Cathodic Protection

Specification

LIST OF CONTENTS
1- SCOPE
2- DEVIATIONS
3- INDUSTRY
4- CATHODIC PROTECTION OF BURIED PIPELINES
A. GENERAL
B. DESIGN CRITERIA
5- THE SPECIFICATION
A. DC POWER SUPPLIES
B. ANODE BEDS
C. THE CABLES
D. TEST STATIONS
E. INSULATING MATERIALS
6- INSTALLATION
A. PIPELINE ISOLATION
B. ELECTRICAL CONTINUITY BONDING
C. TEMPORARY PROTECTION
D. IMPRESSED CURRENT ANODES
E. TRANSFORMER / RECTIFIER UNIT
F. DC CABLES
G. TEST STATIONS, ANODE JUNCTION BOXES AND CATHODE
JUNCTION BOXES
H. AC INTERFERENCE MITIGATION SYSTEM
7- COMMISSIONING AND INSPECTION
8- CATHODIC PROTECTION DOCUMENTATION FOR CUSTOMER
9- LIST OF APPLICATION DOCUMENTS
10- SHOP TEST AND INSPECTION
11- CONDITIONS FOR SUPPLYING & CONSTRUCTION SOLAR
CATHODIC PROTECTION STATION.

1- Scope:
This specification covers the minimum technical requirements covering the
design and installation of cathodic protection systems for buried pipelines.
Structures which shall be cathodically protected are:
a. underground pipes
b. buried steel valves
c. Crossing of: rivers, roads, and railway.
d. Crossing or parallel of existing pipelines.
2-Deviations:
Any deviation providing less than the minimum requirements of this standard
specification requires written approval from the engineer representative.
3- Industry standards, codes and references:
Those documents listed herein are guidelines or practice intended to
establish

a basis of design and level of quality to be applied to

develop standards for cathodic protection system as supplemented by

this standard specification which are mandatory .
CP- 1021: code of practice for cathodic protection by the British standard
institute.
NACE: National association of corrosion engineers.
ASTM, UL83, UL 486A, ANSI, DIN, NEC, NEMA,EPRIEL-904,CSAC22-3
NO.6-M91.
4- Cathodic protection of buried pipelines;
a. General:
The design shall be prepared by the contractor in details and shall include
the following:
1) Design basis and design calculations.

(2) Soil resistively survey (on the pipelines rout and for ground bed
locations) shall be made including evaluation and shall be used for
cathodic protection design.
(3) Detailed engineering design and construction drawings.
(4) Technical satisfactions for materials and equipments of construction,
Transformer/Rectifiers, anodes and assembly, junction boxes, test
stations, cables, insulating Flanges or joints and other items as required.
(5) Operation manual, including test and adjustment procedures.
b- Design criteria:
1. Buried pipelines shall be cathodically protected with impressed current
systems.
2. The impressed current cathodic protection systems shall utilize surface
ground beds when applicable.
3. Galvanic anodes shall be installed for buried pipeline at cased
road crossings, buried valves.
4. Temporary protection must be employed during construction.
5. The design life of the cathodic protection systems shall be (20) years.
6. The system design requirements shall provide current density values
after putting Detail soil resistivity survey, type of coating and natural
potential (steel - to- soil) Survey, for
densities

maybe

required so

as

the

total

pipeline, current

to achieve minimum (-0.9 v)

guaranteed negative pipe - to - soil potentials. The calculations shall

be taken in the considerations the existing pipe lines (crossing and
parallel) to the new pip .
7. Cathodic protection power supplies shall be installed at intervals
along the pipelines so as to achieve the maximum potential at
the drainage point shall be (-1.7v) with reference to ( Cu . / CuSo 4 )
R

half cell.

4- The specifications:
A- DC power supplies:
Transformer / Rectifier units:
Oil immersed transformer / rectifier units, in accordance with general
specifications The specification describes the requirements for an oil cooled
transformer - rectifier For powering a cathodic protection system.
a. Catalog cuts
Manufacturers, catalog cuts for each T/R unit supplied will include
information to verify that the materials meet the requirements of project
drawings and specification.
b- Rectifier operation and maintenance manual.
i-

The manufacturer will include a complete operation and maintenance

manual with each rectifier.

ii The manual will outline operating instructions, a circuit diagram, a

spare part list.
iii- The rectifier will be operated under full load conditions at the factory
and be thoroughly inspected and tested prior to delivery to the job
site.
iv- Results of this testing will be provided on quality control form in the
operation manual.
v-

Manufacturers shall provide certificates that all the components of

the cathodic protection T/R meet the requirements and all materials,
fabrication and installations are subjected to inspection and testing.

c- Oil cooled T/R

- T/R will be oil cooled, tap adjusted custom model.
- Rectifiers will be capable of supplying continuous, full rated output, in full
sunlight.

- AC input 220v, 50Hz, full rated DC output shall be obtainable with an AC

input voltage at 5% below the nominal value.
- Continuous AC input voltage at 10% above nominal will not damage the
transformer, the diode bridge assembly or exceed any component ratings.
- Units will be oil cooled, cabinets will be sealed in accordance with / NEMA
250.
- Constant voltage control, by means of steps (5- Course, 5 Fine).
- Silicon diode Rectifying elements, full wave bridge, protected by
semiconductor. Fuses, surge arrestors at the diode bridge.
- AC circuit Breakers.
- Separate AC and DC surge protection.
- IP 55 min (with CSA, NEMA).
- Analog ammeter and voltmeter.
- Floor - mounted.
B Anode beds:
i- Anode beds shall be sized to discharge (120%) to the rated current
capacity of the DC power source and shall be designed to achieve the
following overall circuit resistances:
- Transformer / rectifier system shall have an overall circuit resistance
of less than (1) ohm and the maximum system operating voltage
shall be less than (60v).
- Back fill resistance will not be greater than (0.5) ohm.
ii- surface ground bed shall be used when soil resistivity is compatible with
system design requirements, deep well beds shall be used in high
resistivity surface soil .
iii- The minimum anode bed (surface anode or deep anode bed) distances
from the pipeline or adjacent structures depend on anode bed discharged
current capacity .

v- Anode material shall be selected from standard specification for cathodic

protection anodes.
1.Impressed current anodes:
1. Mixed metal oxide anode
- The anode shall be mixed metal oxide coated titanium tubes with 32 mm
(1.25- inch) diameter 1219 mm (48- inch) length.
- The anode shall be grade 1 / or 2 titanium per ASTM B -339.
- The minimum size anode wires is 10 mm2 strand copper conductor
P

HMWPE insulation.
2. Galvanic Anodes:
(1) Upon completion of the detailed design, specify the following items:
- Type of anode material.
- Number of anodes.
- Net anode material mass.
- Approximate anode weight and dimensions.
- Ampere year requirement.
- Anode (installation, erection, mounting) details.
C. The Cables:
Stranded copper conductor, (600/1000) v, cables shall be sized to carry the
maximum designed current load of the circuit and to have maximum voltage
drop of (5%) of the rated output voltage for rectifier systems.
1- Positive cable from the anode junction box to the positive terminal
rectifier shall be, single conductor, strand copper HMWPE insulation.
2- Negative cable from negative terminal of the rectifier unit to the pipe line
being protected shall be single conductor, strand copper with medium
density, HMWPE insulation.

D- Test stations:
1- Potential test stations:
Test stations consist of test wires, a terminal box and a traffic box as
follows:
a- for the terminal box, use a five terminal Big Fink, mount on a 1.52 m
length of 76.2 mm diameter UV- Resistant plastic.
b- Pole mounted. Herein a guideline to establish a basis of design and
level of quality to be applied:
1. Test station for measuring (pipe - to - soil) potential shall be provided
at an interval of not more than one kilometer along the pipeline.
2. Test station for measuring (pipe to soil ) potential shall be provided
and installed at the following locations:
Pipeline insulated cased crossings.
cased road crossing.
Insulating joint or flanges.
Close foreign structures.
And at other locations as required by O.P.C representatives.
3- If the test locations are covered with pavement, soil access manholes or
(Cu/CuSo4) Long life reference cells which are permanently installed in
the soil shall be provided.
4- Minimum conductor size for test station shall be (6) sq. mm.
5- During installation and construction, maintain as built drawings of the
corrosion Control test stations.

2- Bond and compensating stations:

a. Electrical (metallic) continuity of the pipeline must be insured
b. Electrical bonds shall be provided for electrical continuity to prevent
interference.
All bond terminations shall be made above grade in an approved
electrical enclosure.

c. Bond conductors shall be sized to carry the rated design current of the
bond box Minimum conductor size shall be (35) sq. mm. Strand copper
cable.
d. Bonding shall be provided at all locations where buried metallic pipelines
cross each Other.
e. Compensating current limitation unit for parallel pipelines.
3- Anode junction boxes
a. All cables inside anode lead junction boxes shall be identified with a
permanent and durable tag indicating the anode or the structure to
which they are connected. Nameplates shall also be affixed on all boxes
to indicate the type of service; anode Lead junction boxes shall also
indicate the rectifier unit to which they are connected.
b. junction boxes shall be located in non hazardous areas whenever
practical.
c. junction boxes shall be located in readily accessible areas and at a
height for easy Inspection and maintenance.
4- Cathode junction boxes:
This junction box is used as compensating current limitation unit which
facilitates the adjustment of current in each pipeline circuit, prevents the flow
of uncontrolled circulating current between pipelines and uniform potential
levels.
E. Insulating materials:
1. Pipe shall be electrically isolated by insulating flanges at upstream &
downstream location. Full Faced E type.
2. Insulating flange kits will be utilized consist of:
a. Gasket
- Retainer phenolic
- seal Nitrile

b- Sleeves and washers

- sleeve mylar
- Washer phenolic
- Steel washer
o Insulating flange sets shall not be installed in buried portion of
pipeline.
o All locations where isolation of underground protected structures
from over ground structures is required.
o Surge diverters shall be used across each insulating joint or flange.
o Each insulating joint shall be megger - tested with (1000) VDC.
5- Installation:
a. Pipeline isolation: In accordance to standards.
b. Electrical continuing bonding: In accordance to standards.
c. Temporary protection: In accordance to standards.
a. Impressed current anodes
i. General:
1. All anodes shall be installed in sequential order. Cables shall be durably
tagged to indicate the anode number at the termination point inside the
anode lead junction box.
2. Anode cables shall be (100%) holiday free.
3. Repaired anodes and repaired anode - to - cable connections shall not
be used.
ii. Surface anode beds:
Anode number (1) shall be the farthest anode on the right hand side when
facing the anode lead junction box.

iii. Back fill :

For impressed current anodes shall utilize coke breeze backfill, maximum
resistivity (50) ohm cm, and for galvanic anodes shall utilize bentonite
mixture, maximum resistivity (100) ohm- cm.
iv. Anode back fill coke breeze shall conform to the following:
- Typical chemical analysis carbon (fixed) 99, 77% Ash 0.1%.
- Density: 1121 kg /m3.
P

- Dust free with max particle size of (1) mm.

b. Transformer / rectifier unit
i. If the positive cable insulation is damaged at or below ground level, it
shall be replaced.
ii. AC power input to the rectifier shall be circuit breaker; the current rating
of the protective device shall be a minimum (125%) of the rectifier input
current at rated load.
iii. Fencing: transformer/rectifiers installation shall be protected from
damage (vandalism) by being placed in a security fenced enclosure.
c. DC cables:
i. Negative DC and positive anode cables shall be laid in a padding of
sand at least (10) Cm thick in a trench at least (60) Cm deep. They
shall be covered with at least (10) Cm of soft earth padding and the
trench fully backfilled.
ii. Main cables from rectifiers to anode terminal boxes and cathode
junction boxes shall be run in continuous (uncut) lengths.
iii. All negative drain cable connections to steel pipes and structures shall
be made using thermit welds.

d. Test stations, anode junction boxes and cathode junction boxes

i.

All test station shall be installed and completed after the pipeline
backfilling operation.

ii. Cables inside test stations, anode junction boxes and cathode junction
boxes shall be identified with durable tag and labeled.
e. Cased crossing:
Casing insulators and end seals to be installed on any carrier pipe passing
through a pipe casing. They are designed to protect the carrier pipe coating
and electrically isolate the carrier pipe.
i. Casing spacers:
- Wooden skids are not acceptable as an alternative.
- Use injection molded PE insulators.
ii. Casing end seals:
- use hard rubber seals.
iii. Test stations are to be installed to allow testing of electrical isolation of the
casing and carrier pipe, the test station type is post mounted including:
- Pipe line wire for potential testing (2)
- Casing wire for potential testing (2)
- AC interference mitigation system.
7- Commissioning and inspection:
Cathodic protection systems pre-commissioning and commissioning tests in
accordance with: API, IEEE, NACE, NEPA, EPRIEL 904,CSAC22-3 NO.6M91.

8- Cathodic protection documentation:

a. C.P system design and calculations .
b. C.P system key diagrams.
c. C.P station layout cathodic protection equipment and materials
specifications.
d. C.P system installation specifications .
e. Manufacturers

drawing

and

documentation

including

shop

test

certificates.
f. C.P system on site test report.
g. All electrical and cathodic protection construction drawings.
h. All equipment catalogues, instruction, operation and maintenance
manuals.
i. List of the tests to be carried out on each component with details of test
procedure.
j. Proposed test data records forms.
9- List of application documents.
10- Shop test and inspection:
According to manufacturer routine tests and third party approval.
11- Conditions for Supplying and Construction Solar Cathodic
Protection Station:
Bidders must make a full survey for the whole route of the pipeline to

measure soil resistivity for design purposes and determining Cathodic

Protection station locations and all accessories shall get approval
from authorized O.P.C. Engineer.
Installing Solar Cathodic Protection station on the whole pipeline

routes except Nassriyah and Khor Al Zubair depots because the

electrical energy sources supplies are already available there.

 Building rooms for Batteries units' and also all accessories, Building

service room for guarders in far away areas to protect the system from
vandalism actions and construct BRC fence surrounded the whole
systems.
Bidders shall submit detailed technical offer for Solar Cathodic

Protection station and all relevant accessories.

Origin for the whole system of Solar Cathodic Protection station shall

be from (USA, Germany, Norway, Netherlands, France, and UK).

Contractor shall bear all expenses of a complete training program for

engineers and technicians for Five (5) persons and for ten (10) days
in the origin country include factory visit and training on maintenance
the Solar Cathodic Protection station.