Cathodic Protection System Failure Report

Camau fertilizer Plant Page 1

Nov. 26

Cathodic Protection System Failure Report

1. INTRODUCTION
The scope of this document is to provide a guide line to find out a Root Cause
Analysis related to the cathodic protection system for tanks & underground piping
system of Camau Fertilizer Plant, and to provide a quick reference in one
document for investigation reports, and all data collected during inspection, test
and cross-check at Site.
2. BRIEF DESCRIPTION OF THE SYSTEM
- Protection method: applying the impressed current cathodic protection
system.
- Anode type: High silicon chromium cast iron (chrome 4 ~5%)
- Operation lifetime: 20 years
- Protected Items/ systems:
No. System Tagname
1 Fresh cooling water supply FCS
2 Fresh cooling water return FCR
3 Fire Fighting water FFW
4 Oily water OW
5 Portable water PTW
6 Tank Z27001
7 Tank Z26001
8 Tank T04302
9 Tank T04303
- Well type: the anode well is 36m depth
- Number of nodes well: total 6 wells, each well is equipped 4 sets of
subsection prefabricated anode body except well No.6
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- Schematic of cathodic protection system.


3. INSPECTION
The system is regularly inspected as operation and maintenance manual (OMM) of
Vendor. All results of potential and protective current are in the working range as
design until the last inspection. The results of last inspection are not totally met
requirement. Details are as follows:
3.1 Measure voltage.
The system No.1: Protection potential with reference electrode Cu/CuSO4 is out of range
of protection value (-1150-850mV).

No.
Anode
Well
Item/ System Test Point
Result
(mV)
Ramark
1 Y1
FFW TPS1 -850
FFW 1 -879
FFW 2 -810 Out of protection
FFW 3 -836 Out of protection
FFW 4 -820 Out of protection
FFW 5 -856
FFW 6 -855
FFW 7 -839 Out of protection
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FFW 8 -740 Out of protection
FFW 9 -880
FFW 10 -840 Out of protection
FFW 53 -850
FFW 54 -850
FFW 55 -750 Out of protection
FFW 56 -840 Out of protection
FFW TPS2 -800 Out of protection
2 Y2
FFW 45 -900
FFW 46 -900
FFW 47 -900
FFW 48 -900
FFW 49 -900
FFW 50 -910
FFW 51 -900
FFW 52 -900
FFW 57 -750 N/A
FFW 58 -900
FFW 59 -970
FFW 60 -900
3 Y3
FFW 24 -900
FCR 64 -1150
FFW 23 -970
FCS 25 -1050
FFW 26 -900
FCS 27 -950
FFW 28 -930
FFW 29 -1000
FCS 30 -900
FFW 31 -950
FFW 32 -900
T04302 61 -1100
T04303 62 -1000
4 Y4
FFW 19 -850
FFW 20 -950
FFW 21 -1150
FFW 22 -970
FCR 63 -950
FFW 39 -970
FFW 40 -900
FFW 41 -900
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FFW 42 -970
FFW 43 -850
T26001 44 -850
Z27001 45 -850
FFW TPS4 -850
FFW TPS4 -850
5 Y5
FFW 33 -900
FFW 34 -810 N/A
FFW 35 -900
FFW 36 -900
FFW 37 -850
FCR 38 -850
FCS 39 -890
6 Y6
FFW TPS3 -900
This well is different
from the original
design. This well
was additionally
installed after
commissioning
system with
unsatisfied results.
FCR TPS3 -900
FCS TPS3 -900
FFW 11 -900
FFW 12 -950
FCS 13 -900
FFW 14 -900
FFW 15 -900
FFW 16 -900
FFW 17 -950
FFW 18 -850
3.2 Measure impressed current:
There is not impressed current output of Transformer No.1. Please refer to the
attached report No.1.

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4. FINDING ERROR.
4.1 Probability of Failure
The inspected results show that there is 3 reasons may happen:
a. Circuit from transformer rectifier TR1 to piping may open
b. Circuit from transformer rectifier TR1 to anode well Y1 may open
c. Transformer rectifier TR1 got malfunction
4.2 Finding error.
References to OMM of Vendor and carrying out some test by trial-error and cross-check
methods, the following testes have been done:
Test 1: Please refer to the attached report No. 2 for details:
Disconnect anode well Y1 from transformer rectifier TR1
Disconnect anode well Y5 and connect anode well Y5 to TR1
Turn-on the TR1, there is output current of 15.5mA

Test 2: Please refer to the attached report No. 3 for details:
Connect the TR1 to its anode and cathode and turn-on TR1
Measure the voltage between junction box of anode PJ B1 and junction box
of cathode NJ B1: 60V
Test 3: Please refer to the attached report No. 4 thru No. 9 for details
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According to above reason, additional test have been performed for the rest of anode well
(Y2 Y6) to check the current through each wire of anode well and the result are:
- Anode well Y3: there are 2 wires without protective current
- Anode well Y4: there is 1 wire without protective current
4.3 Conclusion
a. Circuit from transformer rectifier TR1 to piping is ok
b. Anode well Y1 totally failed. The reason either all 4 wires have
disconnected from anodes or anodes have been failed.
c. Transformer rectifier TR1 is ok
d. Anode well Y3: there are 2 wires being disconnected from nodes
e. Anode well Y4: there is 1 wire being disconnected from node
5. RECOMENDATION
In order to absolutely solve problem and prevent failure in future, It is strongly
recommended that the following actions must be taken into account:
1. Verification design of whole system
2. Verification construction design in consideration of soil data and actual soil
improvement result at site.
3. Carrying-out root cause analysis
4. Install new anode well Y1 (redesign and construction design need to consider)
5. Evaluation the remain working ability and likelihood of failure of well Y3 &
Y4, and solution therefore (may it be modified or replaced with new well)
6. ATTACHMENTS:
There are total 9 attached reports (named Report No.1 thru No. 9) which
accompany to this document