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00 15/04/2014 ISSUED FOR APPROVAL



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
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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

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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



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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.

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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


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SN Terms Description
21 mV Milivolts
21 m2 Square meter
22 mg miligrams
23 Amps Ampere
24 PSP Pipe to Soil potential
25 CPS Cathodic Protection Station
26 HPCL Hindustan Petroleum Corporation Limited
27 KazStroy KSS Petron Private Limited
28 Raychem RPG Raychem RPG Pvt. Ltd.

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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


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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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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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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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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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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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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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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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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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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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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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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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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.
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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

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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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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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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





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The surface area & current requirement calculations are tabulated as under:

Chainage
(km)
Dia.
(m)
Pipeline
Length (m.)
Surface Area
(m
2
)
Current
Density (mA/m
2
)
Current Required
(Amps)
0.577 0.457 27 38.76 0.055 0.0028
3.387 0.457 74 106.24 0.055 0.0076
10.747 0.457 18 25.84 0.055 0.0018
22.865 0.457 18 25.84 0.055 0.0018
33.876 0.457 25 35.89 0.055 0.0026
62.608 0.457 32 45.94 0.055 0.0033
82.564 0.457 14 20.10 0.055 0.0014
92.680 0.457 20 28.71 0.055 0.0021
98.076 0.457 35 50.25 0.055 0.0036
99.961 0.457 22 31.59 0.055 0.0023
122.770 0.457 17 24.41 0.055 0.0017
127.241 0.457 16 22.97 0.055 0.0016
136.215 0.457 22 31.59 0.055 0.0023
140.377 0.457 36 51.69 0.055 0.0037
141.917 0.457 55 78.96 0.055 0.0056
158.440 0.457 30 43.07 0.055 0.0031
161.957 0.457 30 43.07 0.055 0.0031
162.348 0.457 47 67.48 0.055 0.0048
163.166 0.457 47 67.48 0.055 0.0048
164.684 0.457 47 67.48 0.055 0.0048
165.712 0.457 47 67.48 0.055 0.0048
216.460 0.457 74 106.24 0.055 0.0076
226.000 0.457 29 41.64 0.055 0.0030











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06-10-1403-DD-PH1, Rev-01 Page 29 of 113
iii) Anode required by weight



Where:
W
t
= Weight of anode required (kg)
I
t
= Current requirement (Amps)
C
t
=

Consumption rate of anode

(11.24 Kg/Amp-Year)
L = Design Life (35 years)
U
f
= Anode Utilisation factor (0.5)

Type of anode: Zinc Ribbon Anode
Total
current
required
(Amps)
Anode
Weight as per
design (Kgs)
Weight
Of Anode
per mtr.
Total Length of
Anode required as
per design (m)
Individual length
of Anode proposed
(Between 2 spacer)
(m)
Total Length of Ribbon
proposed considering
1no zinc ribbon in
between 2 spacer (m)
0.0028 2.18 0.850 2.57 0.48 6.46
0.0076 5.98 0.850 7.03 0.48 17.71
0.0018 1.45 0.850 1.71 0.48 4.31
0.0018 1.45 0.850 1.71 0.48 4.31
0.0026 2.02 0.850 2.38 0.48 5.98
0.0033 2.58 0.850 3.04 0.48 7.66
0.0014 1.13 0.850 1.33 0.48 3.35
0.0021 1.62 0.850 1.90 0.48 4.79
0.0036 2.83 0.850 3.33 0.48 8.37
0.0023 1.78 0.850 2.09 0.48 5.26
0.0017 1.37 0.850 1.62 0.48 4.07
0.0016 1.29 0.850 1.52 0.48 3.83
0.0023 1.78 0.850 2.09 0.48 5.26
0.0037 2.91 0.850 3.42 0.48 8.61
0.0056 4.44 0.850 5.23 0.48 13.16
0.0031 2.42 0.850 2.85 0.48 7.18
0.0031 2.42 0.850 2.85 0.48 7.18
0.0048 3.80 0.850 4.47 0.48 11.25
0.0048 3.80 0.850 4.47 0.48 11.25
0.0048 3.80 0.850 4.47 0.48 11.25
0.0048 3.80 0.850 4.47 0.48 11.25
0.0076 5.98 0.850 7.03 0.48 17.71
0.0030 2.34 0.850 2.76 0.48 6.94
Total 187.12

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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.


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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:


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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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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.

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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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EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT

06-10-1403-DD-PH1, Rev-01 Page 36 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.)
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

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 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



EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT

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

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 39 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.)
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


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 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

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 41 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.)
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

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 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

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 43 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.)
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


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 44 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.)
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

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 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


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 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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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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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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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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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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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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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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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

RAYCHEM RPG WORLEYPARSONS KSS HPCL
Name: Name: Name: Name:
Sign: Sign: Sign: Sign:
Date: Date: Date: Date:

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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

Cable entry sealing
Cable Termination
NOTES:



RAYCHEM RPG WORLEYPARSONS KSS HPCL
Name: Name: Name: Name:
Sign: Sign: Sign: Sign:
Date: Date: Date: Date:



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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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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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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


RAYCHEM RPG WORLEYPARSONS KSS HPCL
Name: Name: Name: Name:
Sign: Sign: Sign: Sign:
Date: Date: Date: Date:
R-1

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06-10-1403-DD-PH1, Rev-01 Page 58 of 113

INSTALLATION REPORT 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.
WORLEYPARSON
S STD. DWG
2-D-103-106-MG 2.5 KG/ 2-D-107-MG 20-10KG
REF. DRG.

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)

PSP w.r.to Cu/CuSO
4
Ref.
Cell (Before Connecting Anode)

PSP w.r.to Cu/CuSO
4
Ref. Cell
(After Connecting Anode)

Instrument Details (Make/ model / Sr. No.) Calibration certificate. No. & validity

RAYCHEM RPG WORLEYPARSONS KSS HPCL
Name: Name: Name: Name:
Sign: Sign: Sign: Sign:
Date: Date: Date: Date:


R-1

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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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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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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

RAYCHEM RPG WORLEYPARSONS KSS HPCL
Name: Name: Name: Name:
Sign: Sign: Sign: Sign:
Date: Date: Date: Date:


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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



RAYCHEM RPG WORLEYPARSONS KSS HPCL
Name: Name: Name: Name:
Sign: Sign: Sign: Sign:
Date: Date: Date: Date:


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

RAYCHEM RPG WORLEYPARSONS KSS HPCL
Name: Name: Name: Name:
Sign: Sign: Sign: Sign:
Date: Date: Date: Date:


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 65 of 113
INSTALLATION REPORT 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.
REPORT NO.
06-10-1403-IR-SD,
WORLEYPARSON
S STD. DWG
-

REF. DRG. - DATE

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




RAYCHEM RPG WORLEYPARSONS KSS HPCL
Name: Name: Name: Name:
Sign: Sign: Sign: Sign:
Date: Date: Date: Date:


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

RAYCHEM RPG WORLEYPARSONS KSS HPCL
Name: Name: Name: Name:
Sign: Sign: Sign: Sign:
Date: Date: Date: Date:

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

RAYCHEM RPG WORLEYPARSONS KSS HPCL
Name: Name: Name: Name:
Sign: Sign: Sign: Sign:
Date: Date: Date: Date:


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

RAYCHEM RPG WORLEYPARSONS KSS HPCL
Name: Name: Name: Name:
Sign: Sign: Sign: Sign:
Date: Date: Date: Date:

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

RAYCHEM RPG WORLEYPARSONS KSS HPCL
Name: Name: Name: Name:
Sign: Sign: Sign: Sign:
Date: Date: Date: Date:

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

RAYCHEM RPG WORLEYPARSONS KSS HPCL
Name: Name: Name: Name:
Sign: Sign: Sign: Sign:
Date: Date: Date: Date:


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 77 of 113

INSTALLATION REPORT 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.
WORLEYPARSONS
STD. DWG
-
REF. DRG. 06-10-1403-PCTS
REPORT NO. 06-10-1403-IR-PC, DATE

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

Make Date of Calibration



RAYCHEM RPG WORLEYPARSONS KSS HPCL
Name: Name: Name: Name:
Sign: Sign: Sign: Sign:
Date: Date: Date: Date:




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
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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

RAYCHEM RPG WORLEYPARSONS KSS HPCL
Name: Name: Name: Name:
Sign: Sign: Sign: Sign:
Date: Date: Date: Date:

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 81 of 113

INSTALLATION REPORT 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.
REPORT NO.
06-10-1403-IR-PR
WORLEYPARSONS
STD. DWG
2-D-PCP-SCH
REF. DRG. - DATE

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



RAYCHEM RPG WORLEYPARSONS KSS HPCL
Name: Name: Name: Name:
Sign: Sign: Sign: Sign:
Date: Date: Date: Date:


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

RAYCHEM RPG WORLEYPARSONS KSS HPCL
Name: Name: Name: Name:
Sign: Sign: Sign: Sign:
Date: Date: Date: Date:

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 84 of 113

INSTALLATION REPORT 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
WORLEYPARSONS
STD. DWG
2-D-106-P COUP TS
REPORT NO. 06-10-1403-IR-PCC DATE

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


RAYCHEM RPG WORLEYPARSONS KSS HPCL
Name: Name: Name: Name:
Sign: Sign: Sign: Sign:
Date: Date: Date: Date:




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

RAYCHEM RPG WORLEYPARSONS KSS HPCL
Name: Name: Name: Name:
Sign: Sign: Sign: Sign:
Date: Date: Date: Date:


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 87 of 113

INSTALLATION REPORT 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.
REF. DRG. 06-10-1403-ZR-HT
WORLEYPARSON
S STD. DWG
2-D-115-Z RIB HT
REPORT NO. 06-10-1403-IR-ZN, DATE

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


RAYCHEM RPG WORLEYPARSONS KSS HPCL
Name: Name: Name: Name:
Sign: Sign: Sign: Sign:
Date: Date: Date: Date:


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 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.


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 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

RAYCHEM RPG WORLEYPARSONS KSS HPCL
Name: Name: Name: Name:
Sign: Sign: Sign: Sign:
Date: Date: Date: Date:

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 90 of 113

INSTALLATION REPORT 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
WORLEYPARSON
S STD. DWG
-
REPORT NO. 06-10-1403-IR-ER, DATE

ER Probe Sr. No.

Test Station Location

Test Station No.

ER Probe Condition OK/ NOT OK
Depth of ER Probe Installation Mtrs
Distance from Pipeline Mtrs
Cable Termination in Test Station

OK/ NOT OK
Notes:


RAYCHEM RPG WORLEYPARSONS KSS HPCL
Name: Name: Name: Name:
Sign: Sign: Sign: Sign:
Date: Date: Date: Date:

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 91 of 113
19.0 INCOMING MATERIAL INSPECTION REPORT
INCOMING MATERIAL INSPECTION REPORT
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. -

REPORT NO. 06-10-1403-IR-IMIR, JOB NO. DATE

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

RAYCHEM RPG WORLEYPARSONS KSS HPCL
Name: Name: Name: Name:
Sign: Sign: Sign: Sign:
Date: Date: Date: Date:

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 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



DESIGN DOCUMENT FOR TEMPORARY
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PHASE-I



EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT

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
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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

RAYCHEM RPG WORLEYPARSONS KSS HPCL
Name: Name: Name: Name:
Sign: Sign: Sign: Sign:
Date: Date: Date: Date:

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

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 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
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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

Difference
(V) (Amp) DC (V) (mA)
1
2
3
4
5
6
7


RAYCHEM RPG WORLEYPARSONS KSS HPCL
Name: Name: Name: Name:
Sign: Sign: Sign: Sign:
Date: Date: Date: Date:





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.


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 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



EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT

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








RAYCHEM RPG WORLEYPARSONS KSS HPCL
Name: Name: Name: Name:
Sign: Sign: Sign: Sign:
Date: Date: Date: Date:






























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 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




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 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

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 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



EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT

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









RAYCHEM RPG WORLEYPARSONS KSS HPCL
Name: Name: Name: Name:
Sign: Sign: Sign: Sign:
Date: Date: Date: Date:
R-1

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 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



EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT

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








RAYCHEM RPG WORLEYPARSONS KSS HPCL
Name: Name: Name: Name:
Sign: Sign: Sign: Sign:
Date: Date: Date: Date:

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

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