Paper No.

CP11

Implementation of cathodic protection system in Jamnagar refinery for

plant piping

RAJIV MANDAL,
GM-Central Engineering Services, Reliance Industries Limited.
ABSTRACT

ICCP System has been implemented successfully for the plant service pipelines in biggest refinery in
record time. From conceptualization to realization of this project has been covered in this paper. Over
360 KM of pipelines sized from 2 to 48 inch dia spread over 45 plants has been covered in this projects.
Strategic Planning for Design, Engineering, Resource, Construction and Commissioning contributed in
a great way to complete the project in 36 months. This was possible with huge direct support form top
management. Continuous learning from events and failures with desire to achieve during this period
was key success to complete the installation activities in highly interfered construction environment.
Proper selection of protection criterion and implementation of protection controls considering pas data
in different environmental and soil conditions limited the current demand and expenditure on account of
augmentation.

Key word: Design, Implementation, Training, Commissioning, Conclusion

Page 1 of 9
INTRODUCTION

RIL Jamnagar has commissioned its 580,000 barrels of crude oil per stream day (BPSD) in 2009-2010.
This Refinery complex has 40 different process units alongwith tanks farm. Cathodic Protection system
has been implemented for all the underground piping and storage vessels as an integral part of the
units. All the refinery units were commissioned alongwith it’s cathodic protection system which was a
major achievement in this tight scheduled project in highly complex and closely interfered project. This
paper discuss the implementation strategy upto commissioning, key issues and achievements in
implementing this cathodic protection system for approx. 340 KM of plant piping and 45 underground
storage vessels in 40 Refinery, Petrochemical, Utility Units and Tank Farm Area.

SCOPE

The overall scope for cathodic protection is as follows:

Description Unit of Quantity

Measurement
Total Area Square K.M. 10
No of Major Units. Number 39
Total Length of pipelines Meter 340,000
Total Surface Area Square Meter 450,000
Reinforcement Steel Square Meter 1,200,000
Earthing Steel Square Meter 60,000

IMPLEMENTATION PROCESS

In order to complete the project before commissioning in a scenario where detail engineering of
construction of UG system was planned with zero time lags (engineering and construction), ICCP
system design and installation process needed to be handled with great planning and strategy.
Advance material planning and service contract arrangements enabled this project to be executed
within the stipulated time schedule.

Design Detail Procurement Installation Commissioning O&M

Basis Design
06/2006 Overall SACP
12/2006 SACP SACP
06/2007 SACP ICCP SACP
12/2007 ICCP ICCP
06/2008 ICCP ICCP
12/2008 ICCP ICCP ICCP
06/2009 ICCP ICCP
12/2009 ICCP ICCP ICCP ICCP
06/2010 ICCP ICCP ICCP
12/2010 ICCP ICCP ICCP

CONCEPTUALIZATION

Cathodic Protection System has been accepted as an important means of underground structure
corrosion protection in this project. Following are the major aspects were deliberated and finalized
during conceptualization of the project.

Page 2 of 9
 CTE Coating was finalized considering the easy application and availability of joint coating.
Scope of cathodic Protection: All Underground piping (approx.340 KM) for fire water, drainage
systems, cooling water systems, Underground Storage Tanks, sea water intake lines.
Temporary CP with magnesium anodes during construction phase.
Permanent CP with MMO strip anodes.
Finalize current density data from the previous experiences.
Universal continuity in underground piping considering the dense piping network.
Consideration of other structures during design of CP system.
Limitation of current drainage through measures in underground civil structural engineering.
Application 100 mVolt Polarization criterion in complex piping areas.

As per the overall project guidelines, ICCP systems were supposed to be commissioned alongwith the
commissioning of the units. Multi disciplinary clashes with other underground Civil, Mechanical and
Electrical activities were apprehended and clash checks were included in engineering process.

All these factors were finalized in conceptualization stage with past experience and feedback from the
performance of different ICCP system at Reliance, Jamnagar.

The basic design also became guideline for detail design and followed by the Detail Engineering
Centers during production of unit wise design and construction drawings.

DESIGN & ENGINEERING

Based on this basic design, type and rating of all the anodes, rectifier, cables and junction boxes were
finalized and standardized for the project. Standard construction/layout drawings were issued to
standardize the material take off process and detailed engineering process.

The design work was planned in order to produce over 1300 nos. layout drawings and other design
engineering deliverables in sync with civil underground construction drawings. This helped the
construction groups to take up the ICCP underground activities alongwith piping, civil and electrical
constructional underground activities.

The entire Design and Engineering work was done in three levels. Reliance appointed Specialists
Engineers as consultants for these design offices:

Level 1 Main Design Office Design Guidelines.

Appointment of CP engineers at Package design offices and
site design office.
Approving of Detailed Design deliverables.
Harmonization of all systems.
Finalization of Vendor and Material Data Sheet.
Advance planning of Material Movement.
Reconciliation of unit wise BOM.
Conflict management with other disciplines.
Level 2 Package Design Detailed Design and Engineering.
Offices Clash checks with other UG facilities.
Unit wise Bill Of Materials.
Unit wise Contract Scope.
Level 3 Site Design Office Site Engineering Issues,
Quality Check List

Page 3 of 9
 EPC co-ordination
Review of installation and commissioning reports.

Total 2225 documents were prepared including work procedures, layout drawings, data sheets and
design documents for procurement and construction activities. This includes 39 design calculation docs
and 1330 cathodic Protection Layout drawings. These design group also supported with vendor
document review for speedy approval of equipment layout / design sketch / calculation / Inspection
Release Note / Type test certificates / and specification finalization process.

Key Design Factors

Harmonization of all ICCP systems: Harmonization amongst different ICCP systems was most
important factor in order to optimize power source and control overlapping of protection zones in the
interface areas between two or more units. This also helped to ensure seamless protection with 100%
redundancy in the system even in the offsite areas.

Unit 1 Unit 2 Unit 3

Unit 6
Unit 7 Non Plant

Pond Unit 4 Unit 5

Store Store Unit 8

Figure 1. Overall layout of underground services

Targeted Design Utilization Factor of TRUs : 70%

Actual Design Utilization Factor of TRUs : 73%

Universal Continuity and shallow anode beds: It is experienced that the isolation concept between
underground pipeline (to be protected) and other incidental structures in plants with high density of
underground structures is not effective. In this project, universal continuity concept was accepted with
no isolation flanges and continuity loops across all valve pits in fire water lines and collection pits.

In order to restrict current leakages in incidental structures, shallow anodes were installed at close
interval (10 to 25 mtr.) using voltage interference methods. Wire Anodes were used for piping in highly
populated areas. Approx. 60% of the piping was laid under RCC paved area or close to foundation.

Page 4 of 9
It was also decided to calculate actual contribution of each incidental structure i.e. RCC reinforcement
bars, earthing strips as per follows:

Sr No Type of Structure Current Density

1 Piping with CTE coating 05 mA / Sq. Mt.
2 Reinforcement bars 01 mA / Sq. Mt.
3 Earthing Strip 20 mA / Sq. Mt.

Total Current Requirement (at 25 years) : 4420 Amps.

Total Current Capacity designed (Anodes) : 4563 Amps.
Total Current Capacity of Rectifiers : 6000 Amps.

Considering the complexity of the underground structure and piping network, design loading found to
be very close to the rating of the Anodes. 100% redundancy has been ensured with strategic placement
of anodes.

Soil Resistivity survey conducted throughout the plot. Depth of 3-6 Mtr. found most suitable with an
average soil resistivity of 2000 Ohm–cm.

100.00
90.00
Soil Resistivity Data
Soil resistivity in Ohm Meter

A1 A2 F1 F2 F4
80.00
70.00 E1 E2 C1 CPP Average
60.00
50.00
40.00
30.00
20.00
10.00
0.00
1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00 10.00 15.00
Depth in Meter

Chart 1: Soil Resistivity data comparison.

TRAINING AND DEVELOPMENT

Extensive training on various aspects of cathodic protection was arranged throughout the project
schedule. Training has been impart to all disciplines of design, engineering construction and O&M
Managers and Engineers at start of project, till completion of project and handing over for O&M. These
training programs includes theoretical, constructional aspects in addition to on-job training. 21 such CP
trainings were conducted involving 450 plus participants in total.

CATHODIC PROTECTION SYSTEM DETAILS

The cathodic Protection implementation was controlled and monitored centrally through a dedicated
team of coordinators for manpower mobilization and material flow. Offsite areas were handled through

Page 5 of 9
the Central Group. Central Group also coordinated with Engineering Group for final commissioning and
harmonization.

The ICCP installation activities were divided into unit wise and monitored and controlled by individual
unit planning group for implementation upto handing over to O&M. The unit wise CP implementation
schedule was coordinated in line with the plant construction schedule in order to minimize clashes with
other engineering activity, interference with other construction groups and optimization of
interdisciplinary engineering and construction manpower.

Field installations for Sacrificial Anode Cathodic Protection:

a) More than 1500 Test Stations with different connection schemes,
b) 3000 nos. of Sacrificial anodes (Magnesium) as Temporary and at crossings.
c) TCP anodes are designed for 18 months. Cased crossing CP, earthing anodes and monitoring
devices are considered for 25 Years life.

ICCP System installations:

117 nos of ICCP Rectifiers were installed at location identified with an effort to optimize the power
requirement through 980 nos. Junction Boxes with current control facilities. A total of 456 KMs of
different dimension cables were used at different current levels.

4272 nos. Shallow Vertical Anodes were used as per design alongwith 26 nos. Semi Deep
Anode Beds and 5353 mtrs. of continuous anodes.

1200 nos. Soil Access points were provided in paved area inside the plants for taking PSP.

COMMISSIONING

In order to implement a systematic commissioning of this huge system, Internal (third party) and
External audits were conducted. Detailed Inspection & Test Plan were developed and placed during
installation and commissioning activities.

Pre-Commissioning checks and initial charging of ICCP system for individual units was conducted
jointly by Maintenance and Construction Groups before the units were ready for hydrocarbon charging.

Measurements were taken in 2503 nos. of Test Points including Test Posts and Other pipeline access.

Following were two major observations:

1. Pipeline grid normally outside the paved are found almost 100% protected.
2. Pipeline within the unit paved area found protected at approx. 70% locations.

Major issues identified were as follows:

Unit 1 at inside plant RCC areas Unit 2 at inside plant RCC areas

Page 6 of 9
Unit 1 at outside plant RCC areas Unit 2 at outside plant RCC areas

100 % Protected

After pre-commissioning checks and initial charging, additional anodes were installed to protect the
identified hot spots aroused due to various reasons mentioned above. However detailed testing and
survey was conducted to analyze the polarization pattern and adjusted current by introducing variable
resistors wherever applicable. At present the protection is achieved at almost every location.
Improvement achieved pre and post current adjustment is as follows:

100.0%
June 2011 Protection
90.0% June 2010 Protection
% Pipeline Protected

80.0%
70.0%
60.0%
50.0%
40.0%
30.0%
20.0%
10.0%
0.0%

Units with ICCP system

Chart 1: Change in Overall performance of ICCP systems in different units from Year 2010 to

Page 7 of 9
 2011.

70.0%
June 2010 Utilisation
60.0%
June 2011 Utilisation
% of Designed Current

50.0%
40.0%
30.0%
20.0%
10.0%
0.0%

Units with ICCP

Chart 2: Change in Current of ICCP systems in different units from Year 2010 to 2011.
12.00
Circuit Resistance in Ohm

10.00
8.00
6.00
4.00
2.00
0.00

Units with ICCP

Chart 3:Unitwise circuit resistance variation.

CHALLENGES AND MILESTONE:

1. Largest Refinery ICCP system with 340 KM of underground plant piping sizing from 90” to 4” Dia. It
was challenge considering the fact the 60% of the piping was under RCC.

2. Job co-ordination with total of 39 record capacity Refinery Units, with parallel progressive working in
all EPC front; to match with project progress. This is one of the largest green field refineries
commissioned alongwith it’s ICCP systems.

3. The first ever ICCP system for plant piping with universal continuity concept. The ICCP system
accepted all available underground structures for protection. No Isolation devices are used, hence
possible source of spark eliminated.

4. Optimization of power sources with harmonization of 39 nos. ICCP systems. This has given an
excellent utilization factor of 73% against design target of 70%. However the system is loaded at 40%
of the installed capacity.

Page 8 of 9
5. Protection achieved with current density of 5.4 mA./Sq.Mt. against design current density of
10mA./Sq. Mtr.

CONCLUSION

Implementation of cathodic protection systems for complex piping in Greenfield project requires lot of
high level commitment and devotion from working level.

It is also important to allow system to polarize with systematic program in case of complex pipeline in
green field project involving backfill materials from different sources. Complex pipelines cathodic
protection system shall be considered alongwith it’s associated incidental structures. Decision to isolate
or include the incidental structures taken during project conceptualization stage was crucial. All these
factors helped to obtain proper polarization of the system with max. utilization of ICCP installations at
the end of commissioning.

ACKNOWLEDGEMENT

Reliance Industries Ltd. for giving an opportunity to lead the CP team for this project and thus for
publishing this paper

Page 9 of 9