NAME YOGESH JAYRAJ RAYCHEM RPG KSS TITLE DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I CONTRACT NO- DOCUMENT NO - R1 WORK ORDER NO- MH2145-C000-EL-SPC-SPC-0025, DATED 2/5/13 06-10-1403-DD-PH1
EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT
OWNER
HINDUSTAN PETROLEUM CORPORATION LIMITED
MAIN CONTRACTOR
KSS Petron Private Limited (Formerly KazStroy Service Infrastructure India Pvt.Ltd)
CONSULTANT
WORLEYPARSONS SEA INDIA PVT. LTD.
CP CONTRACTOR
RAYCHEM RPG (P) LIMITED
WORLEYPARSONS APPROVAL
Approved by NAME SIGN
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT
06-10-1403-DD-PH1, Rev-01 Page 2 of 113
Contents 1.0 INTRODUCTION .................................................................................................................................. 4 2.0 SCOPE ................................................................................................................................................. 4 3.0 ABBREVATIONS ................................................................................................................................. 5 4.0 SYSTEM OVERVIEW .......................................................................................................................... 7 5.0 CORROSION SURVEY REPORT ....................................................................................................... 8 5.1 OBJECTIVE OF THE SURVEY ........................................................................................................... 8 5.2 SCOPE OF WORK .............................................................................................................................. 8 5.3 SOIL RESISTIVITY SURVEY .............................................................................................................. 8 5.4 SOIL RESISTIVITY VS. DEGREE OF CORROSIVITY ....................................................................... 9 5.5 SOIL SAMPLES................................................................................................................................... 9 5.6 ADDITIONAL DATA COLLECTION ................................................................................................... 11 5.7 SURVEY RESULT ............................................................................................................................. 13 6.0 DESIGN DATA & CRITERIA ............................................................................................................. 13 6.1 INTRODUCTION ................................................................................................................................ 13 6.2 PIPELINE DETAILS ........................................................................................................................... 13 6.3 CATHODIC PROTECTION SYSTEM DESIGN LIFE ........................................................................ 13 6.4 CODES AND STANDARDS .............................................................................................................. 13 6.5 PHILOSOPHY OF CATHODIC PROTECTION SYSTEM ................................................................. 14 6.6 PROTECTION CURRENT DENSITY ................................................................................................ 15 6.7 CATHODIC PROTECTION DESIGN CRITERIA ............................................................................... 15 7.0 DESIGN CALCULATION ................................................................................................................... 16 7.1 TOTAL CURRENT REQUIREMENT ................................................................................................. 16 7.2 CURRENT REQUIREMENT .............................................................................................................. 17 7.3 ANODE WEIGHT REQUIREMENT ................................................................................................... 18 7.4 HORIZONTAL GROUNDBED RESISTANCE ................................................................................... 19 8.0 EHV / HV CROSSINGS ..................................................................................................................... 23 9.0 CATHODIC PROTECTION AT CASED CROSSINGS ...................................................................... 27 9.1 CATHODIC PROTECTION FOR CARRIER PIPE ............................................................................ 27 10.0 INSULATION JOINTS ...................................................................................................................... 30 11.0 EARTHING ELECTRODE ............................................................................................................... 30 12.0 POLARISATION COUPONS ........................................................................................................... 31 13.0 REFERENCE CELL ACCESS POINTS........................................................................................... 31 14.0 ER PROBE & READER ................................................................................................................... 31
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
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06-10-1403-DD-PH1, Rev-01 Page 3 of 113 15.0 TEST STATION ............................................................................................................................... 32 16.0 CABLE LAYING DETAILS ............................................................................................................... 50 17.0 CABLE TO PIPE CONNECTIONS .................................................................................................. 50 18.0 INSTALLATION PROCEDURE ....................................................................................................... 51 18.1 FOR TEST STATION ....................................................................................................................... 51 18.2 FOR SACRIFICIAL ANODES .......................................................................................................... 55 18.3 FOR CABLE LAYING....................................................................................................................... 59 18.4 FOR SURGE DIVERTER ................................................................................................................ 63 18.5 FOR THERMIT WELD ..................................................................................................................... 66 18.6 FOR PIN BRAZING .......................................................................................................................... 71 18.7 FOR POLARISATION CELL ............................................................................................................ 75 18.8 FOR PERMANENT REFERENCE CELL ......................................................................................... 78 18.9 FOR POLARISATION COUPON ..................................................................................................... 82 18.10 FOR ZINC RIBBON ANODES ....................................................................................................... 85 18.11 FOR ER PROBE ............................................................................................................................ 88 19.0 INCOMING MATERIAL INSPECTION REPORT ............................................................................ 91 20.0 STANDARD QAP ............................................................................................................................. 92 21.0 RECORD OF CALIBRATION OF MEASURING INSTRUMENTS .................................................. 94 22.0 INTERFERENCE DETECTION AND MITIGATION ........................................................................ 95 22.1 PROCEDURE FOR AC INTERFERENCE SURVEY ...................................................................... 96 22.2 PROCEDURE FOR DC INTERFERENCE SURVEY ...................................................................... 99 23.0 TESTING AND COMMISIONING .................................................................................................. 105 24.0 SYSTEM MONITORING ................................................................................................................ 109 25.0 BILL OF MATERIAL ....................................................................................................................... 111 26.0 REFERENCE DRAWING LIST ..................................................................................................... 113
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
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06-10-1403-DD-PH1, Rev-01 Page 4 of 113 1.0 INTRODUCTION M/s Hindustan Petroleum Corporation Limited is setting up Multi-product pipeline of approx. 441 Km of 18 Dia from Rewar Dispatch Terminal to Kanpur Receipt terminal. The Entire Pipeline works is divided into two different parts. The details are as follows: PART Section Approx. Length (Km) Dia. (inch) Part-1 Rewari Dispatch terminal to SV-6(Ch:228 km) 228 km 18 Part-2 SV-6 (Ch:228 km) to Receipt terminal Kanpur 213 km 18
M/s. HPCL is awarded the Contract to M/s KSS Petron Private Limited undertake complete construction of pipeline. M/s KSS Petron Private Limited awards Cathodic Protection works to M/s. Raychem RPG Pvt. Ltd for Pipelines in Part I & II. It is intended to provide a Temporary and Permanent Cathodic Protection System to these Pipelines. This document prepared by Raychem RPG Pvt. Ltd. present the design & Calculation for the Temporary Cathodic Protection system using Galvanic Sacrificial anodes for Part-I Pipeline.
2.0 SCOPE The scope of work includes Corrosion survey, Design Detailed Engineering, supply, Installation, Quality Assurance and Quality Control, Testing and commissioning of the Temporary Cathodic Protection system with galvanic anode to protect external surface of the pipeline against corrosion for the period of 2years or till commissioning of the Permanent Cathodic Protection System whichever is later and all other common CP activities such as measuring the soil resistivity along ROU, collection of CP related data along the ROU as per specification no:MH2145-C000-EL-SPC-0025 RevA.
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
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06-10-1403-DD-PH1, Rev-01 Page 5 of 113 3.0 ABBREVATIONS SN Terms Description 1 Anode An electrode placed in the electrolyte to apply Cathodic protection to the structure 2 Backfill Low resistance material surrounding the anode to reduce the anode to electrolyte resistance 3 Cathode The structure that is to be protected by Cathodic protection 4 Cathodic Protection The prevention or reduction of corrosion of metal by making the metal the cathode in a galvanic or electrolytic cell 5 Corrosion The deterioration of metal caused by its electrochemical reaction with its environment 6 Corrosion Current The current flowing in a corrosion cell & which is electrochemically equivalent to the anode & cathode reactions 7 Current Density Current flowing into the cathode divided by cathode surface area. 8 Electrolyte A liquid or the liquid component in a composite material such as soil, in which electric current may flow by ionic charge transfer 9 Instantaneous off potential A potential substantially free of voltage gradients 10 Polarization A change in the potential of a metal from its natural steady state value as a result of current flow 11 Polarized Potential The potential value of a metal after polarization reaches the steady state 12 Reference Electrode An electrode that has a stable potential in one or more electrolytes at a given temperature, thus enabling it to be used for the measurement of other reference electrode 13 Structure A metal which has a surface in contact with an electrolyte 14 Dia Diameter 15 Ch Chainage 16 Km Kilometer 17 m Meter 18 mm Millimeter 19 Nos Number 20 V Voltage
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT
06-10-1403-DD-PH1, Rev-01 Page 7 of 113 4.0 SYSTEM OVERVIEW 1) For RKPL Ph-1 Rewari Dispatch terminal to SV-6(Ch:228 km)Pipeline Section: 1 Design Life 2 Year or till PCP commissioning 2 P i p e l i n e
D e t a i l s
RKPL Ph-1 to Murudeshwar Dia (m) Length (m) 0.457 228 P r o t e c t i o n
C u r r e n t
d e n s i t y
Pipeline Surrounding Current Density (mA/m 2 ) Soil Resistivity < 10 ohm-m 0.075 Soil Resistivity 10 ohm-m to 100 ohm- m 0.055 Soil Resistivity > 100 ohm-m 0.035 3
Total Current Requirement Dia (m) Length (m) Surface Area (m 2 ) Current Density (mA/m 2 ) Current required (Amps) Type of Coating 0.457 228000 327341.3 0.055 23.40 3PE coated 4 Total nos of Mg anodes Total Nos. Type Net Weight of Anode (kg) Dimension (mm) Bare Prepacked Bare Prepacked 458 Low Potential 2.5 40 approx. 38 x 38 x 1000 (Long) 150 (Dia) x 1500 (Long) 12 Low Potential 10 90 approx. 76 x 76 x 1000 (Long) 200 (Dia) x 2000 (Long) 6 Configuration of Anode Installation Horizontal Installation 7
Distance between anode from edge of pipeline Mg Anode (mm) Zn Anode (mm) Zn ribbon Anode for HT line crossing (mm) 5000 2000 500 8 Zinc ribbon anode proposed for HT line crossing 116 mtr 9 Test Station Proposed Normal Size (Nos.) Pol cell (Nos.) ICCP (Nos.) CTSU (Nos.) 245 17 10 12 10 Cables Copper Conductor PVC/PVC Cable
11 Polarisation Coupon with Permanent Reference Cell (Cu-CuSO4) 02 Nos. 12 Polarisation Cell Proposed Total Nos. Type Rating 17 Solid-State 3.7 KA
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
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06-10-1403-DD-PH1, Rev-01 Page 8 of 113 5.0 CORROSION SURVEY REPORT 5. 1 OBJECTIVE OF THE SURVEY The survey aim to generate sufficient data and correlated information which will provide the basis for designing of cathodic protection system. The same information shall be used as input parameters with which the C.P. system has to eventually cope with. The basic data and generated information shall be comprehensively analysied and interpreted to lay down the guidelines for the C.P. system Design and Engineering.
5. 2 SCOPE OF WORK The Corrosion Survey includes, Soil Resisitivity survey Additional data collection to generate design data for evaluation of interaction possibilities due to presence of other services in ROU. Soil samples shall be collected on an average for every 10 km along ROU.
5. 3 SOIL RESISTIVITY SURVEY The Soil resistivity measurements have been carried out using 4 pins WENNER method. The measurements were carried out at pin spacing of 1, 1.5 and 2.5 m. INSTRUMENT USED FOR THE SURVEY Soil Resistivity meter Make: Nilsson Electrical Lab, INC. USA/MC Miller USA, NILSSON 400 & Motwane-DET-20
RESISTIVITY CALCULATIONS d = 2 x x a x R Where: a = Consecutive distance in cm R = Resistance measured as indicated by unit in ohms d = Resistivity (ohm-cm)
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06-10-1403-DD-PH1, Rev-01 Page 9 of 113 5. 4 SOIL RESISTIVITY VS. DEGREE OF CORROSIVITY Soil resistivity (ohm-m) Degree of corrosivity 0-5 Very corrosive 5-10 Corrosive 10-20 Moderately Corrosive 20-100 Mildly Corrosive Above 100 Negligible As per the Soil Resistivity report attached in Annexure A.
5. 5 SOIL SAMPLES Soil samples have been collected along the Row for analysis. Samples were collected from two depths (1.0 M) and (2.0 M) of pipeline ROW at every 10 Km. Exact location shall be decided at site depending on the type of soil, soil resistivity and in consultation with Owner or his representative. The major constituents that accelerates corrosion are chlorides, sulphates and the acidity pH of the soil. The effect of chlorides, sulphates and pH on corrosion of Buried Steel Pipelines. (Refer Peabody control of pipeline corrosion second edition): Sr. No. COMPONENT CONCENTRATION DEGREE OF CORROSITIVITY 1 Chloride > 5000 PPM Severe 1500-5000 PPM Considerable <500 PPM Threshold 2 Sulphate > 10000 PPM Severe 1500-10000 PPM Considerable 150-1500 PPM Positive 0-150 PPM Negligible 3 PH 2
< 5.5 Severe 5.5-6.5 Moderate 6.5-7.5 Neutral >7.5 None (Alkaline)
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06-10-1403-DD-PH1, Rev-01 Page 10 of 113 Chainage wise chemical analysis report readings are tabulated below: Sr. No. Chainage (Km) Chloride (ppm) Sulphate (ppm) pH (Digital mtr) 1.0 Mtr 2.0 Mtr 1.0 Mtr 2.0 Mtr 1.0 Mtr 2.0 Mtr 1 0 749 649 93 86 7.13 6.95 2 10 949 949 33 17 7.18 7.23 3 20 1199 1449 123 153 6.93 7.48 4 30 200 150 167 93 7.03 7.96 5 40 120 180 123 153 6.93 7.48 6 50 250 210 167 93 7.03 7.96 7 60 135 140 123 153 6.93 7.48 8 70 899 949 167 93 7.03 7.96 9 80 749 899 123 153 6.93 7.48 10 90 300 450 33 27 7.18 7.23 11 100 227 230 123 153 6.93 7.48 12 110 999 1049 18 9 7.4 4.14 13 120 1199 1449 123 153 6.93 7.48 14 130 200 250 167 93 7.03 7.69 15 140 649 699 227 212 7.6 7.58 16 150 600 500 19 41 7.01 7.05 17 160 200 150 5 6 8.08 8.03 18 170 250 899 17 95 7.31 7.21 19 180 500 350 123 153 6.93 7.48 20 190 150 150 123 153 6.93 7.48 21 200 250 253 167 93 7.03 7.96 22 210 200 300 123 153 6.93 7.48 23 220 200 250 167 93 7.03 7.96 24 228 699 550 123 153 6.93 7.48 As per the chemical analysis report attached in Annexure A we can conclude the following points: The Chloride content was less than 520 PPM. The Sulphate content was less than 109 PPM. The pH value varies from 6.93 to 8.8 The soil resistivity report, its graphs and soil samples chemical analysis report and its graph are attached in Annexure A.
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06-10-1403-DD-PH1, Rev-01 Page 11 of 113 5. 6 ADDITIONAL DATA COLLECTION Additional data has been collected from Various sources like owner, consultant, contractor, aligment sheet and from the field survey. List of Major Road, River & Canal Crossings IN Phase-1 are as follows: 1) RKPL Ph-1 Rewari Dispatch Terminal to SV-4, Ch:228 km: MAJOR RAILWAY CROSSING Sr. No. Chainage (km) DESCRIPTION Length Of Crossing (Km) 1 98.111 RAILWAY XING (NCR) 35 2 141.972 WEASTERN CENTRAL RAILWAY 55 3 158.470 MATHUTA ACHNERA RAILWAY XING 30 4 162.395 CENTRAL RAILWAY CROSSING 47 5 163.213 RAILWAY XING-MATHURA TO FARAH 47 6 164.731 RAILWAY XING-MATHURA TO FARAH 47 7 165.759 RAILWAY XING-MATHURA TO FARAH 47 8 216.534 NORTHAN RAILWAY MAINLINE XING 74
2) RKPL Ph-1 Rewari Dispatch Terminal to SV-4, Ch:228 km: MAJOR HT LINE CROSSING Sr. No. Chainage (km) DESCRIPTION 1 2.885 110 KVA HT CROSSING 2 5.151 132 KVA HT LINE CROSSING 3 10.765 ASPHALTED ROAD GUJAR MAJARI TO GUJARI & 132 KVA CROSSING 4 19.774 220 KVA HT LINE XING 5 33.054 220 KVA HT LINE XING NEAR BRICK KILN 6 34.248 220 KVA HT XING 7 34.850 110 KVA HT CROSSING, NEAR CHAMBORDA VILLAGE 8 63.010 400 KVA HT LINE XING 9 134.851 220KVA LINE XING NEAR ASPHALTED ROAD
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06-10-1403-DD-PH1, Rev-01 Page 12 of 113 MAJOR HT LINE CROSSING Sr. No. Chainage (km) DESCRIPTION 10 145.049 400KV HT LINE XING 11 158.270 400 KV HT LINE XING 12 166.385 440KVA HT LINE XING 13 177.354 220KV HT XING NEAR KHADERA VILLAGE 14 197.417 400 KVA HT LINE XING 15 199.079 200 KV HT LINE XING 16 201.754 220 KVA HT LINE XING 17 217.007 400KVA HT XING, NEAR GOWAL VILLAGE
3) RKPL Ph-1 Rewari Dispatch Terminal to SV-4, Ch:228 km: MAJOR ROAD CROSSING Sr. No. Chainage (km) Crossing 1 0.577 NH-71 2 3.387 NH-08 3 4.018 NATIONAL HIGHWAY JAIPUR-DELHI 4 33.876 STATE HIGHWAY-25 5 62.608 SH-35 XING 6 82.564 SH-45 7 92.680 STATE HIGHWAY-22 8 99.961 SH-14 XING 9 122.770 STATE HIGHWAY-14 10 136.215 STATE HIGHWAY-43 11 140.377 STATE HIGHWAY-24 12 161.957 NH-02 Farah To Mathura 13 226.000 STATE HIGHWAY-31
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06-10-1403-DD-PH1, Rev-01 Page 13 of 113
5. 7 SURVEY RESULT Soil resistivity report and graphs is attached in Annexure-A. Average Soil Resistivity at 2m depth in Phase 1 is 22.23 ohms-m
6.0 DESIGN DATA & CRITERIA 6. 1 INTRODUCTION The Tender Specifications indicate the type of Cathodic Protection System, Protection criteria and input parameters for detailed design of the Cathodic Protection System. The intent of this section is to propose design data and criteria for the Temporary Cathodic Protection System.
6. 2 PIPELINE DETAILS PART Section Approx. Length (Km) Dia. (inch) Part-1 Rewari Dispatch terminal to SV-6(Ch:228 km) 228 km 18
6. 3 CATHODIC PROTECTION SYSTEM DESIGN LIFE In accordance with the project specification, the Cathodic Protection System shall have a design life of two year or till the commissioning of the PCP system whichever is later.
6. 4 CODES AND STANDARDS The Design generally conforms to the Specification no:MH2145-C000-EL-SPC-0025 RevA The design, selection and installation of equipment and materials shall also conform to the requirements of the latest relevant applicable standards of: NACE RP-0169 Recommended Practice control of external corrosion on underground or submerged metallic piping systems NACE RP-0286 Recommended Practice The electrical isolation of catholically protected pipelines
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06-10-1403-DD-PH1, Rev-01 Page 14 of 113 NACE RP-10A190 Measurement technique related to criteria for CP of Underground or Submerged steel piping system NACE RP-0177 Recommended Practice Mitigation of AC and Lighting Effects on Metallic Structures and Corrosion Control Systems NACE No. 54276 Cathodic Protection Monitoring For Buried Pipelines NACE RP-0572 Recommended Practice Design, Installation, Operation and of Impressed Current Deep Ground Beds DNV RP-B403 Recommended Practice Monitoring of CP System DNV RP-B401 Recommended Practice Cathodic Protection Design IS 8062 Recommended Practice ICCP for Underground Pipe VDE 0150 Protection against Corrosion due to stray current from DC Installation IS: 1554 Part1 PVC insulated (Heavy Duty) Cables. BS:7361 Part I Code of Practice for Cathodic Protection for Land and Marine applications
6. 5 PHILOSOPHY OF CATHODIC PROTECTION SYSTEM As provided in the enquiry specifications, the cathodic protection system shall be a Galvanic/ Sacrificial Anodes system and shall be designed using pre-packed Magnesium anodes. The prepacked Magnesium anodes shall be installed in a horizontal configuration in a trench of depth 2 M. to ensure that it reach moist soil and it should be 2 to 5 M. away from the edge of pipeline.Considering Minimum 2 Nos. of 2.5 Kg prepacked magnesium anode for soil resistivity upto 90 ohm-M. and Minimum 3 Nos. of 2.5 Kg prepacked magnesium anode for soil resistivity above 90 ohm-M. and upto 110 ohm-M.,for carrier pipe protection along the pipeline route at every 1 km interval. However any unprotected Pipeline area is observed during construction the same shall be protected by providing additional anodes.
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06-10-1403-DD-PH1, Rev-01 Page 15 of 113 6. 6 PROTECTION CURRENT DENSITY The Pipeline is coated with 3 layer PE Coating and the minimum protective current density for Temporary Cathodic Protection system as per the Specification no: MH2145-C000-EL-SPC- 0025 RevA is as given below. Pipeline Surrounding Minimum Protection Current Density (mA / m 2 ) Soil Resistivity < 10 ohm-m 0.075 Soil Resistivity 10 ohm-m to 100 ohm-m 0.055 Soil Resistivity > 100 ohm-m 0.035 A safety margin of 1.3 i.e. 30% has been provided for in the current calculations over and above the specified protective current density. Soil Resistivity in phase 1 of RKPL is in the range of 10 ohm-m to 100 ohm-m, The Average soil resistivity at 2 m depth is 22.23 ohms-m in Phase1 of RKPL, hence current density of 0.055 mA / m 2 is considered.
6. 7 CATHODIC PROTECTION DESIGN CRITERIA Cathodic Protection system shall be designed to meet the following any one of the criteria: The pipe to Soil Potential measurements shall be in between (-) 0. 95 V ON to (-) 1.5 V ON as measured between the pipe surface and a saturated copper - copper sulfate reference electrode. The pipe to Soil Potential measurements shall be in between (-) 0. 95 V (IR Free) to (-) 1.18 V (IR Free) as measured between the pipe surface and a saturated copper - copper sulfate reference electrode. A positive potential swing of 100 mV or more shall be considered as the criteria for presence of an interaction / interference situation requiring investigation and incorporation of mitigation measures.
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06-10-1403-DD-PH1, Rev-01 Page 16 of 113 7.0 DESIGN CALCULATION The following calculations have been used to design the Temporary Cathodic Protection system.
7. 1 TOTAL CURRENT REQUIREMENT Surface Area
Where: S a =
Surface area of Pipeline
(m 2 ) D = Diameter of pipeline (m) L = Length of pipeline (m) The surface area calculations are tabulated as under:
Pipeline Section Dia. (m) Pipeline Length (m) Coating Surface Area (m 2 ) Rewari Dispatch terminal to SV- 6(Ch:228 km) 0.457 228000 3LPE 327341.3
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06-10-1403-DD-PH1, Rev-01 Page 17 of 113
7. 2 CURRENT REQUIREMENT The Pipeline is coated with 3 layer PE Coating and the current density considered for the Temporary Cathodic Protection design is 0.055 mA / m 2
Based on the above current density, the total current requirement as per soil resistivity span is calculated as follows:
Where I t = C.P. current requirement (Amp) S a = Surface area of Pipeline (m 2 ) C d = C.P. protective current density (mA/m 2 ) 1.3 = Safety Margin
Chainage Span Soil resistivity (Ohms-m) Dia (m) Pipeline Length (m) Surface Area (m 2 ) Protective Current Density (mA/ m 2 ) Current Required (Amp.) Rewari Dispatch terminal to SV-6(Ch:228 km) 0.00-228 Km 22.23 0.457 228000 327341.3 0.055 23.40
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06-10-1403-DD-PH1, Rev-01 Page 18 of 113 7. 3 ANODE WEIGHT REQUIREMENT The total anode weight requirement is calculated using the following formula:
Where W t = Total Anode Weight (Kg.) I t = C.P. current requirement (Amps) C t =
Consumption Rate of Anode (7.9 Kg/Amp-Year) L = Design Life (2 years) U f = Anode Utilisation factor (0.85) Pipeline Section Individual Anode Weight (Kgs) (W) Total Current (Amp) (I t ) Total Anode Requirement (Kgs) (W t ) Total Anode Requirement (Nos) (N a ) Total No. of Anode Proposed (Nos) Rewari Dispatch terminal to SV-6(Ch:228 km) 2.5 23.40 434.96 174 458
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06-10-1403-DD-PH1, Rev-01 Page 19 of 113 7. 4 HORIZONTAL GROUNDBED RESISTANCE a) Resistance of Single horizontal anode
Where: R ah = Resistance of Single horizontal anode P s = Soil Resistivity in (5 ohm-m) L = Length of prepackaged anode in (1.5 m) d = diameter of prepackaged anode in (0.15 m) t = Depth of Anode in (2 m) R ah = 1.068 ohms
b) Resistance of multiple horizontal
Where R gbh = Resistance of multiple horizontal anodes in (ohms) R ah = Resistivity of single horizontal anode in (1.068 ohms) N = Number of anodes (2 Nos.) F = Crowding Factor (1.134) R gbh =0.606 ohms
c) Crowing Factor
Where: F = Crowding Factor R ah = Resistance of Single horizontal anodes (1.068 ohms) P s = Soil Resistivity in (5 ohm-mtr.) S
= End to End spacing of Anode (3 mtr.) N = Number of Anodes (2 Nos.) F=1.134
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06-10-1403-DD-PH1, Rev-01 Page 20 of 113 d) Cable Resistance For the ground bed using 1 horizontal anode, the longest anode tail cable of 9 m ofPVC/PVC single core copper conductor 6mm 2 cable shall be used. The cable resistance of copper conductor single core 6 mm 2 size is 3.08 ohm/Km. Therefore the cable resistance for 1 No. Anode tail cables of 9 mtr. Length shall be,
Where: R C = Total Cable Resistance (ohms) R a = Cable Resistance (0.00308 ohm-m) L = Length of the Cable (9 m) N = Number of anodes (2 Nos.) R C = 0.0139 ohms
e) Total Circuit Resistance The total circuit resistance for each anode bed
Where: R t = Total circuit resistance (ohms) R gbh = Resistance of multiple horizontal anodes (0.606 ohms) R C = Total Cable Resistance (0.0139 ohms) R t = 0.620 ohms f) The current output at each ground bed
Where: I= Current Output per anode bed (Amps.) V= Driving potential for Mg anodes with line polarized is =1.55 - 0.95 = 0.6 V R t = Total circuit resistance (0.620 ohms) I=0.967 Amps
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06-10-1403-DD-PH1, Rev-01 Page 21 of 113 Pipeline Coverage by Anodes at various Soil Resistivities for RKPL is as below:
Soil Resistivity range Ohm-m Using 2Nos of MG anode
Using 3Nos of MG anode Total Circuit Resistance Current O/P of Anode (Amps) KM Coverage of Pipeline Total Circuit Resistance Current O/P of Anode (Amps) KM Coverage of Pipeline 1 0.135 4.439 43.26 0.104 5.74 55.98 1-3 0.377 1.58 15.48 0.294 2.034 19.83 3-5 0.620 0.967 9.42 0.485 1.23 12.05 5-8 0.984 0.610 5.94 0.771 0.778 7.59 8-10 1.227 0.489 4.77 0.961 0.624 6.08 10-15 1.833 0.327 3.19 1.43 0.417 4.07 15-20 2.44 0.246 2.40 1.91 0.314 3.06 20-25 3.04 0.197 1.92 2.389 0.251 2.45 25-30 3.65 0.164 1.60 2.86 0.209 2.04 30-35 4.25 0.141 1.37 3.34 0.180 1.75 35-40 4.86 0.123 1.20 3.81 0.157 1.53 40-50 6.07 0.099 0.96 4.77 0.126 1.23 50-60 7.29 0.082 0.80 5.722 0.105 1.02
Hence, The anode ground bed locations and the number of anodes to be used for each location has been decided considering 2 Nos. of 2.5 Kg prepacked magnesium anode for soil resistivity upto 90 ohm-m. and 3 Nos. of 2.5 Kg prpacked magnesium anode for soil resistivity above 90 ohm-m and upto 110 ohm-m, for carrier pipe protection along the pipeline route at every 1 km interval. However any unprotected pipeline area is obsreved during construction time, The same shall be protected by providing additional anodes. R-1
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06-10-1403-DD-PH1, Rev-01 Page 22 of 113 The ground bed details are mentioned in the enclosed Schedule. The actual chainages may vary as per actual site conditions at the time of selection of locations during installation.
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06-10-1403-DD-PH1, Rev-01 Page 23 of 113 8.0 EHV / HV CROSSINGS Zinc earthing anode & polarization cell shall be provided as per Project Specification MH2145- C000-EL-SPC-0025 RevA. For earthing of pipeline at the 66KV and above HT Line crossings, at 1 km interval of parallel run (if horizontal distance of HT line is within 25 m. of the pipeline) and at the departure points from the parallel run for earthing purpose Zinc ribbon anode so that the earthing resistance is restricted within acceptable limit of 5 ohm. The total meter of Zinc ribbon anode proposed (Size 12.7 X 14.28 mm) = 110 m Sample calculation of resistance of Horizontal anode bed for Zinc Ribbon anode:
Where: R b = Anode to Earth resistance (ohm) P s = Soil Resistivity in ohm-M (2.885 ohm-m) L = Length of prepackaged anode in m (3 m) D = Diameter of prepackaged anode in m (0.15 m) S = Twice the Depth of Anode (4 m) R b =2.425 ohms
ii) Resistance of the anode to backfill:
Where: R bs = Resistance of anode to backfill in ohms (ohms) P s = Resistivity of backfill material (0.5 ohm-m) L = Length of anode in m (3 m) d = Effective diameter of anode in m (0.0151 m) R bs =0.108 ohms
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
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06-10-1403-DD-PH1, Rev-01 Page 24 of 113 iii) Cable resistance: For the groundbed using 1 Zinc Ribbon anode of 10 m. Length, the anode tail cable of 8 m. Of PVC/PVC single core copper conductor 25 mm 2 cable shall be used. The cable resistance of copper conductor single core 25 mm 2 size is 0.727 ohm/Km. Therefore, the cable resistance for 1 No. anode tail cables of 8 m. Length shall be calculated as follow:
Where: R C = Total Cable Resistance (ohms) R a = Cable Resistance (0.000727 ohm-m) L = Length of the Cable (8 m) R c =0.0058 ohms
iv) Total circuit resistance:
Where: R T = Total circuit resistance (ohms) R b = Resistance of horizontal anode to electrolyte (2.425 ohms) R bs = Resistance of Anode to backfill (0.108 ohms) R C = Cable Resistance (0.0058 ohms) N = Number of Anodes (2 No) R T =1.270 ohms
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DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
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06-10-1403-DD-PH1, Rev-01 Page 26 of 113 Detail calculation for zinc grounding anode for HT Line Xings are tabulated below: SN Chainage (km) Soil Resistivit y (Ohm- M) No. of Anode s (Zn) Length of the Pre- Packe d Anode (Mt) Anode Dia (mt) Length of Bare Anode (mt) Dia of Bare Anode (mt) Twice the Depth of Anod e Anode to earth Resistanc e (ohm Anode to backfill Resistanc e (ohms) Cable Resistanc e (ohms) Total circuit Resistanc e No of Zinc anode Total weigh t of Anod e Polarisati on cell (Solid State-5.0 KA) N L D l d S Rb Rbs Rc RT Nos (Kg) Nos 1 2.885 12.230 2 3 0.150 3 0.151 4.0 2.425 0.108 0.0058 1.270 3mtr x 2Nos 5.1 1 2 5.151 64.995 2 5 0.150 5 0.151 4.0 9.218 0.073 0.0058 4.648 5mtr x 2Nos 8.5 1 3 10.765 32.905 2 3 0.150 3 0.151 4.0 6.526 0.108 0.0058 3.320 3mtr x 2Nos 5.1 1 4 19.774 31.870 2 3 0.150 3 0.151 4.0 6.320 0.108 0.0058 3.217 3mtr x 2Nos 5.1 1 5 33.054 26.875 2 3 0.150 3 0.151 4.0 5.330 0.108 0.0058 2.722 3mtr x 2Nos 5.1 1 6 34.248 19.310 2 3 0.150 3 0.151 4.0 3.830 0.108 0.0058 1.972 3mtr x 2Nos 5.1 1 7 34.850 27.315 2 3 0.150 3 0.151 4.0 5.417 0.108 0.0058 2.765 3mtr x 2Nos 5.1 1 8 63.010 51.855 2 5 0.150 5 0.151 4.0 7.354 0.073 0.0058 3.716 5mtr x 2Nos 8.5 1 9 134.851 20.515 2 3 0.150 3 0.151 4.0 4.068 0.108 0.0058 2.091 3mtr x 2Nos 5.1 1 10 145.049 15.840 2 3 0.150 3 0.151 4.0 3.141 0.108 0.0058 1.627 3mtr x 2Nos 5.1 1 11 158.270 19.090 2 3 0.150 3 0.151 4.0 3.786 0.108 0.0058 1.950 3mtr x 2Nos 5.1 1 12 166.385 13.655 2 3 0.150 3 0.151 4.0 2.708 0.108 0.0058 1.411 3mtr x 2Nos 5.1 1 13 177.354 8.895 2 3 0.150 3 0.151 4.0 1.764 0.108 0.0058 0.939 3mtr x 2Nos 5.1 1 14 197.417 18.550 2 3 0.150 3 0.151 4.0 3.679 0.108 0.0058 1.896 3mtr x 2Nos 5.1 1 15 199.079 25.900 2 3 0.150 3 0.151 4.0 5.136 0.108 0.0058 2.625 3mtr x 2Nos 5.1 1 16 201.754 24.565 2 3 0.150 3 0.151 4.0 4.872 0.108 0.0058 2.493 3mtr x 2Nos 5.1 1 17 217.007 9.370 2 3 0.150 3 0.151 4.0 1.858 0.108 0.0058 0.986 3mtr x 2Nos 5.1 1 Total Length of Zinc Ribbon anode=110Mtrs
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DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
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06-10-1403-DD-PH1, Rev-01 Page 27 of 113 9.0 CATHODIC PROTECTION AT CASED CROSSINGS As per specification no MH2145-C000-EL-SPC-0025 RevA, Cathodic protection to casing shall be provided if casing is coated. In This project all cased crossing are uncoated, therefore additional protection is not Provided.
9.1 CATHODIC PROTECTION FOR CARRIER PIPE Carrier pipe inside casing shall be protected by Zinc ribbon anodes well connected to the outer surface of bottom of carrier pipe extending between hour hand positions of 4 and 8 o clock. The anodes shall be placed at close intervals as per design calculations and sized based on the permanent CP design parameters for 35 years.
The calculations are as below,
i) Surface Area
Where: S a =
Surface area of Pipeline
(m 2 ) D = Diameter of pipeline (m) L = Length of pipeline (m)
ii) Current requirement
Where: I t = Current requirement (Amps) S a =
Surface area of Pipeline
(m 2 ) C d = CP protective current density (mA/m 2 ) 1.3 = Safety factor
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
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06-10-1403-DD-PH1, Rev-01 Page 28 of 113 The surface area & current requirement calculations are tabulated as under:
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
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06-10-1403-DD-PH1, Rev-01 Page 30 of 113 10.0 INSULATION JOINTS The Surge Diverter Flame Proof type shall be connected across each Isolation Joints. The proposed locations of IJ are as follows: Sr. No. Pipeline Section Chainage (Km) Location Qty (Nos.) 1 RKPL-Phase I 00 Rewari Dispatch Terminal 1 2 141.80 Bharatpur Terminal Receiver Side 1 3 141.80 Bharatpur Terminal Launcher Side 1 4 164.378 Mathura Terminal Receiver Side 1 5 164.378 Mathura Terminal Launcher Side 1
11.0 EARTHING ELECTRODE The above ground unprotected portion of the pipeline at the pipeline terminal and intermediate station shall be earthed through earthing system consisting of earth electrodes and earthing conductor. All flanges on unprotected pipe shall be shorted with 25 Sq. mm copper cables.The resistance of grounding shall be limited to 5 ohms. The motor operated valves located on cathodically protected pipeline shall be separately grounded with the help of 20kg zinc anode.
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
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06-10-1403-DD-PH1, Rev-01 Page 31 of 113 12.0 POLARISATION COUPONS The Polarisation coupons of pipeline material shall be provided along the pipeline to monitor the adequacy of the cathodic protection. The Polarisation coupon shall be made as per drawing no 06-10-1403-PCC & specification MH2145-C000-EL-SPC-0025 RevA The coupon shall be installed as per table given below:
RKPL Ph-1 Pipeline Section: Sr. No. Chainage (Km) Location Test Station Type Qty (Nos.) 1 5.151 132 KVA HT LINE CROSSING ML 1 2 158.270 400 KV HT LINE XING ML 1
13.0 REFERENCE CELL ACCESS POINTS Reference cell access points shall be provided near insulating joint locations at SV stations where the ground is paved, for measurement of pipe to soil potentials. A perforated PVC pipe filled with native soil and buried at the location shall be provided for measurement purpose. The length of the PVC pipe shall be adequate to reach the native soil below the paving.
14.0 ER PROBE & READER Electrical Resistance Probe and Reader shall be provided along the pipeline ROU for monitoring the rate of metal loss due to corrosion. The ER Probes shall be implemented for external corrosion monitoring. The lead wires of the probe shall be connected to pipeline through test station and terminated inside test station enabling periodic resistance measurement of the probe using a portable probe-measuring instrument. The material of the E/R probe element shall be of same alloy as of the pipeline material. Probe shall be provided preferably at the bottom portion of pipeline. 2 Nos ER Probe shall be considered with 2 Nos. Of Reader for pipeline in Phase I. The location for installation of ER probe has been proposed, however exact location shall be decided at site after post commissioning survey in consultation with consultant/owner. The Proposed location of ER probe is as below:
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
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06-10-1403-DD-PH1, Rev-01 Page 32 of 113 RKPL Ph-1 Pipeline Section: SN Chainage (Km) Location Test Station Type Qty (Nos.) 1 33.054 220 KVA HT LINE XING NEAR BRICK KILN M 1 2 217.007 400KVA HT XING, NEAR GOWAL VILLAGE ML 1
15.0 TEST STATION Test Station shall be provided along the pipeline ROU for monitoring the performance of the Cathodic protection system at an interval of about 1000 m in inhabited areas and 2000 m in Un-inhabited areas such as forests / deserts etc. In addition to the above Test Stations shall be provided at the following points, At the locations of Anode ground beds. At all Insulation Joints. At vulnerable locations with drastic changes in Soil Resistivity. At locations of Surge diverters, Polarisation Coupons, pipeline grounding through polarization cells, Zinc & Mg Anodes. At EHV/HV AC/DC overhead line crossings and selected locations where EHV/HV overhead lines are in the vicinity of the pipeline. At Railway Line crossing and at selected location along lines running parallel to pipeline. At both sides of major river crossings. At EHV/HV cable crossings or along routes where EHV/HV cables are running in parallel. In the vicinity of DC network or grounding systems and HVDC grounding systems where interference problems are suspected. At crossing of other pipelines / structures At the Location of Reference cell and ER Probe Installation. At both sides of Cased crossings. Locations where interference is expected. At locations of Sectionalizing Valves (SV) Stations. At any other locations considered necessary by Owner/Owners Representative.
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06-10-1403-DD-PH1, Rev-01 Page 33 of 113 Test Station Connection Scheme as given below: Purpose Type Pipe to soil potential measurement A Pipe to soil potential measurement with Galvanic Anode Connection AL Line Current measurement B Line Current measurement with Galvanic Anode Connection BL Isolating Joint, Line Current measurement with Galvanic Anode Connection BFL Cased crossing with uncoated casing C Uncoated cased crossing with Galvanic Anode Connection CL Cased crossing with coated casing D coated cased crossing with Galvanic Anode Connection DL Insulating Joint F Intermediate CP station impressed current drainage point. G Intermediate CP station impressed current drainage point with galvanic anode connection. GL Intermediate CP station impressed current drainage point with Insulating Joint and galvanic anode connection. GFL Foreign pipeline crossing E Foreign pipeline crossing with Galvanic Anode Connection EL HT Line crossings Grounding Through Polarisation Cell and Zinc ribbon anode M HT Line crossings Grounding Through Polarisation Cell, Zinc ribbon anode with Galvanic Anode Connection ML HT line crossing & cased crossing with uncoated casing CM HT line crossing & cased crossing with coated casing DM HT Line crossings Grounding Through Polarisation Cell, Zinc ribbon anode & foreign pipeline crossing ME Cased Crossing with uncoated casing & foreign pipeline crossing CE
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06-10-1403-DD-PH1, Rev-01 Page 34 of 113 Cased Crossing with coated casing & foreign pipeline crossing DE HT Line crossings Grounding Through Polarisation Cell and Zinc ribbon anode & Foreign pipeline crossing with Galvanic Anode Connection MEL Coated cased crossing with HT Line crossings Grounding Through Polarisation Cell, Zinc ribbon anode with Galvanic Anode Connection DML Un-Coated cased crossing with HT Line crossings Grounding Through Polarisation Cell, Zinc ribbon anode with Galvanic Anode Connection CML
Test Station installation chainage & types are mentioned in the schedule. All the chainage are indicative only. The test stations shall be installed as per the actual details like HT Line/ Pipeline crossings, cased crossings, MOV etc., at site during actual execution of the job.
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
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06-10-1403-DD-PH1, Rev-01 Page 35 of 113 1) The Schedule of Test stations for RKPL Ph-1 are as follows: SN Location Chainage (km) Test Station Type (TS) CP Statio n Size Test station (ICTS) (Nos.) Normal Size Test station (TS) (Nos.) Pol cell Size Test Station (PCTS) (Nos.) CTSU Size Test Station (CTS) (Nos.) Perman ent Ref. Cell CuCuSo 4 (Nos) Mg Anode (2.5 KG) (Nos.) Mg Anode (10 KG) (Nos.) Bare Zn Ribbon Anode for HT Line crossing (m.) ZN Anode (20 KG) (Nos.) Polarisa tion cell (solid state) (Nos.) Polaris ation Coupon (Nos.) ER probe (Nos.) 1 HPCL Rewari Terminal 0.000 GFL 1 2 2 1 2 NH-71 0.577 C 1 3 NH-71 0.604 C 1 4 IN FIELD 1.000 AL 1 2 5 KARNAWAS TO DODHI ROAD XING 2.000 AL 1 2 6 110 KVA HT CROSSING 2.885 M 1 4 1 7 IN FIELD 3.000 AL 1 2 8 NH-08 3.387 C 1 9 NH-08 3.461 C 1 10 NATIONAL HIGHWAY JAIPUR-DELHI 4.018 AL 1 3 11 132 KVA HT LINE CROSSING 5.151 ML 1 1 3 24 1 1 12 IN FIELD NEAR DHANI VILLAGE 6.151 AL 1 3 13 KHERIMOLTA DISTRIBUTORY 7.167 AL 1 2 14 IN FIELD 8.167 AL 1 2 15 IN FIELD 9.167 AL 1 2 16 NEAR GUJRAS CART TRACK 10.000 AL 1 2 17 ASPHALTED ROAD GUJAR MAJARI TO GUJARI 10.747 C 1 19 HPCL PIPELINE CROSSING, NEAR GUJARI BUS 11.851 EL 1 2
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SN Location Chainage (km) Test Statio n Type (TS) CP Statio n Size Test station (ICTS) (Nos.) Normal Size Test station (TS) (Nos.) Pol cell Size Test Station (PCTS) (Nos.) CTSU Size Test Station (CTS) (Nos.) Perman ent Ref. Cell CuCuSo 4 (Nos) Mg Anode (2.5 KG) (Nos.) Mg Anode (10 KG) (Nos.) Bare Zn Ribbon Anode for HT Line crossing (m.) ZN Anode (20 KG) (Nos.) Polarisa tion cell (solid state) (Nos.) Polarisa tion Coupon (Nos.) ER probe (Nos.) 20 IN FIELD 12.851 AL 1 2 21 CART TRACK JAKAPUR BHAGANA 13.778 AL 1 2 22 IN FIELD 14.778 AL 1 2 23 IN FIELD 15.778 AL 1 2 24 IN FIELD 16.778 AL 1 2 25 IN FIELD 17.778 BL 1 1 2 26 NEAR SAHIBI RIVER 18.691 AL 1 3 27 220 KVA HT LINE XING 19.774 ML 1 2 8 1 28 IN FIELD 20.774 AL 1 2 29 IN FIELD 21.774 AL 1 2 30 MAJOR DISTRICT ROAD XING-61 22.865 CL 1 3 31 MAJOR DISTRICT ROAD XING-61 22.883 C 1 32 CART TRACK JAKAPUR BHAGANA 23.883 AL 1 2 33 IN FIELD NEAR PUR VILLAGE & BHADUKA 24.883 AL 1 2 34 IN FIELD 25.883 AL 1 2 35 IN FIELD NEAR KASWAR VILAGE 26.883 AL 1 2 36 NEAR NALLAH XING 27.883 AL 1 2 37 HPCL PIPELINE CROSSING, NEAR 28.754 EL 1 2 38 IN FIELD 29.754 AL 1 2 39 IN FIELD 30.754 AL 1 2 R-1 R-1
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06-10-1403-DD-PH1, Rev-01 Page 37 of 113 SN Location Chainage (km) Test Statio n Type (TS) CP Statio n Size Test station (ICTS) (Nos.) Normal Size Test station (TS) (Nos.) Pol cell Size Test Station (PCTS) (Nos.) CTSU Size Test Station (CTS) (Nos.) Perman ent Ref. Cell CuCuSo 4 (Nos) Mg Anode (2.5 KG) (Nos.) Mg Anode (10 KG) (Nos.) Bare Zn Ribbon Anode for HT Line crossing (m.) ZN Anode (20 KG) (Nos.) Polarisa tion cell (solid state) (Nos.) Polarisa tion Coupon (Nos.) ER probe (Nos.) 40 IN FIELD AFTER METALLED ROAD 31.754 AL 1 2 41 IN FIELD 32.754 AL 1 2 42 220 KVA HT LINE XING NEAR BRICK KILN 33.054 M 1 1 6 1 1 43 STATE HIGHWAY-25 33.876 CL 1 2 44 STATE HIGHWAY-25 33.901 C 1 45 220 KVA HT XING 34.248 M 1 4 1 46 110 KVA HT CROSSING, NEAR CHAMBORDA VILLAGE 34.850 M 1 6 1 47 SV-1 34.913 GL 1 2 2 1 48 IN FIELD 35.913 AL 1 2 49 IN FIELD 36.913 AL 1 2 50 IN FIELD 37.913 AL 1 2 51 IN FIELD NEAR BAMBREADY VILLAGE 38.913 AL 1 2 52 IN FIELD NEAR MANDPUR VILLAGE 39.913 AL 1 2 53 IN FIELD BEFOR MANPUR VILLAGE RD 40.913 AL 1 2 54 NEAR DHAMUKAD VILLAGE 41.913 AL 1 2 55 DHAMUKAD VILLAGE NER MASJID 42.913 AL 1 2 56 DHAMUKAD VILLAGE 43.913 AL 1 2 57 IN FIELD NEAR CHACHARA VILLAGE 44.913 AL 1 2 58 IN FIELD NEAR BAGODA VILLAGE 45.913 AL 1 2 59 IN FIELD NEAR BAYADIWAS 7 JHAMPADIWAS VILLAGE 46.913 BL 1 1 2
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
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06-10-1403-DD-PH1, Rev-01 Page 38 of 113 SN Location Chainage (km) Test Statio n Type (TS) CP Statio n Size Test station (ICTS) (Nos.) Normal Size Test station (TS) (Nos.) Pol cell Size Test Station (PCTS) (Nos.) CTSU Size Test Station (CTS) (Nos.) Perman ent Ref. Cell CuCuSo 4 (Nos) Mg Anode (2.5 KG) (Nos.) Mg Anode (10 KG) (Nos.) Bare Zn Ribbon Anode for HT Line crossing (m.) ZN Anode (20 KG) (Nos.) Polarisa tion cell (solid state) (Nos.) Polarisa tion Coupon (Nos.) ER probe (Nos.) 60 IN FIELD NEAR MEDAWAS VILLAGE 47.913 AL 1 2 61 AFTER CANEL XING, NER MEDAWAS VILLAG 48.913 AL 1 2 62 AFTER ROAD XING, NER GUNDIWA VILLAGE 49.913 AL 1 2 63 ASPHALTED ROAD NER GUNDIWA VILLAGE 50.959 AL 1 2 64 NER KALAANI VILLAGE 51.913 AL 1 2 65 NER KALAANI VILLAGE 52.913 AL 1 2 66 NER KALAANI VILLAGE 53.913 AL 1 2 67 NER SLIKAWAS VILLAGE 54.913 AL 1 2 68 NER MUBARAKPUR VILLAGE 55.913 AL 1 2 69 NER MUBARAKPUR VILLAGE & TRANSFARMER 56.913 AL 1 2 70 NER MUBARAKPUR VILLAGE 57.913 AL 1 2 71 SV-2 59.022 BL 1 1 2 1 72 NEAR NALLAH,BARAMBO VILLAGE 60.008 AL 1 3 73 NEAR NAGARAMB POLIC CHOWKI 61.022 AL 1 3 74 NEAR NAGARAMB VILLAGE 62.022 AL 1 2 75 SH-35 XING 62.608 C 1 76 SH-35 XING 62.640 C 1 77 400 KVA HT LINE XING 63.010 ML 1 3 18 1 78 NEAR NOGAANB VILLAGE 64.022 AL 1 2 79 NEAR TIKRI VILLAGE 65.022 AL 1 2 R-1 R-1
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SN Location Chainage (km) Test Station Type (TS) CP Statio n Size Test station (ICTS) (Nos.) Normal Size Test station (TS) (Nos.) Pol cell Size Test Station (PCTS) (Nos.) CTSU Size Test Station (CTS) (Nos.) Perman ent Ref. Cell CuCuSo 4 (Nos) Mg Anode (2.5 KG) (Nos.) Mg Anode (10 KG) (Nos.) Bare Zn Ribbon Anode for HT Line crossing (m.) ZN Anode (20 KG) (Nos.) Polarisa tion cell (solid state) (Nos.) Polaris ation Coupon (Nos.) ER probe (Nos.) 80 IN FIELD NEAR TIKRI VILLAGE 66.022 AL 1 2 81 ASPHALTED RD XING, NEAR SHERPUR VILLAGE 67.008 AL 1 2 82 IN FIELD NEAR SUNERA VILLAGE 68.022 AL 1 2 83 IN FIELD NEAR BORE WELL & SUNERA VILLAGE 69.022 AL 1 2 84 IN FIELD NEAR RAWAKA VILLAGE 70.022 AL 1 2 85 ASPHALTED ROAD, NEAR RAWAKA VILLAGE 71.128 AL 1 2 86 IN FIELD NEAR INDPWARA VILLAGE 72.128 AL 1 2 87 CART TRACK NEAR INDPWARA VILLAGE 73.128 AL 1 2 88 ASPHALTED ROAD, NEAR SHERPURA VILLAGE 74.235 AL 1 2 89 NEAR ASPHATED RD XING (JOTHPUR-SHERPUR) 75.165 AL 1 2 90 IN FIELD DAYANA KAWAS VILLAGE 76.165 BL 1 1 2 91 IN FIELD DAYANA KAWAS VILLAGE AFETR METALICA RD XING 77.165 AL 1 2 92 METEL ROAD, KHELI VILLAGE 78.087 AL 1 2 93 IN FIELD KHELI VILLAGE 79.165 AL 1 2 94 METEL ROAD, KHELI VILLAGE 80.129 AL 1 2 95 RUPARE RIVER 80.522 B 1 1 2 96 RUPARE RIVER 80.742 B 1 2
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06-10-1403-DD-PH1, Rev-01 Page 40 of 113 SN Location Chainage (km) Test Station Type (TS) CP Statio n Size Test station (ICTS) (Nos.) Normal Size Test station (TS) (Nos.) Pol cell Size Test Station (PCTS) (Nos.) CTSU Size Test Station (CTS) (Nos.) Perman ent Ref. Cell CuCuSo 4 (Nos) Mg Anode (2.5 KG) (Nos.) Mg Anode (10 KG) (Nos.) Bare Zn Ribbon Anode for HT Line crossing (m.) ZN Anode (20 KG) (Nos.) Polarisa tion cell (solid state) (Nos.) Polaris ation Coupon (Nos.) ER probe (Nos.) 97 NEAR CHAMARBARA VILLAGE 81.342 AL 1 3 98 IN FIELD BETWEEN BARDI- CHAMARBARA VILLAGE 82.378 AL 1 3 99 SH-45 82.564 C 1 100 SH-45 82.578 C 1 101 AFTER SH-4X, NEAR BAROLI VILLAGE 83.478 AL 1 2 102 IN FIELD NEAR DOMRAKI VILLAGE 84.578 AL 1 2 103 BFOR METALIC ROAD XING NEAR KHESTI VILLAGE 85.578 AL 1 2 104 ASPHALTED ROAD XING NEAR KHESTI VILLAGE 86.500 AL 1 2 105 IN FIELD NEAR KHESTI VILLAGE 87.500 AL 1 2 106 IN FIELD NEAR DHUTKA VILLAGE 88.500 AL 1 2 107 IN FIELD BEFORE REVER 89.400 AL 1 2 108 RUPARE RIVER 89.485 B 1 1 2 109 RUPARE RIVER 89.695 B 1 2 110 IN FIELD AFTER RIVER 90.395 AL 1 2 111 MUD ROAD XING NEAR BOARWELL 91.448 AL 1 2 112 IN FIELD 92.448 AL 1 2 113 STATE HIGHWAY-22 92.680 C 1 114 STATE HIGHWAY-22 92.700 C 1 R-1
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SN Location Chainage (km) Test Station Type (TS) CP Statio n Size Test station (ICTS) (Nos.) Normal Size Test station (TS) (Nos.) Pol cell Size Test Station (PCTS) (Nos.) CTSU Size Test Station (CTS) (Nos.) Perman ent Ref. Cell CuCuSo 4 (Nos) Mg Anode (2.5 KG) (Nos.) Mg Anode (10 KG) (Nos.) Bare Zn Ribbon Anode for HT Line crossing (m.) ZN Anode (20 KG) (Nos.) Polarisa tion cell (solid state) (Nos.) Polaris ation Coupon (Nos.) ER probe (Nos.) 115 SV-3 93.532 GL 1 2 2 1 116 IN FIELD KUTAKPUR TO ARSI VILLAGE 94.532 AL 1 2 117 ASPLATED ROAD XING ARSI TO NAGAR MARKET 95.643 AL 1 2 118 METAL ROAD XING BHUKI TO ARSI VILLAGE 96.678 AL 1 2 119 IN FIELD 97.700 AL 1 2 120 RAILWAY XING (NCR) 98.076 C 1 121 RAILWAY XING (NCR) 98.111 C 1 122 METAL ROAD XING 98.805 AL 1 2 123 SH-14 XING 99.961 CL 1 2 124 SH-14 XING 99.983 C 1 125 IN FIELD AFTER SH-14, NEAR BURJA VILLAGE 100.983 AL 1 2 126 IN FIELD NEAR GANGABAK VILLAGE 101.983 AL 1 2 127 IN FIELD AFTER RD, NR GANGABAK VILLAGE 102.983 AL 1 2 128 KENDALE TO MOBAI RD XIG 103.933 AL 1 2 129 METAL ROAD XING DABHARA TO WOBAI 105.088 BL 1 1 2 130 NEAR MORLI VILLAGE & BADESRA ROAD 106.000 AL 1 2 131 NEAR MOBAIT TOMORALI ASPHALTED RD 107.000 AL 1 2
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06-10-1403-DD-PH1, Rev-01 Page 42 of 113 SN Location Chainage (km) Test Station Type (TS) CP Statio n Size Test station (ICTS) (Nos.) Normal Size Test station (TS) (Nos.) Pol cell Size Test Station (PCTS) (Nos.) CTSU Size Test Station (CTS) (Nos.) Perman ent Ref. Cell CuCuSo 4 (Nos) Mg Anode (2.5 KG) (Nos.) Mg Anode (10 KG) (Nos.) Bare Zn Ribbon Anode for HT Line crossing (m.) ZN Anode (20 KG) (Nos.) Polarisa tion cell (solid state) (Nos.) Polaris ation Coupon (Nos.) ER probe (Nos.) 132 NEAR BOAR WELL 108.000 AL 1 2 133 IN FIELD NEAR 11 KV LINE 109.000 AL 1 2 134 IN FIELD NEAR JANUTHER VILLAGE 110.000 AL 1 2 135 IN FIELD NEAR JANUTHER VILLAGE 111.000 AL 1 2 136 METALICA ROAD XING 111.958 AL 1 2 137 METALED ROAD XING 113.184 AL 1 2 138 IN FIELD SINSINI VILLAGE 114.184 AL 1 2 139 IN FIELD NEAR SONGAANB VILLAGE 115.184 AL 1 2 140 IN FIELD NEAR SONGAANB VILLAGE 116.184 AL 1 2 141 IN FIELD NEAR BADANGASH VILLAGE 117.184 AL 1 2 142 SV-4 118.254 GL 1 2 2 1 143 IN FIELD 119.190 AL 1 2 144 IN FIELD PALA VILLAGE 120.190 AL 1 2 145 IN FIELD PALA VILLAGE 121.190 AL 1 2 146 NEAR CART TRACK PALA VILLAGE 122.190 AL 1 2 147 STATE HIGHWAY-14 122.770 C 1 148 STATE HIGHWAY-14 122.787 C 1 2 149 ASPHALTED ROAD XING 123.190 AL 1 2 150 IN FIELD, NEAR SAINTHRI VILLAGE 124.190 AL 1 2 151 AFTER MUD ROAD, NEAR KUMHER VILLAGE 125.190 AL 1 2
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SN Location Chainage (km) Test Station Type (TS) CP Statio n Size Test station (ICTS) (Nos.) Normal Size Test station (TS) (Nos.) Pol cell Size Test Station (PCTS) (Nos.) CTSU Size Test Station (CTS) (Nos.) Perman ent Ref. Cell CuCuSo 4 (Nos) Mg Anode (2.5 KG) (Nos.) Mg Anode (10 KG) (Nos.) Bare Zn Ribbon Anode for HT Line crossing (m.) ZN Anode (20 KG) (Nos.) Polarisa tion cell (solid state) (Nos.) Polaris ation Coupon (Nos.) ER probe (Nos.) 152 IN FIELD, NEAR SAINTHRI VILLAGE 126.100 AL 1 2 153 MAJOR DISTRICT ROAD-71 127.241 CL 1 2 154 MAJOR DISTRICT ROAD-71 127.257 C 1 155 IN FIELD BEFORE ASPHALTED ROAD 128.257 AL 1 2 156 IN FIELD 129.257 AL 1 2 157 NAAR ALEYA VILLAGE & BOMBO PLACE 130.024 B 1 1 158 IN FIELD 130.257 AL 1 2 159 IN FIELD NEAR DERAA VILLAGE 131.257 AL 1 2 160 DERAA VILLAGE ROAD XING 132.159 AL 1 2 161 IN FIELD 133.159 AL 1 2 162 ASPHALTED ROAD 134.057 AL 1 2 163 220KVA LINE XING NEAR ASPHALTED ROAD 134.851 ML 1 2 4 1 164 ASPHLATED ROAD XING 135.894 AL 1 2 165 STATE HIGHWAY-43 136.215 C 1 166 STATE HIGHWAY-43 136.237 C 1 167 IN FIELD NEAR MEGHAYA VILLAGE 136.894 AL 1 2 168 FOREGIN PL XING (WRPL IOCL) 137.705 EL 1 2 169 CART TRACK 138.724 AL 1 2 170 IN FIELD 139.724 AL 1 2
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SN Location Chainage (km) Test Station Type (TS) CP Statio n Size Test station (ICTS) (Nos.) Normal Size Test station (TS) (Nos.) Pol cell Size Test Station (PCTS) (Nos.) CTSU Size Test Station (CTS) (Nos.) Perman ent Ref. Cell CuCuSo 4 (Nos) Mg Anode (2.5 KG) (Nos.) Mg Anode (10 KG) (Nos.) Bare Zn Ribbon Anode for HT Line crossing (m.) ZN Anode (20 KG) (Nos.) Polarisa tion cell (solid state) (Nos.) Polaris ation Coupon (Nos.) ER probe (Nos.) 171 STATE HIGHWAY-24 140.377 C 1 172 STATE HIGHWAY-24 140.413 CL 1 2 173 IOCL MBPL P/L XING 141.136 E 1 174 BPCL MBPL P/L XING 141.369 EL 1 2 175 BHARATPUR TERMINAL 141.800 GF 1 2 176 BHARATPUR TERMINAL 141.800 GF 1 2 177 WEASTERN CENTRAL RAILWAY 141.917 C 1 178 WEASTERN CENTRAL RAILWAY 141.972 CL 1 2 179 NEAR DAURAMKI VILLAGE 142.972 AL 1 2 180 NEAR DAURAMKI VILLAGE 143.972 AL 1 2 181 400KV HT LINE XING 145.049 ML 1 2 4 1 182 NEAR BILOTHI VILLAGE 146.049 AL 1 2 183 HPCL P/L XING 147.051 EL 1 2 184 NEAR KARAUTI VILLAGE & BILWATHI VILLAGE 148.051 AL 1 2 185 IN FIELD 149.051 AL 1 2 186 NEAR SANTRAUK VILLAGE 150.051 AL 1 2 187 NEAR OLL VILLAGE 151.051 AL 1 2 188 NEAR HASANPUR VILLAGE 152.051 AL 1 2 189 NEAR HASANPUR VILLAGE 153.051 BL 1 1 2 190 NEAR IKDONIA VILLAGE 154.051 AL 1 2
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06-10-1403-DD-PH1, Rev-01 Page 45 of 113 SN Location Chainage (km) Test Station Type (TS) CP Statio n Size Test station (ICTS) (Nos.) Normal Size Test station (TS) (Nos.) Pol cell Size Test Station (PCTS) (Nos.) CTSU Size Test Station (CTS) (Nos.) Perman ent Ref. Cell CuCuSo 4 (Nos) Mg Anode (2.5 KG) (Nos.) Mg Anode (10 KG) (Nos.) Bare Zn Ribbon Anode for HT Line crossing (m.) ZN Anode (20 KG) (Nos.) Polarisa tion cell (solid state) (Nos.) Polaris ation Coupon (Nos.) ER probe (Nos.) 191 NEAR PILWA VILLAGE 155.051 AL 1 2 192 NEAR PILWA VILLAGE 156.051 AL 1 2 193 NEAR BORI VILLAGE 157.150 AL 1 2 194 400 KV HT LINE XING 158.270 ML 1 1 2 4 1 1 195 MATHUTA ACHNERA RAILWAY XING 158.440 C 1 196 MATHUTA ACHNERA RAILWAY XING 158.470 C 1 197 IN FIELD 159.261 AL 1 2 198 NEAR DHAMA SHASABAD VILLAGE 160.261 AL 1 2 199 ASPHALTED ROAD XING 161.289 AL 1 2 200 NH-02 Farah To Mathura 161.957 C 1 201 NH-02 Farah To Mathura 161.987 C 1 202 CENTRAL RAILWAY CROSSING 162.348 CL 1 2 203 CENTRAL RAILWAY CROSSING 162.395 C 1 204 RAILWAY XING-MATHURA TO FARAH 163.166 C 1 205 RAILWAY XING-MATHURA TO FARAH 163.213 CL 1 2 206 NEAR LADPUR VILLAGE 164.213 AL 1 2 207 MATHURA TERMINAL 164.378 GF 1 2 208 MATHURA TERMINAL 164.378 GF 1 2 209 RAILWAY XING-MATHURA TO FARAH 164.684 C 1 210 RAILWAY XING-MATHURA TO FARAH 164.731 C 1
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06-10-1403-DD-PH1, Rev-01 Page 46 of 113 SN Location Chainage (km) Test Statio n Type (TS) CP Statio n Size Test station (ICTS) (Nos.) Normal Size Test station (TS) (Nos.) Pol cell Size Test Station (PCTS) (Nos.) CTSU Size Test Station (CTS) (Nos.) Perman ent Ref. Cell CuCuSo 4 (Nos) Mg Anode (2.5 KG) (Nos.) Mg Anode (10 KG) (Nos.) Bare Zn Ribbon Anode for HT Line crossing (m.) ZN Anode (20 KG) (Nos.) Polarisa tion cell (solid state) (Nos.) Polarisa tion Coupon (Nos.) ER probe (Nos.) 211 NEAR LADPUR VILLAGE 165.213 AL 1 2 212 RAILWAY XING-MATHURA TO FARAH 165.712 C 1 213 RAILWAY XING-MATHURA TO FARAH 165.759 C 1 214 IOCL P/L CROSSING 166.018 E 1 215 440KVA HT LINE XING 166.385 ML 1 2 4 1 216 NEAR BHADURI VILLAGE 167.385 AL 1 2 217 BEFORE ASPHALTED ROAD NATHALA-LADPUR 168.385 AL 1 2 218 KARNAWAL MINOR CANEL 169.426 AL 1 2 219 ASPHALTED ROAD XING 170.400 AL 1 2 220 YAMUNA RIVER XING 170.486 B 1 1 2 221 YAMUNA RIVER XING 170.876 B 1 2 222 AFTER YAMUNA RIVER XING 171.400 AL 1 2 223 BEFORE NABIPUR MINOR CANAL 172.400 AL 1 2 224 AFTER ASPHALTED RD XIN HAIBPUR-NABIPPUR 173.400 AL 1 2 225 NEAR PIMPARI VILLAGE 174.400 AL 1 2 226 NEAR PIMPARI VILLAGE 175.400 AL 1 2 227 BEFORE YAMUNA EXPRESS HIGHWAY 176.400 BL 1 1 2 228 220KV HT XING NEAR KHADERA VILLAGE 177.354 ML 1 2 4 1 229 AFTER CANEL, KHANGARI GRAM 178.354 AL 1 2
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06-10-1403-DD-PH1, Rev-01 Page 47 of 113 SN Location Chainage (km) Test Statio n Type (TS) CP Statio n Size Test station (ICTS) (Nos.) Normal Size Test station (TS) (Nos.) Pol cell Size Test Station (PCTS) (Nos.) CTSU Size Test Station (CTS) (Nos.) Perman ent Ref. Cell CuCuSo 4 (Nos) Mg Anode (2.5 KG) (Nos.) Mg Anode (10 KG) (Nos.) Bare Zn Ribbon Anode for HT Line crossing (m.) ZN Anode (20 KG) (Nos.) Polarisa tion cell (solid state) (Nos.) Polarisa tion Coupon (Nos.) ER probe (Nos.) 230 ASPHALTED ROAD XING KILONI- PATLONI VILLAGE 179.354 AL 1 2 231 IN FIELD 180.354 AL 1 2 232 NEAR JATERA KILONI VILLAGE 181.354 AL 1 2 233 ASPHALTED ROAD XING NEAR BAMARASPUR VILLAGE 182.214 AL 1 2 234 NEAR PATLONI VILLAGE 183.214 AL 1 2 235 NEAR PATLONI VILLAGE 184.214 AL 1 2 236 AWERNI MINOR CANEL 185.271 AL 1 2 237 NEARM BAHARATIYA VILLAGE 186.271 AL 1 2 238 ASPHALTED ROAD XING NEAR PAUCHAVARI VILLAGE 187.382 AL 1 2 239 SV-5 188.058 G 1 2 1 240 AFTER ROAD XING, PANCHWARI- BISAWAR 188.382 AL 1 2 241 METTALLED ROAD XING 189.233 AL 1 2 242 NEAR BHILAHAR VILLAGE 190.233 AL 1 2 243 ASPHALTD ROAD, BHILARAH- GARHI 191.331 AL 1 2 244 IN FIELD 192.331 AL 1 2 245 NEAR CHIRAWALI VILLAGE 193.331 AL 1 2 246 NEAR MAI VILLAGE BEFORE ASPHALTED RD 194.331 AL 1 2 247 ASPHALTED RD XING 195.337 AL 1 2 248 KHANDAULI DISTRIBUTION 196.442 AL 1 2
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06-10-1403-DD-PH1, Rev-01 Page 48 of 113 SN Location Chainage (km) Test Statio n Type (TS) CP Statio n Size Test station (ICTS) (Nos.) Normal Size Test station (TS) (Nos.) Pol cell Size Test Station (PCTS) (Nos.) CTSU Size Test Station (CTS) (Nos.) Perman ent Ref. Cell CuCuSo 4 (Nos) Mg Anode (2.5 KG) (Nos.) Mg Anode (10 KG) (Nos.) Bare Zn Ribbon Anode for HT Line crossing (m.) ZN Anode (20 KG) (Nos.) Polarisa tion cell (solid state) (Nos.) Polarisa tion Coupon (Nos.) ER probe (Nos.) 249 400 KVA HT LINE XING 197.417 ML 1 2 4 1 250 NEAR NAGIRIA VILLAGE 198.417 AL 1 2 251 200 KV HT LINE XING 199.079 M 1 6 1 252 ASPHALTED ROAD XING 199.557 AL 1 2 253 IN FIELD AFTER NH 200.600 AL 1 2 254 220 KVA HT LINE XING 201.754 ML 1 2 6 1 255 IN FIELD NEAR SEMRA VILLAGE 202.754 AL 1 2 256 IN FIELD 203.754 BL 1 1 2 257 ASPHALTED ROAD NEAR MAHARA GHARI VILLAGE 204.839 AL 1 2 258 IN FIELD NEAR RAGALA RAMBAL VILLAGE 205.839 AL 1 2 259 IN FIELD NEAR SIRAIKA VILLAGE 206.839 AL 1 2 260 ASPHALTED ROAD NEAR SIRAKA VILLAGE 207.941 AL 1 2 261 IN FIELD NEAR AKBAR BURJ VILLAGE 209.000 AL 1 2 262 IN FIELD USMANPUR VILLAGE 210.000 AL 1 2 263 IN FIELD NEAR HOGIGHARI VILLAGE 211.000 AL 1 2 264 IN FIELD NEAR BENAI VLLAGE 212.000 AL 1 2 265 IN FIELD AFTER ASPHALTED RD, NEAR BENAI VLLAGE 213.000 AL 1 2 266 IN FIELD NEAR GHARI HARPAL VILLAGE 214.000 AL 1 2
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06-10-1403-DD-PH1, Rev-01 Page 49 of 113 SN Location Chainage (km) Test Station Type (TS) CP Statio n Size Test station (ICTS) (Nos.) Normal Size Test station (TS) (Nos.) Pol cell Size Test Station (PCTS) (Nos.) CTSU Size Test Station (CTS) (Nos.) Perman ent Ref. Cell CuCuSo 4 (Nos) Mg Anode (2.5 KG) (Nos.) Mg Anode (10 KG) (Nos.) Bare Zn Ribbon Anode for HT Line crossing (m.) ZN Anode (20 KG) (Nos.) Polarisa tion cell (solid state) (Nos.) Polaris ation Coupon (Nos.) ER probe (Nos.) 267 IN FIELD NEAR MUKHBAR VILLAGE 215.000 AL 1 2 268 IN FIELD NEAR GOWAL VILLAGE 216.000 AL 1 2 269 NORTHAN RAILWAY MAINLINE XING 216.460 C 1 270 NORTHAN RAILWAY MAINLINE XING 216.534 C 1 271 400KVA HT XING, NEAR GOWAL VILLAGE 217.007 ML 1 1 2 4 1 1 272 ASPHALTED ROAD, NEAR HEMRAJPUR VILLAGE 218.039 AL 1 2 273 SV-6 218.859 G 1 2 1 274 IN FIELD, NEAR ETA VILLAGE 219.000 AL 1 2 275 IN FIELD NEAR SALEMPUR VILLAGE 220.000 AL 1 2 276 IN FIELD DEVKHERA VILLAGE BEFORE ASPHALTED RD 221.000 AL 1 2 277 IN FIELD DEVKHERA VILLAGE 222.000 AL 1 2 278 IN FIELD DEVKHERA VILLAGE 223.000 AL 1 2 279 NEAR DYAGHARI VILLAGE 224.000 AL 1 2 280 NEAR DYAGHARI VILLAGE MINOR CANNEL 225.016 AL 1 2 281 STATE HIGHWAY-31 226.000 CL 1 2 282 STATE HIGHWAY-31 226.029 C 1 283 IN FIELD NEAR GHARIJORI VILLAGE 227.029 AL 1 2 284 IN FIELD NEAR TARANAGAR VILLAGE 228.000 AL 1 2 TOTAL 10 245 17 12 36 468 12 116 7 17 2 2
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06-10-1403-DD-PH1, Rev-01 Page 50 of 113 16.0 CABLE LAYING DETAILS All cables shall be laid in accordance with approved layout drawings. Half-meter cable slack shall be provided near anodes, pipeline and test station in account for any settling. All cable inside plant/station area shall be laid at a depth of 0.75 m and cables outside station area shall be laid at a depth of minimum 1.5 m. The buried cables laid outside the Station area shall be mark with Polyethylene warning mats placed at 60 % of depth from the finished ground. All cable shall be laid in sand under brick cover and back filled with normal soil as per cable laying details drawing no. 06-10-1403-CLD.
17.0 CABLE TO PIPE CONNECTIONS Connections of all CP cables to the charged pipelines shall be made by Pin Brazing and for uncharged pipeline by Thermit weld. Pipe coating shall be repaired after connection of cable to pipeline and the coating repair material shall cover, exposed portion of the pipeline against ingress of water/moisture.
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06-10-1403-DD-PH1, Rev-01 Page 51 of 113 18.0 INSTALLATION PROCEDURE 18.1 FOR TEST STATION a) Introduction This procedure covers installation of the Test Station. b) Materials and reference
Sr. No. Material/Tool Make Application/Purpose 1 Test Station along with Bend Raychem For Erection of test station 2 Pharma Standard For Casting 3 PCC materials like cement, Stone chips & sand Standard For Casting 4 MS Sheet for Mixing of PCC materials Standard For Mixing PCC material 5 Tools such as Hammer, Spanner sets, Pliers Standard For Casting 6 Water cans Standard For Casting Drawings:06-10-1403-TS, 06-10-1403-PCTS, 06-10-1403-CTSUTS WORLEYPARSONS Reference MH2145-C000-EL-SPC-0025 RevA. c) Procedure The location of the test stations shall be marked on row as per approved design with their connection scheme and other related information on alignment sheet. Foundation shall be cast at site location. The overall dimensions of foundations shall be 600 mm x 600 mm x 800 mm. As shown in the standard drawing No. 06-10-1403- TS. The foundation cast should be properly watered and cured. Excavate 1m x 1 m x 1 m where the foundation is to cast. Prepare PCC for height of 600+200 mm as per installation drawing & WORLEYPARSONS standard drawing. Placed TS bend (Bottom) above PCC. Take MS shuttering and placed it in right position. The PCC (M-15) mixture shall be constantly rammed for proper compaction. Remove the shuttering after 24 hrs. The foundation shall be cured by proper curing for minimum 7 days Placed the TS boxes on the studs of the bend cast in concrete foundation and tighten the bolts. 50 mm PCC shall be done on the top of foundation after installation of Test Station.
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06-10-1403-DD-PH1, Rev-01 Page 52 of 113 The bolts shall then be distorted by hitting with a heavy hammer to make the installation vandal proof and also to ensure that the installation becomes theft proof. Bottom Cable entry of Test station Foundation shall be closed/Sealed by using Bitumen Compound to prevent water entry. The test station shall be installed in front side of the test station facing the pipeline & left hand side of the product flow in the pipeline. The name plate of test station (Black background with white letters) shall in min. carry following information: Test Station Number, Chainage in Km Test Station Connection Scheme Type Distance from Pipeline in mtrs Direction of Product flow d) PRECAUTIONS: Cables used shall be of sufficient length so as to reach termination point without any joint. Provide sufficient slack for future maintenance purpose (Loop shall be 1mtr before Test station). All the connections should be checked for proper tightening and tagged. Cable tags are to be provided at end before final termination Cable should be neatly dressed inside the trench and to be terminated inside test station. In case of location, where sacrificial anode is to be installed, the same should be taken parallel and the anode cable to be terminated at test station. 20% of Spare terminal shall be provided in Test Stations. Test station used for sacrificial anodes shall have shunt for measurement of anodes current and provision for resistance insertion to limit the anode current output. Test Station shall be installed at left side of the pipeline towards flow. Test report Record and document all the inspection results obtained in the below inspection report format.
e) FORMATS Inspection & Test Plan :06-10-1403-ITP-TS, Installation report : 06-10-1403-IR-TS, NOTE: In case of any conflict between the above procedures and contract specifications, the later shall be governed.
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06-10-1403-DD-PH1, Rev-01 Page 53 of 113 INSPECTION AND TEST PLAN FOR TEST STATION PROJECT EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT OWNER HINDUSTAN PETROLEUM CORPORATION LIMITED. CONSULTANT WORLEYPARSONS SEA INDIA PVT. LTD. CONTRACTOR KSS PETRON PRIVATE LIMITED CP CONTRACTOR RAYCHEM RPG PVT. LTD. REF. DRG. 06-10-1403-TS, 06-10-1403-PCTS, 06-10-1403-CTSUTS REPORT NO. 06-10-1403-ITP-TS WORLEYPARSON S STD. DWG 2-D-109-P CEL TS/ 2-D-110-TS PERSONNEL RESPONSIBLE RAYCHEM RPG: SITE ENGINEER / SUPERVISOR HPCL/WORLEYPARSONS: INSPECTOR
SR. NO. ACTIVITY RAYCHEM RPG WORLEYP ARSONS/K SS HPCL 1 Check Location P RM RM 2 Concrete Foundation Size, PCC Mixture, & Curing P S RM 3 Installation Test Post Mounting Above Foundation P S RM 4 Termination Of Cables In The Test Station P S RM 5 Check Proper Sealing Of Cable Entry At Foundation P RM RM 6 Cable Height Above Ground Level P RM RM LEGEND:
A : APPROVAL R : REVIEW OF RECORD P : PERFORM RM : RANDOM CHECK W : WITNESS ALL S : SUBMISSION
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06-10-1403-DD-PH1, Rev-01 Page 54 of 113
INSTALLATION REPORT FOR TEST STATION PROJECT EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT OWNER HINDUSTAN PETROLEUM CORPORATION LIMITED. CONSULTANT WORLEYPARSONS SEA INDIA PVT. LTD. CONTRACTOR KSS PETRON PRIVATE LIMITED CP CONTRACTOR RAYCHEM RPG PVT. LTD. REF. DRG. 06-10-1403-TS, 06-10-1403-PCTS, 06-10-1403-CTSUTS WORLEYPARSON S STD. DWG 2-D-109-P CEL TS/ 2-D-110-TS REF. SPECIFICATION REPORT NO. 06-10-1403-IR-TS, Date
Test station Location (Chainage in Km) Test Station Type Distance from the pipeline (m) Foundation Test Station Mounting Test station Doors / Locks / Gasket
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06-10-1403-DD-PH1, Rev-01 Page 55 of 113
18.2 FOR SACRIFICIAL ANODES a) Introduction: This procedure covers installation of the prepackaged Sacrificial Anode assemblies. b) Materials required Sr. No. Material/Tool Make Application/Purpose 1 Magnesium Anode with cotton bag Scientific Metal / Yuxi China/Xiang Metal, China For Protection of Pipeline 2 Backfill Powder Standard For Installation 3 Water can Standard For Installation 4 Excavation tools Standard For excavation Drawings:06-10-1403-MG2.5, 06-10-1403-MG10, 06-10-1403-ZN20 & 06-10-1403- GAI c) Responsibility: It is the responsibility of the contractors engineer to ensure that the Anodes, cables and the associated test station are correctly installed. The responsibility shall also cover the proper supervision in excavation, backfilling and concreting work as required. d) Detailed Procedure: The Anodes shall be suitably located as enumerated in the Design Package to provide the adequate levels of corrosion protection. The installation procedure is as follows: The Mg anode groundbed shall be located at 5 mtrs away from the pipeline For Zinc anode groundbed shall be located at 2 mtrs away from the pipeline. For Zinc anode installed for HT line crossing shall be located at 5 mtrs away from the pipeline. The anodes shall be installed in Horizontal configuration perpendicular to the pipeline. The anodes shall be installed in suitable trench at min 1.5 Mtrs depth. The Spacing between consecutive Anodes shall be 5 Mtrs as per the standard procedure. The top of the anode shall be at the bottom of the pipeline The prepacked anodes shall be lowered inside the trench and the balance spaced around the anodes shall be filled with native soil. After installing the anode the soil surrounding the anode shall be compacted. While lowering, the anode should not be suspended or lowered by its lead wire. In dry locations water shall be poured directly on the anode.
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06-10-1403-DD-PH1, Rev-01 Page 56 of 113 Wherever Hard Rock / Hard Soil Observed Depth of Anode bed shall be installed at a minimum depth equal to bottom level of the pipeline. The anode installation shall be checked by measuring the potential of the pipeline against a standard Cu-Cu So4 reference cell before and after connection of the anodes. e) Backfill: Anodes shall be packaged in a cotton bag and shall be surrounded by a low resistivity rapid wetting chemical backfill of the following composition: Gypsum : 75% Bentonite : 20% Sodium Sulphate : 5%
f) Precautions: Cables used shall be of sufficient length so as to reach termination point without any joint. Provide sufficient slack for future maintenance purpose. All the connections should be checked for proper tightening and tagged. Cable tags are to be provided at end before final termination Cable should be neatly dressed inside the trench and to be terminated inside test station e) FORMATS Inspection & Test Plan :06-10-1403-ITP-ANODES, Installation report :06-10-1403-IR-ANODES, NOTE: In case of any conflict between the above procedures and contract specifications, the later shall be governed.
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06-10-1403-DD-PH1, Rev-01 Page 57 of 113 INSPECTION AND TEST PLAN FOR ANODES PROJECT EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT OWNER HINDUSTAN PETROLEUM CORPORATION LIMITED. CONSULTANT WORLEYPARSONS SEA INDIA PVT. LTD. CONTRACTOR KSS PETRON PRIVATE LIMITED CP CONTRACTOR RAYCHEM RPG PVT. LTD. REF. DRG. 06-10-1403-MG2.5, 06-10-1403-MG10, 06-10-1403-ZN20 & 06-10-1403-GAI REPORT NO. 06-10-1403-ITP-ANODES WORLEYPARSON S STD. DWG 2-D-103-106-MG 2.5 KG/ 2-D-107-MG 20-10KG PERSONNEL RESPONSIBLE RAYCHEM RPG: SITE ENGINEER / SUPERVISOR HPCL/WORLEYPARSONS: INSPECTOR
SR NO ACTIVITY RAYCHEM RPG WORLEYP ARSONS/ KSS HPCL 1 Check Location P RM RM 2 Check Depth P RM RM 3 Open Circuit Potential Measurement P S RM 4 Natural PSP Measurement P S RM 5 Anode Open circuit potential(Before Connecting With PL) P RM RM 6 PSP Measurement (After Connecting With Anode) P RM RM 7 Anode Condition (Backfill, Cable, Bag) P S RM 8 Spacing Between Anodes P RM RM 9 Cable Connection & Connector Assembly With Anode Continuity Check P S RM 10 Check cable termination & tagging P RM RM LEGEND:
A : APPROVAL R : REVIEW OF RECORD P : PERFORM RM : RANDOM CHECK W : WITNESS ALL S : SUBMISSION
06-10-1403-MG2.5, 06-10-1403-MG10, 06-10-1403-ZN20 & 06-10-1403-GAI REPORT NO. 06-10-1403-IR-ANODES, DATE
Anode Location (Chainage in Km) Test Station Type Test Station No. Type of Sacrificial Anode Mg Anode/ Zinc Anode Distance from Pipeline (Mtr) No. Of Anodes Spacing Between Anodes Current Output of Anode mA Anode Condition & Anode Laying & Termination with Test station OK/NOT OK Anode Tail Cable Length (Mtr) A1 A2 A3 Anode Open circuit potential w.r.t Cu / CuSO 4 Ref. Cell ( Before connecting to PL)
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06-10-1403-DD-PH1, Rev-01 Page 59 of 113 18.3 FOR CABLE LAYING a) Introduction: This procedure covers the method of under ground cable laying with proper related activities to be performed. b) Materials Sr. No Material/Tool Make Application/Purpose 1 Crimping Tool Standard For Crimping of cable 2 Sand, Bricks Standard For Installation 3 Excavation tools Standard For Excavation Drawings:06-10-1403-CLD c) Procedure: All cables shall be laid in accordance with approved layout drawings. There shall be no joints in a single run of cable. Warning Mats should be placed at 60% of depth from finished ground level. The cables shall be laid at a depth of 0.75 m inside Station / Plant area and at 1.5 m outside station / Plant area with a layer of sand or soft soil as per spec A027-010-06- 45-SW-01, Rev.4 Second Class Bricks shall be placed over the sand spread as per the drawing and backfill with normal soil. Cable tags for buried cables/PVC ferrule are attached to each cable at termination point for identification of individual cable. Crimping the cable to proper sized crimping lugs does termination of cable. Before crimping each strand of cable conductor and the inner surface of lug is cleaned by fine sand paper to remove existing oxide film. Then the conductor is inserted inside the lug and it is crimped by crimping tool. In case of rocky areas for B Type for Current measurement Test station, Reference Cell Cables and other lengthy Cables along the pipeline shall be carried along the side of the pipe by securely strapping it with Nylon cord or equivalent as required. All underground cables shall be enclosed by G.I pipe of appropriate size while passing through road/rail crossings. All cables should be tagged at every 30 m Cables shall be neatly arranged in trenches in such a manner that crisscrossing is avoided and final take off to equipment is facilitated.
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06-10-1403-DD-PH1, Rev-01 Page 60 of 113 d) Precautions: Cables should be cut at sufficient lengths to reach destination without any joint. Care to be taken so that no crisscrossing of cables occurs. Cable Markers shall be provided to mark the cable route inside the station area. Proper Crimping tools to be used for crimping. The armoured of all the cables from pipe line to test station (potential measurement, ref cell cables, cathode cables etc) and test station to ground bed (anode cable) shall be insulated with PVC tape at the end of the cable to avoid armoured carrying CP current e) FORMATS Inspection & Test Plan : 06-10-1403-ITP-CL, Installation report : 06-10-1403-IR-CL, NOTE: In case of any conflict between the above procedures and contract specifications, the later shall be governed.
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06-10-1403-DD-PH1, Rev-01 Page 61 of 113
INSPECTION AND TEST PLAN FOR CABLE LAYING PROJECT EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT OWNER HINDUSTAN PETROLEUM CORPORATION LIMITED. CONSULTANT WORLEYPARSONS SEA INDIA PVT. LTD. CONTRACTOR KSS PETRON PRIVATE LIMITED CP CONTRACTOR RAYCHEM RPG PVT. LTD. REF. DRG. 06-10-1403-CLD, REPORT NO. 06-10-1403-ITP-CL, WORLEYPARSON S STD. DWG -
PERSONNEL RESPONSIBLE RAYCHEM RPG: SITE ENGINEER / SUPERVISOR HPCL/WORLEYPARSONS: INSPECTOR
SR. NO. ACTIVITY RAYCHEM RPG WORLEYPARSON S /KSS HPCL 1 Cable Trench Route Marking P RM RM 2 Excavation Depth Check P RM RM 3 Sand Spreading / Brick Laying P RM RM 4 Warning Mat Placement P RM RM 5 Backfilling / Restoration P RM RM 6 Tagging/Ferruling P RM RM 7 Route Marking P RM RM 8 IR value of cable P RM RM 9 Continuity of cable P RM RM LEGEND:
A : APPROVAL R : REVIEW OF RECORD P : PERFORM RM : RANDOM CHECK W : WITNESS ALL S : SUBMISSION
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT
06-10-1403-DD-PH1, Rev-01 Page 62 of 113
INSTALLATION REPORT FOR CABLE LAYING PROJECT EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT OWNER HINDUSTAN PETROLEUM CORPORATION LIMITED. CONSULTANT WORLEYPARSONS SEA INDIA PVT. LTD. CONTRACTOR KSS PETRON PRIVATE LIMITED CP CONTRACTOR RAYCHEM RPG PVT. LTD. REF. DOC. MH2145-C000-EL-SPC-0025 RevA. WORLEYPARSON S STD. DWG - REF. DRG. 06-10-1403-CLD REPORT NO. 06-10-1403-IR-CL, DATE
Cable size & length
Cable trench OK / NOT OK Depth of laying
Sand/brick spreading OK / NOT OK Warning mat Placement OK / NOT OK Back filling / restoration OK / NOT OK Tagging/Ferruling OK / NOT OK Route Marking OK / NOT OK IR value of cable OK / NOT OK Continuity of cable OK / NOT OK Instrument Details (Make/ model / Sr. No.) Calibration certificate. No. & validity
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT
06-10-1403-DD-PH1, Rev-01 Page 63 of 113 18.4 FOR SURGE DIVERTER a) Purpose To define the procedure for the installation of Surge Diverter required for diverting / arresting the surge in the pipeline at the isolation Joints in permanent Cathodic protection and provide adequate quality assurance / control. b) Material Sr. No Material/Tool Make Application/Purpose 1 Surge Diverter Dehn Sohne For IJ protection 2 Portable half cell Mc Miller For PSP measurement 3 Hand tools Standard For PSP measurement WORLEYPARSONS Reference MH2145-C000-EL-SPC-0025 RevA.
c) Procedure Check the location of the Isolating Joints and check the insulation of the joint Check cables of the Instrument for any damage prior to installation. Connect the Surge Diverter across the Insulation Joint by bolting with the clit on the Insulation joint. If the cable available with the instrument is short, erect a conductor strip for connecting the instrument. Connect the cables as per the F Type connection Scheme with the Pipeline and TLP Provided. Fill all the exposed connection parts with the pipeline shall be covered by means of Epoxy-Hardener. Measure the PSP readings at both the sides of the IJ / Surge Diverter d) Precautions Care should be taken while installing the Surge Diverter. All cables are to be appropriately tagged. All cable connections should be checked for proper tightening & tagging. Cable tags are to be provided at both ends before final termination. e) FORMATS Inspection & Test Plan: 06-10-1403-ITP-SD, Installation report : 06-10-1403-IR-SD, NOTE: In case of any conflict between the above procedures and contract specifications, the later shall be governed.
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT
06-10-1403-DD-PH1, Rev-01 Page 64 of 113 INSPECTION AND TEST PLAN FOR SURGE DIVERTER PROJECT EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT OWNER HINDUSTAN PETROLEUM CORPORATION LIMITED. CONSULTANT WORLEYPARSONS SEA INDIA PVT. LTD. CONTRACTOR KSS PETRON PRIVATE LIMITED CP CONTRACTOR RAYCHEM RPG PVT. LTD. REF. DOC. MH2145-C000-EL-SPC-0025 RevA. REF. DRG. - WORLEYPARSON S STD. DWG - REPORT NO. 06-10-1403-ITP-SD, PERSONNEL RESPONSIBLE RAYCHEM RPG: SITE ENGINEER / SUPERVISOR HPCL/WORLEYPARSONS: INSPECTOR
Sr. No. ACTIVITY RAYCHEM RPG WORLEY PARSON S/KSS HPCL 1 Location P RM RM 2 Installation of Surge Diverter (No joint of cable to be used) P S RM 3 Cable Connection and Laying P RM RM 4 Insulation of IJ / Surge Diverter P S RM 5 Backfilling & Cable Tags P RM RM LEGEND:
A : APPROVAL R : REVIEW OF RECORD P : PERFORM RM : RANDOM CHECK W : WITNESS ALL S : SUBMISSION
Location / Chainage In Km: Sr. No. Of Surge Divertor Installation of Surge Diverter (No joint of cable to be used) OK / NOT OK Cable Connection OK / NOT OK PSP Reading of Protected Section mV PSP Reading of Other Section mV Polarity check Cable Termination OK / NOT OK Backfill and Restoration OK / NOT OK Instrument Details (Make/ model / Sr. No.) Calibration certificate. No. & validity
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT
06-10-1403-DD-PH1, Rev-01 Page 66 of 113 18.5 FOR THERMIT WELD a) PURPOSE This procedure covers Thermit Weld for cable connection to pipeline for all type of cables related to Cathodic Protection System. Cable to Pipe connection during construction shall be done by Thermit welding method and for Hydrotested / charged and for foreign pipeline, cable to pipe connections shall be carried out through pin brazing.
b) MATERIAL AND REFERENCES Sr. No. Material/Tool Make Application/Purpose 1 Crimping Tool Standard For crimping cable with lug/ferrule 2 Thermit Mould & Sparking Gun Erico, USA Thermit welding & Igniting 3 Cad Weld Powder, CA15 & CA32 Erico, USA Welding 4 Cables Suyog/Netco Connection to pipe 5 Hammer & Chisel Standard Hammering test for Thermit & Coating cutting 6 Epoxy Dobofil-60 Doctor Beck For sealing of Cable to pipe joints 7 Hardner-758 Doctor Beck 8 PVC Funnel Local Coating Repair Filing. 9 Mseal Standard Sealing for PVC funnel 10 Cu Sleeves Standard For Cable Connections 11 Fine File Local Surface Cleaning 12 Sand Paper Local Surface cleaning 13 Holiday Detector Caltech For coating check Drawings:06-10-1403-TW Reference MH2145-C000-EL-SPC-0025 RevA. NOTE: For all the measuring equipments used in TCP, Calibration Certificates shall be provided.
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT
06-10-1403-DD-PH1, Rev-01 Page 67 of 113
c) PROCEDURE Excavate (wherever pipeline backfilled with soil) a pit over the pipeline to expose the pipeline top surface at location of Thermit weld where cable to pipe connection is to be carried out as per design document. Care should be taken not to damage the coating of buried pipeline. Only manual excavation shall be carried out over pipeline. Mark where connection is to be carried out. If there is more than one connection as per design document, consecutive marking shall be minimum 300 mm apart. Connection location shall be minimum 300mm apart from other connection and Welding joint, Seam or Circumferential Weld Joint of the pipeline. The location for cable to pipe connection shall be selected such that the pipe joints and field- coated areas are avoided. Cut open the coating on the pipeline with care and without damaging the pipe for a size of approximately 50 mm x 50 mm (suitable for thermit weld mould). Clean the surface of the pipeline to white metal finish using sand paper and cleaning with fine file as required. Depending on the size of cable select the model of cad weld material i.e. CA-15 or CA-32 and mould. Copper sleeve of suitable size shall be double Crimped on the 4 Sq mm & 6 Sq mm cable. Place the mould on the exposed area and pour the cad weld material. Ignite using the gun and wait for 2 minutes cool down period. Test the connection by striking 0.5 Kg hammer directly over the connection. And if connection fails, the above procedure shall be repeated after waiting time of approx.10min.to cool the pipeline surface. Place a plastic funnel around the exposed area such that about 5mm wide coating remains in side the plastic funnel. Apply mastic/Mseal around the plastic funnel to prevent leakage of encapsulation materials. Mix proper quantity of epoxy-hardner and keep mixing with wooden rod till it gets heated, Fill up the conical funnel from the top by pouring mix of Epoxy Dobofil 60 and hardener 758 at 1:10 ratio. 3/4 th of the cone to be filled with mix and remaining plastic cone to cut after setting of the hardener.
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT
06-10-1403-DD-PH1, Rev-01 Page 68 of 113 Allow the epoxy-hardener to set and test the insulation level by a holiday detector at 25 KV. Cable shall be laid in accordance with approval cable laying drawings. Cable route shall be carefully measured and cable cut to be required length from test station to pipe. A loop of approx 0.5mtr.of cable shall be kept at both pipe and Test Station end. d) PRECAUTIONS Only Manual excavation to be done without damaging the coating. All cables are to be appropriately tagged. Location of cable to pipe connection shall be minimum 300mm apart from other connection and from Pipe weld joint, Seam or Circumferential Weld Joint. Check hardness of encapsulation before holiday test by applying pressure with thumb/Wooden Stick. Coating repair and holiday test should be completed before backfilling. Maximum 15 grams Ignition powder shall be used for each connection. If one connection fails, wait of approx 10 min for pipeline cooling and then repeat the procedure for connection. e) FORMATS Inspection & Test Plan: 06-10-1403-ITP-TW, Installation report : 06-10-1403-IR-TW,
NOTE: In case of any conflict between the above procedures and contract specifications, the later shall be governed.
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT
06-10-1403-DD-PH1, Rev-01 Page 69 of 113
INSPECTION AND TEST PLAN FOR THERMIT WELD PROJECT EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT OWNER HINDUSTAN PETROLEUM CORPORATION LIMITED. CONSULTANT WORLEYPARSONS SEA INDIA PVT. LTD. CONTRACTOR KSS PETRON PRIVATE LIMITED CP CONTRACTOR RAYCHEM RPG PVT. LTD. REF. DOC. MH2145-C000-EL-SPC-0025 RevA. REF. DRG. 06-10-1403-TW WORLEYPARSON S STD. DWG 2-D-112-THER W REPORT NO. 06-10-1403-ITP-TW, PERSONNEL RESPONSIBLE RAYCHEM RPG: SITE ENGINEER / SUPERVISOR HPCL/WORLEYPARSONS: INSPECTOR
SR. NO. ACTIVITY RAYCHEM RPG WORLEYPARS ONS/KSS HPCL 1 Check Location P RM RM 2 Check of Spacing between Two welds P RM RM 3 Check connection to pipeline P W RM 4 Check Holiday at 25 kv P W RM 5 Check The Restoration P RM RM 6 Check Encapsulation P RM RM 7 Continuity test P W RM LEGEND:
A : APPROVAL R : REVIEW OF RECORD P : PERFORM RM : RANDOM CHECK W : WITNESS ALL S : SUBMISSION
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT
06-10-1403-DD-PH1, Rev-01 Page 70 of 113
INSTALLATION REPORT FOR THERMIT WELD PROJECT EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT OWNER HINDUSTAN PETROLEUM CORPORATION LIMITED. CONSULTANT WORLEYPARSONS SEA INDIA PVT. LTD. CONTRACTOR KSS PETRON PRIVATE LIMITED CP CONTRACTOR RAYCHEM RPG PVT. LTD. REF. DOC. MH2145-C000-EL-SPC-0025 RevA. REF. DRG. 06-10-1403-TW WORLEYPARSONS STD. DWG 2-D-112-THER W REPORT NO. 06-10-1403-IR-TW, DATE
Test station Location (Chainage in Km) Test Station Type Spacing between connection Epoxy & Hardner Filling Cable Size in mm Cable length in mtrs Thermit Welding OK / NOT OK Continuity OK / NOT OK Holiday Check OK / NOT OK Restoration Check OK / NOT OK Instrument Details Digital Multimeter Holiday Detector Make Make Model No Model No Date of Calibration Date of Calibration
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT
06-10-1403-DD-PH1, Rev-01 Page 71 of 113
18.6 FOR PIN BRAZING a) Purpose To describe the procedure for Pin Brazing and to provide adequate quality assurance/control of workmanship and inspection at site b) Materials required
Sr. No. Material/Tool Make Application/Purpose 1 Crimping Tool Standard For crimping cable with lug/ferrule 2 Pin Brazing Equipment Safetrack Pin Brazing of cable to Pipe 3 Brazing Pin Safetrack Brazing 4 Cables Asian Cables /Icon Cables /Finolex/Suyog /Netco Connection to pipe 5 Hammer & Chisel Standard Hammering test for Thermit & Coating cutting 6 Epoxy Dobofil-60 Doctor Beck For sealing of Cable to pipe joints 7 Hardner-758 Doctor Beck 8 PVC Funnel Local Coating Repair Filing. 9 Mseal Standard Sealing for PVC funnel 10 Cu Sleeves Standard For Cable Connections 11 Fine File Local Surface Cleaning 12 Sand Paper Local Surface cleaning 13 Holiday Detector Caltech For coating check Drawings:06-10-1403-PB c) Procedure Excavate a pit over the pipeline to expose the pipeline top surface opposite to the test station location where cable to pipe connection is to be carry out as per design document. Care should be taken not to damage the coating of buried Pipeline. Make marking where connection is to be carried out. If there is more than one connection as per design document, consecutive marking shall be minimum 300 mm apart. The location for cable to pipe connection shall be selected such that the pipe
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT
06-10-1403-DD-PH1, Rev-01 Page 72 of 113 joints and field-coated areas are avoided. Care shall be taken that cable to pipe joint is not made upon the long seam or circumferential weld. Cut open the coating on the pipeline with care and without damaging the pipe for a size of approximately 50 mm x 50 mm. Clean the surface of the pipeline to white metal finish using grinder and sand paper. Braze the pin using pin-brazing equipment. All the cables shall be tested before installation to ascertain the healthiness of the cables. Connect the cable to the pin using proper size cable lug as per enclosed Drg no: 06-10-1403-PB. Place a plastic funnel 70mm ID (approx.) around the exposed area such that about 5mm wide coating remains inside the plastic funnel. Place mastic around the plastic funnel to prevent leakage of encapsulation materials. Fill up the conical mould from the top by pouring epoxy Hardner, 3/4th of the cone to be filled with hardener and remaining plastic cone to cut after setting of the hardener. Allow the epoxy-Hardner to set and test the insulation level by a holiday detector. d) Precautions Care should be taken while installing the Polarization Cell All cables are to be appropriately tagged. All cable connections should be checked for proper tightening. Cable ferrules are to be provided at both ends. e) FORMATS Inspection & Test Plan : 06-10-1403-ITP-PB, Installation reports : 06-10-1403-IR-PB, NOTE: In case of any conflict between the above procedures and contract specifications, the later shall be governed.
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT
06-10-1403-DD-PH1, Rev-01 Page 73 of 113
INSPECTION AND TEST PLAN FOR PIN BRAZING PROJECT EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT OWNER HINDUSTAN PETROLEUM CORPORATION LIMITED. CONSULTANT WORLEYPARSONS SEA INDIA PVT. LTD. CONTRACTOR KSS PETRON PRIVATE LIMITED CP CONTRACTOR RAYCHEM RPG PVT. LTD. REF. DOC. MH2145-C000-EL-SPC-0025 RevA. REF. DRG. 06-10-1403-PB WORLEYPARSON S STD. DWG 2-D-112-THER W REPORT NO. 06-10-1403-ITP-PB, PERSONNEL RESPONSIBLE RAYCHEM RPG: SITE ENGINEER / SUPERVISOR HPCL/WORLEYPARSONS: INSPECTOR
SR. NO. ACTIVITY RAYCHE M RPG WORLEYPAR SONS/KSS HPCL 1 Check Location P RM RM 2 Check of Spacing between Two Pin brazing P RM RM 3 Check connection to pipeline P W RM 4 Check Holiday at 25 kv P W RM 5 Check The Restoration P RM RM 6 Check Encapsulation P RM RM 7 Continuity test P W RM LEGEND:
A : APPROVAL R : REVIEW OF RECORD P : PERFORM RM : RANDOM CHECK W : WITNESS ALL S : SUBMISSION
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT
06-10-1403-DD-PH1, Rev-01 Page 74 of 113 INSTALLATION REPORT FOR PIN BRAZING PROJECT EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT OWNER HINDUSTAN PETROLEUM CORPORATION LIMITED. CONSULTANT WORLEYPARSONS SEA INDIA PVT. LTD. CONTRACTOR KSS PETRON PRIVATE LIMITED CP CONTRACTOR RAYCHEM RPG PVT. LTD. REF. DOC. MH2145-C000-EL-SPC-0025 RevA. REPORT NO. 06-10-1403-IR-PB, WORLEYPARSONS STD. DWG 2-D-112-THER W REF. DRG. 06-10-1403-PB DATE
Test station Location (Chainage in Km) Test Station Type Spacing between connection Epoxy & Hardner Filling Cable Size in mm Cable length in mtrs Pin Brazing OK / NOT OK Continuity OK / NOT OK Holiday Check OK / NOT OK Restoration Check OK / NOT OK Instrument Details Digital Multimeter Holiday Detector Make Make Model No Model No Date of Calibration Date of Calibration
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT
06-10-1403-DD-PH1, Rev-01 Page 75 of 113
18.7 FOR POLARISATION CELL a) Purpose To define the procedure for the installation of Polarization Cell required for grounding the AC interference in the pipeline at the HT Line crossing locations in permanent Cathodic protection and provide adequate quality assurance / control. b) Materials required Sr. No. Material/Tool Make Application/Purpose 1 Polarisation cell Dairyland For grounding at HT Line crossing 2 Portable half cell Mc Miller For PSP measurement 3 Hand tools Standard For PSP measurement Ref. Drawing: 06-10-1403-PCTS c) Procedure Check the location of the HT line Crossings Check cable to Pipeline connection and install the polarization cell inside the Test station Connect the cable from the Zn grounding anode / Zinc Ribbon anode and the cable from the pipeline as per the M Type connection Scheme with the polarization cell in the TLP Provided. Measure the standby voltage and current across the terminals of the polarization cell d) Precautions Care should be taken while installing the Polarization Cell All cables are to be appropriately tagged. All cable connections should be checked for proper tightening. Cable ferrules are to be provided at both ends. e) FORMATS Inspection & Test Plan: 06-10-1403-ITP-PC, Installation report : 06-10-1403-IR-PC, NOTE: In case of any conflict between the above procedures and contract specifications, the later shall be governed.
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT
06-10-1403-DD-PH1, Rev-01 Page 76 of 113
INSPECTION AND TEST PLAN FOR POLARISATION CELL PROJECT EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT OWNER HINDUSTAN PETROLEUM CORPORATION LIMITED. CONSULTANT WORLEYPARSONS SEA INDIA PVT. LTD. CONTRACTOR KSS PETRON PRIVATE LIMITED CP CONTRACTOR RAYCHEM RPG PVT. LTD. REF. DOC. MH2145-C000-EL-SPC-0025 RevA. REF. DRG. 06-10-1403-PCTS WORLEYPARSON S STD. DWG - REPORT NO. 06-10-1403-ITP-PC, PERSONNEL RESPONSIBLE RAYCHEM RPG: SITE ENGINEER / SUPERVISOR HPCL/WORLEYPARSONS: INSPECTOR
Sr. No. ACTIVITY RAYCHEM RPG WORLEY PARSONS /KSS HPCL 1 Location P RM RM 2 Installation of Polarisation cell P RM RM 3 Cable Connection and Laying P RM RM 4 Measurement of Standby voltage P RM RM LEGEND:
A : APPROVAL R : REVIEW OF RECORD P : PERFORM RM : RANDOM CHECK W : WITNESS ALL S : SUBMISSION
Location / Chainage In Km: Installation of Polarisation cell OK / NOT OK Cable Termination OK / NOT OK Standby Current mAmps Standby Voltage mV Final Restoration OK / NOT OK Instrument details Digital Multimeter Model No
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT
06-10-1403-DD-PH1, Rev-01 Page 78 of 113 18.8 FOR PERMANENT REFERENCE CELL a) Scope To define the procedure for the installation of reference cells required for monitoring and adjusting the PSP values at preset levels and for measurement of pipe to soil potential near drain point in permanent cathodic protection and provide adequate quality assurance / control. b) Materials required Sr. No. Material/Tool Make Application/Purpose 1 Permanent reference cell (Cu- CuSo4) Borin USA For PSP measurement 2 Backfill Powder Standard Backfill material 3 Cable Lug Standard For Termination of cable 4 Crimping tool Standard For Crimping of cable c) Procedure Check serial number of permanent reference cell and verify with manufacture test certificate. Record sr. no. Of reference cell on inspection report. Before connection cut the 4 sq mm cable with sufficient length so as to reach the test station. Remove the cable insulation (half of the copper ferrule (+/-10%) of reference cell cable and 4 sq mm cable for connection. Soft soldering shall be made above the crimped connection. Electrical continuity test should be performed to ensure the proper connection. Seal the joint with epoxy compound (Dobofil & Hardener) & allow it to get hard. Now reference cell is ready with tail cable for installation. Check cable connection and cotton bag filled with backfill material and permanent reference cell for any damage prior to installation. Soak complete assembly in fresh water (20 Lts) for 24 hours and record following readings. Keep portable reference cell and permanent reference cell on ground above the buried pipeline close to each other near test station. Measure pipe to soil potential with reference to portable as well as permanent reference cell and record it. Similarly measure potential difference between calibrated portable and permanent reference cell. Connect calibrated cell to positive terminal at multimeter. Record the difference on inspection.
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT
06-10-1403-DD-PH1, Rev-01 Page 79 of 113 Excavated and install the permanent reference cell on either sides of the pipeline location at bottom level of the pipe / coupon approximately 200mm distance away from the pipeline. Depth of reference cell assembly should be such that it is at the same level as that of the bottom level of pipe. Cable to be laid along the bottom of pipeline and 250 mm away from the pipeline. Terminate the cable connect to permanent reference cell at test station and proper identification tag to be provided. d) Precautions Reference cell should be soaked in clean water for 24 Hours before installation. Reference cell cables and reference cables (for pipe to cable connection) are to be of sufficient length so as to reach the Test station / TR unit. All cables are to be appropriately tagged. All cable connections should be checked for proper tightening.
e) FORMATS Inspection & Test Plan: 06-10-1403-ITP-PR, Installation report : 06-10-1403-IR-PR, NOTE: In case of any conflict between the above procedures and contract specifications, the later shall be governed.
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT
06-10-1403-DD-PH1, Rev-01 Page 80 of 113 INSPECTION AND TEST PLAN FOR REFERENCE CELL PROJECT EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT OWNER HINDUSTAN PETROLEUM CORPORATION LIMITED. CONSULTANT WORLEYPARSONS SEA INDIA PVT. LTD. CONTRACTOR KSS PETRON PRIVATE LIMITED CP CONTRACTOR RAYCHEM RPG PVT. LTD. REF. DOC. MH2145-C000-EL-SPC-0025 RevA. REF. DRG. - WORLEYPARSON S STD. DWG 2-D-PCP-SCH REPORT NO. 06-10-1403-ITP-PR PERSONNEL RESPONSIBLE RAYCHEM RPG: SITE ENGINEER / SUPERVISOR HPCL/WORLEYPARSONS: INSPECTOR
Sr. No. ACTIVITY RAYCHEM RPG WORLEYPA RSONS/KS S HPCL 1 Identification and physical condition of ref Cell. P S RM 2 Soak in fresh water for 24 hrs P S RM 3 Comparative reading measurement with portable cell P S RM 4 Reference cell installation and backfilling P S RM 5 Cable termination, tags P RM RM LEGEND:
A : APPROVAL R : REVIEW OF RECORD P : PERFORM RM : RANDOM CHECK W : WITNESS ALL S : SUBMISSION
Location / Chainage In Km: Reference cell condition (backfill, cable, bag) OK / NOT OK Depth of Reference cell laying Mtrs Distance from pipeline mm Cable termination at Test Station Ok / NOT OK PSP measurement With permanent reference cell mV Instrument details Digital Multimeter Model No Make Date of Calibration
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT
06-10-1403-DD-PH1, Rev-01 Page 82 of 113 18.9 FOR POLARISATION COUPON a) Purpose To define the procedure for the installation of Polarisation Coupon
b) Materials required Sr. No. Material/Tool Make Application/Purpose 1 Polarisation Coupon Pipeline Material For Installation 2 Cables Asian Cables /Icon Cables /Finolex/Suyog/Netco For connecting to Coupon 3 Excavation tools Standard For Excavation 4 Cable Lug Standard For Termination of cable 5 Crimping tool Standard For Crimping of cable Ref. Drawing: 06-10-1403-PCC c) Procedure Coupons of size 100x100 mm shall be cut from a coated pipe. The cut out coupon shall be grinded on all its edges to strip the loose metal, if any. M/s HPCL shall provide the coated pipe for preparation of coupons. One face of the coupon that corresponds to the internal surface of the pipe will be having pipeline coating. The cable connecting to coupon shall be Thermit welded and to be sealed with epoxy for encapsulation. The coupon to be buried at pipeline depth facing to the pipeline. d) Precautions Cables connecting to corrosion coupon are to be of sufficient length so as to reach the Test station. All cables are to be appropriately tagged. All cable connections should be checked for proper tightening. e) FORMATS Inspection & Test Plan: 06-10-1403-ITP-PCC, Installation report : 06-10-1403-IR-PCC, NOTE: In case of any conflict between the above procedures and contract specifications, the later shall be governed.
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT
06-10-1403-DD-PH1, Rev-01 Page 83 of 113
INSPECTION AND TEST PLAN FOR POLARISATION COUPON PROJECT EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT OWNER HINDUSTAN PETROLEUM CORPORATION LIMITED. CONSULTANT WORLEYPARSONS SEA INDIA PVT. LTD. CONTRACTOR KSS PETRON PRIVATE LIMITED CP CONTRACTOR RAYCHEM RPG PVT. LTD. REF. DOC. MH2145-C000-EL-SPC-0025 RevA. REF. DRG. 06-10-1403-PCC WORLEYPARSON S STD. DWG 2-D-106-P COUP TS REPORT NO. 06-10-1403-ITP-PCC PERSONNEL RESPONSIBLE RAYCHEM RPG: SITE ENGINEER / SUPERVISOR HPCL/WORLEYPARSONS: INSPECTOR
Sr. No. ACTIVITY RAYCHEM RPG WORLEYPAR SONS /KSS HPCL 1 Location check P RM RM 2 Coupon Installation P RM RM 3 Backfilling restoration P RM RM 4 Cable termination, tags P RM RM LEGEND:
A : APPROVAL R : REVIEW OF RECORD P : PERFORM RM : RANDOM CHECK W : WITNESS ALL S : SUBMISSION
Location / Chainage In Km: Corrosion Coupon condition (backfill, cable, bag) OK / NOT OK Distance from pipeline mm Cable termination at Test Station Ok / NOT OK PSP measurement With permanent reference cell MV Coupon Off potential V Instrument Details Digital Multimeter Model No Make Date of Calibration
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT
06-10-1403-DD-PH1, Rev-01 Page 85 of 113 18.10 FOR ZINC RIBBON ANODES a) Purpose To define the procedure for the installation of zinc ribbon anodes at HT line crossing. b) Materials required Sr. No. Material/Tool Make Application/Purpose 1 Zinc Ribbon anode Platline Bros, USA/Yuxi China For grounding at HT Line crossing 2 Backfill Powder Standard Backfill material 3 Cable Lug Standard For Termination of cable 4 Crimping tool Standard For Crimping of cable Ref. Drawing: 06-10-1403-ZR-HT c) Procedure Check and identify the location of HT crossing where the Zinc ribbon anode is to be installed. The zinc ribbon anode to be installed 2mtr away from the pipeline. Cut the cable of required length so as to reach the test station. The zinc ribbon in backfill condition to be installed in trench at HT crossing. Connect the cable to one end of the Zinc ribbon anode sufficient to reach the test station. The Zinc ribbon anode to be installed with Gypsum, Bentonite & sodium Sulphate backfill in trench with size of 0.15 m x 0.15 m. The zinc ribbon anode to cable connection to be made via copper lug & nut bolt. The end of the cable to be sealed by epoxy. Visually examine the cable connection with Zinc ribbon anode.
d) Precautions Remove Zinc from M.S. core carefully ensure that not to damage core of the anode. e) FORMATS Inspection & Test Plan: 06-10-1403-ITP-ZN, Installation report : 06-10-1403-IR-ZN, NOTE: In case of any conflict between the above procedures and contract specifications, the later shall be governed.
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT
06-10-1403-DD-PH1, Rev-01 Page 86 of 113
INSPECTION AND TEST PLAN FOR ZINC RIBBON ANODES PROJECT EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT OWNER HINDUSTAN PETROLEUM CORPORATION LIMITED. CONSULTANT WORLEYPARSONS SEA INDIA PVT. LTD. CONTRACTOR KSS PETRON PRIVATE LIMITED CP CONTRACTOR RAYCHEM RPG PVT. LTD. REF. DOC. MH2145-C000-EL-SPC-0025 RevA. REPORT NO. 06-10-1403-ITP-ZN, WORLEYPARSON S STD. DWG 2-D-115-Z RIB HT PERSONNEL RESPONSIBLE RAYCHEM RPG: SITE ENGINEER / SUPERVISOR HPCL/WORLEYPARSONS: INSPECTOR
Sr. No. ACTIVITY RAYCHEM RPG WORLEYPA RSONS/KS S HPCL 1 Length of Zinc Ribbon Anode P S RM 2 Anode to cable Connection P S RM 3 Check the Distance P RM RM 4 Encapsulation P RM RM
LEGEND:
A : APPROVAL R : REVIEW OF RECORD P : PERFORM RM : RANDOM CHECK W : WITNESS ALL S : SUBMISSION
Test station location (Chainage) Test station type Total Length of Zinc Ribbon Anode Anode to cable connection Instrument Details Digital Multimeter Model No Make Date of Calibration
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06-10-1403-DD-PH1, Rev-01 Page 88 of 113
18.11 FOR ER PROBE a) Purpose To define the procedure for the installation of external ER Probe needed for permanent cathodic protection and provide adequate quality assurance/ control of workmanship and inspection at site. b) Materials required Sr. No. Material/Tool Make Application/Purpose 1 ER Probe & reader Metal samples, USA For corrosion Monitoring 2 Hand Tools Standard For termination of cable 3 Cable Lug Standard For termination of cable 4 Crimping tool Standard For crimping of Lug to cable Ref. Drg: 06-10-1403-ER c) Procedure Identify the location of ER probe. This shall be in line with approved document. Excavate the soil near to pipeline up to pipeline depth. Install ER probe near pipeline as per approved drawing. Cable of ER probe shall be terminated in TLP. d) Precautions Probe should be handled with disposable laboratory gloves to avoid making the probe dirty. The back filling operation shall be completed to finished grade level, using excavated material. All the cable connection should be checked for proper tightening. Any recommendation for installation of ER probe given by manufacturer shall be followed. The ER Probe cable to be connected to the Pipeline immediately after installation of the probe. e) FORMATS Inspection & Test Plan: 06-10-1403-ITP-ER, Installation report : 06-10-1403-IR-ER, NOTE: In case of any conflict between the above procedures and contract specifications, the later shall be governed.
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06-10-1403-DD-PH1, Rev-01 Page 89 of 113 INSPECTION AND TEST PLAN FOR ER PROBE PROJECT EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT OWNER HINDUSTAN PETROLEUM CORPORATION LIMITED. CONSULTANT WORLEYPARSONS SEA INDIA PVT. LTD. CONTRACTOR KSS PETRON PRIVATE LIMITED CP CONTRACTOR RAYCHEM RPG PVT. LTD. REF. DOC. MH2145-C000-EL-SPC-0025 RevA. REF. DRG. 06-10-1403-ER REPORT NO. 06-10-1403-ITP-ER, WORLEYPARSONS STD. DWG
PERSONNEL RESPONSIBLE RAYCHEM RPG: SITE ENGINEER / SUPERVISOR HPCL/WORLEYPARSONS: INSPECTOR
Sr. No. ACTIVITY RAYCHEM RPG WORLEYP ARSONS/ KSS HPCL 1 Verification of ER Probe Location, Pipe to Probe clearance & Level P W RM 2 ER probe Installation P W RM 3 Cable Termination and Tags P W RM 4 Backfilling / Restoration P RM RM
LEGEND:
A : APPROVAL R : REVIEW OF RECORD P : PERFORM RM : RANDOM CHECK W : WITNESS ALL S : SUBMISSION
Work Order No. Sr. No SOR Item No. Material Description TAG No. Date of Receipt Quantity Received Manufact urer / Vendor Material TC No. / Inspection report No with Date Heat / batch No. Ref invoice No. / Challan No. Storage Instruct ion Observation / Remarks
Note:- 1) Quantity verified & found in order 2) Material condition appear good 3) Heat / Batch / Tag No. Verified on the material 4) Colour coding done as applicable 5) Site identification mark on material 6) Correlation w.r.t Inspection report / Material TC/ Lab Tests
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EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT
06-10-1403-DD-PH1, Rev-01 Page 92 of 113 20.0 STANDARD QAP STANDARD QAP FOR TCP INSTALLATION SYSTEM PROJECT EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT OWNER HINDUSTAN PETROLEUM CORPORATION LIMITED. CONSULTANT WORLEYPARSONS SEA INDIA PVT. LTD. CONTRACTOR KSS PETRON PRIVATE LIMITED CP CONTRACTOR RAYCHEM RPG PVT. LTD. Sr. No. Activity Description Procedure No. Code of Conformance Contractor Responsibility Records to be Maintained Performer Checker Approver 1 Incoming Material control 06-10-1403- DD-PH1 - Site Technician Supervisor Site Engineer/ Site In Charge 06-10-1403-IR- IMIR 2 Installation of Test Station 06-10-1403- DD-PH1 MH2145-C000-EL- SPC-0025 RevA. Site Technician Supervisor Site Engineer/ Site In Charge 06-10-1403-IR- TS 3 Installation of Mg Anode & Zn Anode 06-10-1403- DD-PH1 MH2145-C000-EL- SPC-0025 RevA. Site Technician Supervisor Site Engineer/ Site In Charge 06-10-1403-IR- ANODES 4 Laying and termination of CP cables 06-10-1403- DD-PH1 MH2145-C000-EL- SPC-0025 RevA. Site Technician Supervisor Site Engineer/ Site In Charge 06-10-1403-IR- CL
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06-10-1403-DD-PH1, Rev-01 Page 93 of 113 5 Installation of Surge Diverter 06-10-1403- DD-PH1 MH2145-C000-EL-SPC- 0025 RevA. Site Technician Supervisor Site Engineer/ Site In Charge 06-10-1403-IR-SD 6 Pipe to Cable connection by Thermit Welding 06-10-1403- DD-PH1 MH2145-C000-EL-SPC- 0025 RevA. Site Technician Supervisor Site Engineer/ Site In Charge 06-10-1403-IR-TW 7 Pipe to Cable connection by Pin Brazing 06-10-1403- DD-PH1 MH2145-C000-EL-SPC- 0025 RevA. Site Technician Supervisor Site Engineer/ Site In Charge 06-10-1403-IR-PB 8 Installation of Polarisation Cell 06-10-1403- DD-PH1 MH2145-C000-EL-SPC- 0025 RevA. Site Technician Supervisor Site Engineer/ Site In Charge 06-10-1403-IR-PC 9 Installation of Permanent reference cell 06-10-1403- DD-PH1 MH2145-C000-EL-SPC- 0025 RevA. Site Technician Supervisor Site Engineer/ Site In Charge 06-10-1403-IR-PR 10 Installation of Zinc Ribbon anode 06-10-1403- DD-PH1 MH2145-C000-EL-SPC- 0025 RevA. Site Technician Supervisor Site Engineer/ Site In Charge 06-10-1403-IR-ZN 11 Installation of ER probe 06-10-1403- DD-PH1 MH2145-C000-EL-SPC- 0025 RevA. Site Technician Supervisor Site Engineer/ Site In Charge 06-10-1403-IR-ER
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT
06-10-1403-DD-PH1, Rev-01 Page 94 of 113 21.0 RECORD OF CALIBRATION OF MEASURING INSTRUMENTS RECORD OF CALIBRATION PROJECT EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT OWNER HINDUSTAN PETROLEUM CORPORATION LIMITED. CONSULTANT WORLEYPARSONS SEA INDIA PVT. LTD. CONTRACTOR KSS PETRON PRIVATE LIMITED CP CONTRACTOR RAYCHEM RPG PVT. LTD. REF. DOC. MH2145-C000-EL-SPC-0025 RevA. REPORT NO. 06-10-1403-IR-CALR, DATE
Sr. No. Test Equipment Description Make/ Model No. / Sr. No. Calibrated By Calibration Certificate No. With Date Calibration validity period & Date Next Calibration due date Accepted Remarks Contractor WORLEYP ARSONS
Note: Ensure measuring / test equipment is sent to laboratory prior to expiry of present certificate
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT
06-10-1403-DD-PH1, Rev-01 Page 95 of 113 22.0 INTERFERENCE DETECTION AND MITIGATION Investigations shall be made for the following: The Stray current electrolysis of pipeline. The mutual interference between the HPCL pipelines to foreign pipelines and HPCL Pipelines to structures. The interference on foreign pipeline & structures, due to CP system anode bed. The AC induction on pipeline due to overhead HV/EHV line. The interference due to high voltage DC line, HVDC groundings, electric traction etc. AC voltage measurements shall also be made on the pipeline to find out continuous induction of voltage where transmission lines runs parallel within 25 m from the pipeline In case of induced voltage being measured beyond safe limits, the pipeline shall be grounded. Measurements including pipe/ structure to soil potential and pipe/ structure current etc. on the pipe/ structure being CP protected and on foreign pipelines/structures shall be made to investigate the current discharge and pickup locations. In case of fluctuating stray current resulting 100 mV potential shift or more necessary investigations shall be made continuously over a period of time. If required it should be done simultaneously at different locations to find out stray current source(s). For measurements over longer durations, data logger shall preferably be used. Where foreign pipelines (unprotected or protected by independent CP system) run in parallel to the pipeline in same trench or very near to the pipeline, and are not bonded to the pipeline then investigation shall be made for current discharge points on both the pipelines. Mitigation measures shall be provided depending on type stray current electrolysis/interference. These shall include installation of bond with variable resistor, diodes, installation of galvanic anodes for auxiliary drainage of current, adjustment/relocation (if possible) of offending interference source, provision of electrical shied etc. depending on the type of interference. Bonding with foreign pipeline/structure, as a mitigation measure shall be provided where the owner of the foreign pipeline/structure has no objection, otherwise alternative mitigation measure shall be provided. Where bonding is provided for mitigation, the bonding resistor shall be adjusted for optimum value for minimum/no interference. Galvanic anodes installed as a mitigation measure shall be sized for the design life specified for permanent CP.
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT
06-10-1403-DD-PH1, Rev-01 Page 96 of 113
22. 1 PROCEDURE FOR AC INTERFERENCE SURVEY a) Purpose This document describes the procedure for AC interference detection and mitigation measures where pipeline runs parallel or there is crossing of high-tension overhead lines of 66 kV and above. In order to minimize damage to the pipeline and reduce the electrical hazard to persons coming in contact with the pipeline. b) Scope This procedure covers the methodology of AC interference detection and mitigation measures to be taken due to nearby high-tension overhead lines of 66 kV and above. Note: During the construction of the pipeline safety measures have to be taken when work is carried out on the pipeline in the vicinity of high-tension overhead lines. The requirements for such safety measures require mainly the installation of a temporary earthing system. c) Equipment Digital Multimeters, Portable half -cell (Cu-CuSO 4 ). Metallic steel rod AC/DC clamp-on meter Earth resistance meter (Megger) Meter equipped with data logging of DC and/or AC potentials and currents d) Measurement Procedure Measurements to determine AC influencing shall be carried out after installation of the permanent impressed current system. Depending on results of measurements performed with ICCP system in operation, protective devices need to de installed to mitigate the AC interference. Measure the AC continuous potential (if present) at selected test stations using a suitable AC voltmeter and a metallic rod driven over the pipeline in order to get insight about the stray current interference and distribution along the inferred pipeline. The AC voltage shall be measured between the test lead connected to the pipeline and the metallic rod driven into the ground. Make a record of measurements results, date and time. At locations where maximum AC potential (in excess of 15 V AC) is measured the potential measurements with recording instruments shall be carried out over a period of 24 hrs. This measurement should also be carried out at selected locations as per the monthly monitoring reports & as decided by the client.
R-1
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EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT
06-10-1403-DD-PH1, Rev-01 Page 97 of 113 e) Mitigation measures If non-permissible touch voltages are measured, then the pipeline shall be grounded to an earthing system with polarisation cell. Alternatively, grounding can also be achieved by installation of galvanic anodes at the discretion of the owner. After the mitigation measures are carried out for installation of drainage system following procedure should be followed, in order to check the obtained mitigation. Measure and record the AC potential of the pipeline. Measure and record the DC potential of the pipeline. Measure the AC drainage current. If the grounding galvanic anodes have been installed, then DC anode current shall be measured.
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT
06-10-1403-DD-PH1, Rev-01 Page 98 of 113
INSPECTION REPORT FOR AC INTERFERENCE DETECTION AND MITIGATION. PROJECT EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT OWNER HINDUSTAN PETROLEUM CORPORATION LIMITED. CONSULTANT WORLEYPARSONS SEA INDIA PVT. LTD. CONTRACTOR KSS PETRON PRIVATE LIMITED CP CONTRACTOR RAYCHEM RPG PVT. LTD. REF. DOC. MH2145-C000-EL-SPC-0025 RevA. DATE: REF. DRG. - REPORT NO.
Sr. No. Ref. Electrode location (chainage) HPCL Pipeline HPCL Pipeline PSP Installed grounding anode current Measurement of AC Potential Measurement of AC Current With Cu/Cu SO 4
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT
06-10-1403-DD-PH1, Rev-01 Page 99 of 113
22. 2 PROCEDURE FOR DC INTERFERENCE SURVEY a) PURPOSE To describe the procedure for DC interference detection and mitigation measures, provide adequate quality assurance, and control of workmanship. Regarded are the mutual interference between the REWARI KANPUR PIPELINE and foreign pipelines /structures, interference on foreign pipelines/ structures due to the CP of the pipeline or ground bed, interference on metallic structures which lie in between REWARI KANPUR PIPELINE and ground bed or near to ground bed, interference due to high voltage DC lines, HVDC earthing system, electric traction, etc.
b) SCOPE This procedure covers the methodology of interference detection and mitigation measures to be taken for interaction of a. Foreign CP Systems onto the REWARI KANPUR PIPELINE. b. REWARI KANPUR PIPELINE CP System onto foreign pipelines c. Other DC Systems onto the REWARI KANPUR PIPELINE.
c) EQUIPMENT Digital Multimeters, Cu/CuSO 4 portable half-cells etc. Current interrupter Pipeline locator Meter equipped with data logging of DC potentials and currents.
d) CRITERIA TO LIMIT THE STRAY CURRENT INTERFERENCE i) GENERAL Any current flow that makes the pipe to Soil Potential more positive with respect to its surroundings is liable to accelerate corrosion. Therefore the PSP is used as the basis of assessment where in particular the positive changes in the PSP should be looked at. Negative changes in the PSP do not result in corrosion of the steel pipeline at that location. However, very negative changes in the PSP due to interference may indicate positive potential changes elsewhere in the pipe.
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EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT
06-10-1403-DD-PH1, Rev-01 Page 100 of 113 ii) CRITERIA A positive potential swing of 100 mV or more shall be considered sufficient to indicate the presence of an interaction/ interference situation requiring investigation and incorporation of mitigation measures. In rare circumstances, a minimum polarization shift of 100 mV may be accepted as an adequate level of cathodic protection for the pipeline with the approval of Owner. Negative potential shifts due to cathodic interference on a certain part of a structure (usually) imply that there exist other parts, which are subject to anodic interference. If very negative potential shifts (e.g. U > 500 mV, IR-drop included) are measured, it is recommended to identify areas with anodic potential shifts
MEASUREMENT PROCEDURE i) TEMPORARY CATHODIC PROTECTION The interference test should be carried out one month after putting the temporary cathodic protection into operation. Install a test station and make cable to pipe connections on REWARI KANPUR PIPELINE and foreign pipeline/pipelines as required. (The connection on foreign pipeline should be done with prior permission of foreign pipeline owner, as per approved procedure and in presence of foreign pipeline owner or his representative). Install a current interrupter in the nearest T/R unit circuit of the foreign pipeline and set the interrupter cycle to give 12 seconds ON and 3 seconds OFF. With the current interrupter operating measure ON and OFF potentials of REWARI KANPUR PIPELINE and foreign pipeline at the location crossings. Make a record and note down the results on an Inspection Report. During the measurements, the Cu/CuSO 4 portable half-cell is placed directly over the point of crossing/paralleling and as close as possible to the REWARI KANPUR PIPELINE The current of the foreign rectifier should be the maximum required during normal operating conditions. ii) PERMANENT CATHODIC PROTECTION A distinction is made between interference interactions of: a) Foreign CP System(s) onto the REWARI KANPUR PIPELINE b) REWARI KANPUR PIPELINE CP System onto foreign pipeline(s) c) Other DC Systems onto the REWARI KANPUR PIPELINE
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT
06-10-1403-DD-PH1, Rev-01 Page 101 of 113 The interaction test should be carried out 15 days after putting the permanent cathodic protection of REWARI KANPUR PIPELINE into operation. The interaction tests should be carried out at the locations where test stations have been installed for the cathodic protection system. INTERACTION FOREIGN CP SYSTEM (S) ONTO THE REWARI KANPUR PIPELINE Install a current interrupter in the nearest T/R unit circuit of the foreign pipeline/structure and set the interrupter cycle to give 12 seconds ON and 3 seconds OFF. With the current interrupter operating, measure ON and OFF potentials of REWARI KANPUR PIPELINE and foreign pipeline/structure at the location of pipeline crossings. During the measurements, the Cu/CuSO 4 portable half-cell is placed directly over the point of crossing/paralleling and as close as possible to the REWARI KANPUR PIPELINE The current of the foreign rectifier should be the maximum required during normal operating conditions. Make a record and note down the results on an Inspection Report format as enclosed.
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT
06-10-1403-DD-PH1, Rev-01 Page 102 of 113
INTERACTION REWARI KANPUR PIPELINE CP SYSTEM ONTO FOREIGN PIPELINE (S) This test should be carried out when required by foreign pipeline owners. Install a current interrupter in the nearest T/R unit circuit of the foreign pipeline/structure and set the interrupter cycle to give 12 seconds ON and 3 seconds OFF. With the current interrupter operating, measure ON and OFF potentials of REWARI KANPUR PIPELINE and foreign pipeline/structure at the location of pipeline crossings and nearby anode ground beds. Make a record and note down the results on an Inspection Report. During the measurements, the Cu-CuSO 4 portable half-cell is placed directly over the point of crossing/paralleling and as close as possible to the REWARI KANPUR PIPELINE The current of REWARI KANPUR PIPELINE rectifier should be the maximum required during normal operating conditions to give the level of protection for the REWARI KANPUR PIPELINE The normal protective potential shall be limited to 1.18 V (OFF). Only in exceptional cases when it is not feasible to achieve the 1.18 V, the extent of the more negative potential should be investigated and reviewed. INTERACTION OTHER DC SYSTEMS ONTO THE REWARI KANPUR PIPELINE When due to interference at locations DC potentials less negative than 0.9V(OFF) or more negative than 1.18 V (OFF) are measured continuously or with fluctuations, further measurements are necessary to find out the stray current source(s) and to investigate the current pickup and discharge locations. In case of non-fluctuating interference, structure-to-electrolyte potentials or voltage gradients in the electrolyte shall be measured while the stray current source is in and out of operation. The measured values during these two conditions shall be compared with each other. If the stray current source cannot be temporarily switched off, the interference should be extrapolated from tests made under different stray current source operation conditions. In case of fluctuating metal-electrolyte potentials, e.g. as a result of interference from a DC traction system, measurements shall be carried out over a period of 24hours using recording instruments preferably simultaneously at different locations. Record the measured values of the affected system and an operating parameter of the stray current source simultaneously to allow a clear association of the stray current source. Measure in both cases at selected test stations the structure-to-electrolyte potential (ON for REWARI KANPUR PIPELINE). Measure also the magnitude and direction of DC current flow
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT
06-10-1403-DD-PH1, Rev-01 Page 103 of 113 between the REWARI KANPUR PIPELINE and a coupon or metallic rod. When using a rod it shall be driven into the ground at pipeline depth. Make a record of measurements results, date and time. e) Mitigation measures Prior to the installation of mitigation measures, interference measurement results shall be provided to back up consultant for evaluation and recommendation of suitable mitigation measures. Connect a resistance bond between the REWARI KANPUR PIPELINE and foreign pipeline/ structure with prior written permission from the foreign pipeline/structure owner. Wherever bonding is provided for mitigation, the bonding resistor shall be adjusted for optimum value for minimum/no interference. In case owners of foreign pipelines/structures do not agree for bonding, for points having positive swings of 100mV or more on the REWARI KANPUR PIPELINE, sacrificial anodes shall be provided on the REWARI KANPUR PIPELINE of adequate size to last for the design life of the permanent CP System. Depending on the type of interference, suitable mitigation measures shall be provided: a. Bonding (direct/resistance with diodes) between pipelines/structure b. Provision of sacrificial anodes. c. Relocation (if possible) of offending interference source, anode ground bed or sacrificial anodes. d. Provision of electrical shield. Repeat the measurements described above to confirm that the interference is reduced to within acceptable limits. Make a record of all measurements using the Inspection Report format as enclosed. Note: Switching ON/OFF of foreign TRU shall be carried out after taking written consent of owner of foreign pipeline.
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
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06-10-1403-DD-PH1, Rev-01 Page 104 of 113 INSPECTION REPORT FOR DC INTERFERENCE DETECTION AND MITIGATION (INTERRUPTION OF FOREIGN PIPELINE CP) PROJECT EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT OWNER HINDUSTAN PETROLEUM CORPORATION LIMITED. CONSULTANT WORLEYPARSONS SEA INDIA PVT. LTD. MAIN CONTRACTOR KSS PETRON PRIVATE LIMITED CP CONTRACTOR RAYCHEM RPG PVT.LTD. REF. DOC. MH2145-C000-EL-SPC-0025 RevA. REF. DRG. - REPORT NO.
Sr. No. Ref. Electrode location (Chainage) PSP-Foreign P/L with CPS ON PSP- REWARI KANPUR PIPELINE with Mg Anode Connected Remarks Potential (V) Difference Potential (V) Difference ON OFF V ON OFF V
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06-10-1403-DD-PH1, Rev-01 Page 105 of 113 23.0 TESTING AND COMMISIONING a) Introduction The field Commissioning Procedure conforming to WORLEYPARSONS Specification lay down the General specifications for CP system testing, which will required to carry out to ensure the cathodic protection system is correctly installed. b) Instruments We shall provide all necessary instruments, equipment and labor to perform all the required checks and test. For this purpose, the following instruments shall be deployed at site: Copper/Copper sulfate reference half cells (Portable) High impedance multi meter Electricians Tools Kit Cable Testing Megger c) Electrical Facilities Before the electrical facilities are placed in operation, suitable tests to establish that all equipment, devices, wiring and connections have been properly installed and connected and are in good working condition for intended operation. d) Equipment A visual inspection of equipment/facility shall be carried out to detect any mechanical damage and for comparison and verification of dimensions and finish with drawings and specifications and as per agreed ITP being part of approved job procedures. Observations shall be recorded in the agreed formats. e) Installation As a part of the visual exercise impertion the complete installation shall be examined as follows: Correctness of Locations This shall be verified in respect of all important equipment namely: a) Anodes Ground Bed locations b) Cable routes c) Test station locations
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06-10-1403-DD-PH1, Rev-01 Page 106 of 113 f) Correctness of Civil/Mechanical Installation This shall involve checking the completeness of civil and mechanical work and correctness of alignment. Compliance with approved construction drawings and detailed notes appearing therein shall be verified. g) Equipment Test Before putting CP system in service for the first time all components shall be tested. Manufacturers instructions shall be followed, wherever applicable. h) Cables Check the correctness of termination and lug fixing Check the proper mark of cables and verify their compliance with design data. Check the continuity of each cable. Insulating Joint Check will be carried out by means of a voltmeter and a copper sulfate electrode. Measure the voltage on the side not affected by CP D.C. Source. Insulating joint shall be efficient if the potential on the unprotected side of the joint is maintained at a natural level. i) Anode Ground Bed Location of anodes shall be identified and ascertained with the help of the terminations in the Test Stations. j) Grounding Anodes Location Type/No. Of anodes. k) Polarisation Coupons Location Exposed area /Size of coupon Coupon to Soil ON and OFF potentials
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06-10-1403-DD-PH1, Rev-01 Page 107 of 113 j) Commissioning Procedure / Operating Tests The Natural pipe-to-soil potential shall be measured before energizing C.P. system using portable copper-copper sulfate half-cell as reference and a portable high impedance voltmeter. The voltmeter shall be connected through cables at test stations. The reference cell shall be placed on the ground right over the structure. All results shall be recorded on the test report. Format for recording commissioning observations The open circuit potential of anodes shall be recorded. The anodes shall be connected to the pipeline through the test station. The pipe to soil potentials (PSP) is measured after allowing pipe to polarise and shall be recorded in a tabular format. If the current output of the anodes at any of the installation is found to be more than the design current of anode, then variable resistors shall be provided to restrict the current output and have proper protection. Each anode ground bed installed shall become individually operational as above. The above procedure shall be carried out for all the galvanic anode ground beds as well as for the anodes installed for the casing pipe protection. Coupon to soil natural potential and Coupon Off potential shall be measured at the Locations of polarization coupon installation.
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
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06-10-1403-DD-PH1, Rev-01 Page 108 of 113 TCP COMMISSIONING FORMAT PROJECT EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT OWNER HINDUSTAN PETROLEUM CORPORATION LIMITED. CONSULTANT WORLEYPARSONS SEA INDIA PVT. LTD. CONTRACTOR KSS PETRON PRIVATE LIMITED CP CONTRACTOR RAYCHEM RPG PVT.LTD. REF. DOC. MH2145-C000-EL-SPC-0025 RevA. Date Report No.
Sr. No. TS NO. Chainage (km) Natural PSP (- Volts) Instant PSP (- Volts) Polarised PSP (24 hrs) (- Volts) Anode voltage (-Volts) Anode current (Amps) AC Voltage (Volts) Carrier Pipe PSP (Volts) Casing Pipe PSP (- Volts) Coupon Off Potential (-Volts) AC Current (grounding locations) Remarks
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06-10-1403-DD-PH1, Rev-01 Page 109 of 113 24.0 SYSTEM MONITORING The temporary C.P. system shall be monitored at all test stations once in a month for healthiness and adequacy of CP protection till commissioning of permanent CP system. At the location of polarization coupons, the ON and OFF potentials shall be measured by switching off the magnetic reed switch. The coupon OFF potentials shall be within (-) 0.90V to (-) 1.18V (OFF). During this period if any deficiency/interference is noticed in CP system it shall be rectified/ augmented by providing additional anodes as required. The monitoring report shall be submitted regularly to owner for his review/information
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
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06-10-1403-DD-PH1, Rev-01 Page 110 of 113 TCP MONITORING FORMAT PROJECT EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT OWNER HINDUSTAN PETROLEUM CORPORATION LIMITED. CONSULTANT WORLEYPARSONS SEA INDIA PVT. LTD.. CONTRACTOR KSS PETRON PRIVATE LIMITED CP CONTRACTOR RAYCHEM RPG PVT.LTD. REF. DOC. MH2145-C000-EL-SPC-0025 RevA. Date Report No.
Sr. No. TS. NO. Chainage (km) PSP (- Volts) Anode voltage (-Volts) Anode current (Amps) AC Voltage (Volts) Carrier Pipe PSP (Volts) Casing Pipe PSP (-Volts) Coupon Off Potential (-Volts) AC Current (grounding locations) Remarks
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT
06-10-1403-DD-PH1 Page 111 of 113 25.0 BILL OF MATERIAL SN Item Description Estimated Required Quantity 1 Anode Tail Cable From JB to Anode: 1C X 6 Sq mm, Copper Conductor, PVC/PVC, Un-Armoured(Yellow Colour) 4311 m 2 Potential Measurement Cable: 1C X 4 Sq mm, Copper Conductor, PVC( Aluminium backed by mylar/polyster tape shielded)/PVC, GI-Armoured screened Cable(Blue Colour) 6026 m 3 Reference cell Cable: 1C X 4 Sq mm, Copper Conductor, PVC( Aluminium backed by mylar/polyster tape shielded)/PVC, GI- Armoured screened Cable(Blue Colour) 360 m 4 Current Measurement Cable: 1C X 6 Sq mm, Copper Conductor, PVC/PVC, GI-Armoured(Black Colour) 2020 m 5 Anode Header Cable from test Sation to Buried JB: 1C X 10 Sq mm, Copper Conductor, PVC/PVC, GI-Armoured(Yellow Colour) 2227 m 6 Cathode Header Cable from test Sation to Pipeline: 1C X 10 Sq mm, Copper Conductor, PVC/PVC, GI-Armoured(Red Colour) 2485 m 7 Bonding & grounding Cable: 1C X 25 Sqmm, Copper Conductor, PVC/PVC, GI-Armoured(Black Colour) 648 m 8 Drain cable from CJB To Pipeline: 1C X 35 Sqmm, Copper Conductor, PVC/PVC, GI-Armoured(Red Colour) 80 m 9 Test Station-Normal Size 245 Nos. 10 Test Station-Big Size(Polarization Cell) 17 Nos. 11 Test Station-CP Staion 10 Nos 12 Test Station-CTSU Size 12 Nos 13 CTSU 12 nos 14 CTSU reader 2 Nos 15 Magnesium Anode (2.5 kg) 468 Nos. 16 Magnesium Anode (10 kg) for River Crossing 12 Nos
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT
06-10-1403-DD-PH1 Page 112 of 113 17 Zinc Anode (20 Kg) for MOV Grounding at SV Station 07 No. 18 Permanent Reference cell (Cu-CuSo4) for Polarisation Coupon, CTSU & ICCP System 36 Nos. 19 Polarisation Coupon 02 Nos. 20 ER Probe 02 Nos 21 ER Probe Reader 02 Nos 22 Zinc Ribbon Anode for HT line Crossing 150 m 23 Zinc Ribbon Anode for Carrier Pipe 187 m 24 Polarisation Cell-Solid state- (3.7 KA) 17 Nos. 25 Surge Diverter 05 Nos. 26 HDPE sheet As Required 27 Earthing of above ground unprotected Pipeline at Terminals by installing 100mm dia x 3mtr long GI pipe 5 set 28 Thermit Weld CA-15 1508 Nos. 29 Thermit Weld CA-32 77 Nos. 30 Gypsum 18802 Kg. 31 Bentonite 5014 Kg. 32 Sodium Sulphate 1253 Kg. 33 Dobofil 60 286 Kg. 34 Hardener 758 28 Kg. 35 M seal 229 Kg. Above quantities is tentative and for records only, Actual quantity and items may vary according to the site conditions.
DESIGN DOCUMENT FOR TEMPORARY CATHODIC PROTECTION SYSTEM FOR PHASE-I
EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT
06-10-1403-DD-PH1 Page 113 of 113 26.0 REFERENCE DRAWING LIST
Sr. No. Drawing Number Drawing details Rev 1 06-10-1403-TW THERMIT WELDING DETAILS 0 2 06-10-1403-PB STANDARD DRAWING FOR PIN BRAZING 0 3 06-10-1403-ER STANDARD DRAWING FOR INSTALLATION OF ER PROBE 0 4 06-10-1403-CLD STANDARD DRAWING FOR CABLE LAYING 0 5 06-10-1403-ZR-HT INSTALLATION DETAIL FOR ZINC RIBBON ANODE AT HT LINE 0 6 06-10-1403-CTSU CONNECTION SCHEME FOR COMPUTERIZED TEST STATION UNIT 1 7 06-10-1403-TSC STANDARD DRAWING FOR TEST STATION CONNECTION SCHEME (SHEET 1 TO 8) 0
8 06-10-1403-GAI STANDARD DRAWING FOR GALVANIC ANODE INSTALLATION 0 9 06-10-1403-PCC INSTALLATION DETAIL FOR POLARISATION COUPON 0 10 06-10-1403-TCP-SCH TCP SCHEMATIC DRAWING FOR REWARI KANPUR PIPELINE SECTION PHASE 1 ( SHEET 1 TO 3) 0