OWNER'S REQUIREMENT

5E.13 CATHODIC PROTECTION EQUIPMENT FOR BURIED PIPEWORK

AND STRUCTURES:

The scope of work shall include design, supply, installation, testing and
commissioning of the cathodic protection system for the plant

5E.l3.1 DESIGN PARTICULARS

The necessary transformer rectifier equipment, automatic and manual control

equipment, distribution panels, anodes, ground beds and wiring for the cathodic protection system as
necessary to prevent corrosion of pipework and materials buried in the ground as detailed below shall
be provided.

The resistivity of the ground shall be determined by the Contractor and the results
shall be used in the design of the cathodic protection system.

The pipework will be externally wrapped and the design cathode current density shall
be 0.035 A/m of pipe surface.
2

All cables buried in soil and used for cathodic protection system shall be of high
molecular density polyethylene and minimum cross-section shall be 10 mm2 •

A high density polyethylene membrane/sheet shall be used below the anode ground
bed and also to cover the re-enforced ring beam foundation of tank in order to avoid consumption of
current by the surrounding structure/material other than bottom surface of tanks which need cathodic
protection.

The Contractor shall ensure that the cathodic protection system installed under this
Contract is compatible with any existing protection in the adjacent areas.

5E.l3.2 EXTENT OF PROTECTION

All buried metallic pipework and structures supplied under this contract shall be
protected including, but not limited to the following as applicable :

a. base of all water and fuel storage tanks

b. distilled water main and other buried water mains on site, including all fire
fighting mains.

c. cooling water system pipework (if applicable)

d. on site gas pipework (underground)

e. gas pipework from the gas tie in point header to the site (underground).

f. Sea water pumps and pipes.

Specification No. MEW/SOCGT- 2 SE-88 Contractor's

Issued via Addendum No.I : Oct 2014 Initial and Stamp
 g. Steel liner of sea water pipes.

h. Intake screens gate and other structure (if applicable)

1. Condenser and heat exchangers

5E.l3.3 TRANSFORMER RECTIFIERS AND CONTROL EQUIPMENT

The electrical supply for operation of the equipment will be 415 V, three-phase,
50 Hz, 4 wire supply. The control voltage for operation of the relays and control equipment shall not
exceed 110 V and the Contractor shall provide any transformers and rectifiers required .

The transformers associated with the rectifier units shall be of the double wound air
insulated type or oil cooled type as per the manufacturer standard.

The equipment shall incorporate means for protecting transformer sand rectifiers
against damage due to overload or short-circuit of the de output.

The rectifiers shall be of the silicon, three phase full-wave bridge connected type.
The ripple content of the output wave shall not exceed 5% rms over the entire output range. An
approved surge diverter shall be connected across the de terminals.

The transformer rectifier units shall be supplied complete with all external fittings and
instruments which shall include the following as a minimum.

a. AC voltmeter and ammeter

b. DC voltmeter and DC ammeter connected in the negative lead &

protective potential voltmeter.

c. moulded case circuit breaker with provision for position monitoring.

d. DC cable entry box gland plate

e. earthing terminal

f. suitable enclosure with canopy when installed outdoor

g. panel lamp to indicate healthy incoming AC supply

h. panel lamp to indicate healthy total outgoing DC supply

1. lockable covers complete with padlocks with three keys

J. lifting lugs or brackets complete with all fixing bolts, nuts, washers,
screws

k. holding down bolts.

I. Panel illumination light, space heater socket outlet etc.

m. rating plate.

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5E.13.4 GROUNDBEDS

Tubular high silicon cast iron anodes supported within each groundbed shall be used.
After installation of the anodes, the hole shall be backfilled with calcined petroleum coke breeze to
ensure a homogeneous backfill surrounds the anodes. A gas vent pipe shall be installed where
necessary.

Anode ground beds shall have a design life of minimum 30 years.

Irrigation of the groundbeds shall be provided if considered necessary.

Anode ground bed marker posts shall be provided.

5E.13.5 ANODES

Anodes shall be of the high silicon cast iron tubular type having a chromium content
between 4-4.5%. The anode lead cables shall be 8 mm 2 copper insulated with a single cross section
centre by a secure mechanical device resulting in low electrical resistance. Mechanical strength shall
be such that prior to application of the sealing compound a pull test will result in the breaking of the
wire prior to breaking of the connection. The potting material shall be a thermal setting material
capable of adhering firmly to the interior surface of the anode and shall be of a thickness of no less
than 50 mm on each side of the connection when measured along the length of the anode.

5E.l3.6 ANODE JUNCTION BOXES AND SUPPLY CABLES

In order to adjust and monitor the current to each anode, metering equipment and
regulating shunts shall be provided in each weather-proof junction box made of stainless steel.

The DC supply cables to anode junction boxes shall be XLPE insulated single core
multi strand copper cables suitably sized for the current they are to carry.

Underground joints of de cables shall be of the crimped type and insu lated to the
manufacturer's instructions.

5E.13.7 ANODE BACKFILL

All anodes shall be installed in a column of backfill which shall surround the anode
with a minimum thickness of 50 mm and covered top and bottom to a minimum depth of 150 mm.
Material may be metallurgical grade coal coke or calcined petroleum coke having a minimum
resistivity of 50 ohm/cm 3 and density not less than 1040 kg/m3 . Backfill may be installed around the
anode separately in the field or pre-packaged at the point of manufacture with the anode in a
galvanized steel container. An irrigation system shall be incorporated into the anode backfill if the
ground resistivity requires to be lowered for efficient anode operation.

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5E.13.8 BONDING SYSTEM

All pipe joints and fittings shall be made electrically continuous. This shall be
accomplished with steel joints by welding and with ductile iron pipe by bonding across the joints with
insulated copper wiring using the termite brazed Cadweld Process method. In such instances the
bonding cable shall be no smaller than 35 mm2 • Disruption to the pipe and fitting protective coating by
the brazing process shall be repaired. All brazed connections shall be hammer tested and rebrazed
as required to assure secure connections.

5E.13.9 TEST STATIONS

In order to properly adjust the cathodic protection system and test its effectiveness,
the installation of permanent test stations is required. These test stations will provide an electrical
contact to the pipeline for test measurements.

All test stations shall be the above ground type in a housing of stainless steel. All
electrical terminals shall be nickel plated steel or copper. Conductors are not current carrying and
therefore can be 10 mm2 minimum single conductor PVC insulated. Conductors shall be fixed to the
pipe by the Cadweld Process.

Test stations shall be located as follows:

a. a single wire test station at the nearest point of approach of the pipeline to the
groundbed(s). The same colour of wire insulation shall be used throughout the
system.

b. a double wire test station shall be installed at the approximate mid-point between
adjacent rectifier stations and at rectifier unit negative attachment locations. In
such instances the test wiring shall be installed exactly 600 mm apart on the pipe
and be of two different colours.

All test stations shall be located above ground level and shall be an integral part of
pipeline marker posts or propose designed surface terminal boxes. They shall be secured in concrete
no less than 300 mm below ground level.

5E.13.10 PERMANENT REFERENCE ELECTRODES

Permanent reference electrodes shall be installed in conjunction with the test stations
to provide a means of obtaining a repeatable pipe-to-soil potential measurement. The permanent
reference electrodes shall be zinc and shall be prepackaged in a homogeneous backfill and installed
adjacent to the pipeline.

5E.13.11 INSULATION

The areas of plant to be protected shall be electrically isolated from each other by
means of a flange insulation at all crossover points and site boundary interconnections and shall
include:

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 a. the Towns water supply

b. the natural gas supply

c. the gas oil supply

d. any other points deemed necessary.

Such insulation shall consist of a phenolic sheet with a ring type nitrile sealing
element with an outside diameter equal to that of the pipe flange and sufficient and properly spaced
holes for passage of flange bolts. In addition, each flange bolt shall be encased in a mylar sleeve
extending the full length of the width of two flanges and be provided with a phenolic washer and
galvanized steel back-up washer located at the nut attachment.

5E.13.12 INTERFERENCE TESTING

Any other buried metallic structures in the immediate area of the various pipelines
shall be tested before and after commissioning of the cathodic protection system .

Any interference with any other buried structure shall be rectified by approved means
as part of the Contract.

5E.13.13 SACRIFICIAL ANODE SYSTEMS

In areas where interference problems may exist and where the use of sacrificial
anode systems may reduce the extent of the interference, sacrificial anode systems may be proposed.
Sacrificial anodes shall be used to protect the internal surface of the steel liner of the main sea water
conduit, internal of tanks and heat exchanger as applicable as per manufacturer standard. Life of
sacrificial anode type cathodic protection shall not be less than 10 years.

5E.13.14 PORTABLE TEST EQUIPMENT

In addition to the permanently installed equipment for monitoring and controlling the
cathodic protection system portable equipment shall be provided to check the various systems and
shall include two copper/copper sulphate half cells, two silver/silver chloride half cells and two high
resistance voltmeters for use with these portable half cells.

5E.13.15 STRUCTURES IMMERSED IN SEAWATER (IF APPLICABLE)

5E.13.15.1 DESIGN AND OPERATING PARTICULARS

The Contractor shall supply the necessary transformer rectifier equipment, control
equipment, distribution panels, anodes, monitoring equipment and wiring for the cathodic protection
system as necessary to prevent automatically corrosion of plant and materials in contact with
seawater as detailed below:

Unless otherwise approved the current rating of anodes, distribution panels and
transformer rectifiers shall be based on the following design cathode current densities.

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 a. 0.5 A/m 2 of total wetted surface area for seawater pumps.

b. 0.270 A/m 2 of total wetted surface area for uncoated pipework and other ferrous
structures, such as coarse screens, stop gates, penstocks and drum screens.

Notwithstanding the above parameters the Contractor shall satisfy himself that the
current density is adequate for protection and where the cathode current density is different from that
specified the design figures used shall be stated .

The above current densities shall apply when the potential of the anodes measured at
the anodes is not greater than 6 V.

5E.l3.15.2 TRANSFORMER RECTIFIERS AND CONTROL EQUIPMENT

The requirements for this Clause are as for transformers, rectifiers and control
equipment for buried pipework and structures.

5E.l3.15.3 AUTOMATIC POTENTIAL CONTROL EQUIPMENT

The protection system shall be arranged for automatic control of the potential of the
protected metal with respect to the electrolyte. Provisions shall be made in the design of this
equipment for manual operation of the associated electrical equipment.

Automatic control equipment shall be of the silicon controlled rectifier solid state type.

Silver/silver chloride and/or high purity zinc half cells shall be provided for each zone
of the equipment to be protected automatically. Wherever possible the monitoring half cell shall be
supervised by a duplicate half cell in its close proximity and shall be backed up by not less than one
other half cell installed in an approved position. Facilities shall be included whereby spurious signals
such as open or short circuit of the monitoring point are rejected. A high resistance voltmeter shall be
included in the sensing circuits with manual selection switching for checking reference potentials of all
points specified above.

5E.l3.15.4 DISTRIBUTION PANELS

Distribution panels shall be provided with individual circuits for each anode. Each
circuit shall include the following:

a. Cartridge fuse.

b. Series shunt.

c. Variable resistance rheostat of the slider type.

d. Fixed resistance trimmer where necessary.

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 The individual circuits and the distribution panel shall be suitably rated with capacity
and space in hand for not less than four further anode circuits of the maximum rating of any one
anode in the distribution panel concerned.

Distribution panel enclosures shall be of the weather proof type and shall be provided
with lockable covers together with pad locks and three keys.

Where step change is specified for the applied anode potential each anode way shall
be provided with a requisite switching relay for inclusion in the circuit of an adjustable resistance
whereby the anode current shall be reduced to one half of the normal operating current or such other
suitable value as may be approved.

Each distribution panel shall be provided with de moving coil voltmeter and ammeter
switches for indicating output voltage and current of individual anodes and also total output of the
panel.

Distribution panels shall also be provided with a high resistance voltmeter and
selection switch for indicating the protection potential.

The main construction of all cubicles shall be of steel. Panels and removable covers
need not be of steel but specific approval is required for other materials. The stiffness of panels and
cubicles shall be such as to prevent mal-operation of relays or other equipment by impact. Panels
shall be of a suitable thickness. reinforced where necessary, bearing in mind the number and size of
cut-outs and size of the panel. Cubicles shall be seated on an approved form of anti-vibration
mounting.

SE.l3.15.5 ANODES

Except where particularly specified anodes shall be of the cantilever type.

Cantilever rod type anodes shall consist of titanium rods platinized to thickness of 2.5
micron by electro-deposition. Unplatinized length s of anodes shall be protected by a tightly fitting and
waterproof anode shield so arranged that it overlaps the platinized length by not less than 3 mm.

The length of the anodes shall be such that calcareous deposits are not built up in
any zone of the plant under protection that will interfere with its continuous effective operation.

Anodes shall be mounted or designed so as to damp out or avoid vibrations resulting

from the flow pattern of the electrolyte and thereby avoid the possibility of fatigue.

Mountings for cantilever anodes shall be standardized for two boss sizes.

The maximum current densities when operating at a maximum potential of 6 V

measured at the anode shall not exceed the value stated in the offer.

SpecificatiQJJ-Ntr.::M:El SOCGT- 2 5E-94 Contractor's

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 All anodes shall be sized to produce the maximum required current for passivation at
a potential not greater than 6 V measured at the anode.

5E.13.15.6 PROTECTION POTENTIAL REFERENCE POINTS

Potential reference points shall be either

a. High purity zinc with a zinc content of 99.99%. The design shall ensure adequate
surface area so as to minimize polarization of the zinc.

b. Silver/silver chloride half cells for use in conjunction with the automatically
controlled protection equipment.

The Contractor shall provide not less than one reference point for each section of the
plant under protection. The position of half cells and reference points shall be to approval.

5E.13.15.7 BONDING

All bonding as may be necessary between the various components parts of the plant
to be protected shall be provided. This shall include bonding across pipe flanges, slip joints and valve
bod ies, bonding between valve bodies and valve spindles and/or discs.

5E.13.15.8 SUPERVISION AND CERTIFICATION

The cathodic protection design and installation testing and commissioning shall be
carried out under the supervision of a qualified and certified cathodic protection specialist and
representative of the equipment manufacturer.

5E.14 NOT USED

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