anode is located indicates potential of corrosion. Therefore the
extent of protection of the pipeline cannot be established as there is no comprehensive
measurement along the TPs on the RoW.

Conclusion

While the transformer rectifier at the GMS process area has been satisfactorily restored as
evidenced in the standard readings obtained after the job (see fig. 2), the effectiveness and
extent of the cathodic protection on the entire 24”, 21km pipeline cannot be ascertained. This is
majorly due to obstructions posed by overgrown vegetation and thick shrubs all through the right
of way (see fig. 7 & 8) which makes access difficult. The right of way has not been cleared ever
since the cathodic protection was implemented in 2016 (7 years ago).

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Recommendations

As gas pipeline system is an integral part of the gas transmission system to power plant,
protection from corrosion cannot be overemphasized. It is very important that the RoW be
cleared and all the test posts traced. This will make the measurement of the effectiveness of the
cathodic protection possible. Also after clearing the RoW, if test points are found to be absent
either having been vandalized or damaged unknowingly, the test points have be erected for
timely checks to be conducted on the pipeline to ascertain its integrity and any other checks that
may not be limited to the above. We recommend a timely intervention as highlighted below:

1. Immediate clearing of bushed, stumps, palm trees, ant hills etc.

2. Engage Swamp boogey to clear the swamps at River Crossing.
3. Effective display of pipeline km markers at road crossings.
4. Total erection of missing test points.
5. Engagement of local community patrol men and prohibition of community farming on the
ridges.
6. Mandate and mobilize quarterly clearing of RoW.
7. Quarterly pipe-to-soil measurement at all test points.
8. Replacement of TR oil and silica gel every 2 years.
9. Any other maintenance inspection that may be required.

Please refer to the pictures attached.

Reported by Reviewed and Approved by

Ola Ojo & Uyoemem Ibia Anthony Ochonogor
Maintenance (Electrical) GMS O&M Manager

Date: 14th February, 2023

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Picture Page

Figure 1: Refilling The Transformer Rectifier with New Oil. Figure 2: Reactivated Transformer Rectifier Display Meters.

Figure 3: Reading Taken at Drain Point at GMS, Satisfactory Figure 4: Reading at First Test Point at the Back of GMS,
Satisfactory.

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Picture Page Contd.

Figure 5: The Only Test Point Found along Inaccessible Figure 6: Potential Measured at Mkpara Village
ROW (Label completely erased) (Inadequate)

Figure 7: RoW Completely Overtaken by Thick Vegetation Figure 8: Palm Tree Growing on RoW