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ILF-SPC-SRT-EL-810-0

THE HASHEMITE KINGDOM OF JORDAN


MINISTRY OF ENERGY AND MINERAL
RESOURCES

Amman Strategic Reserve


Terminal for Petroleum Products
CATHODIC PROTECTION
SPECIFICATION
07.11.2013

ILF CONSULTING ENGINEERS

Werner-Eckert-Str. 7, 81829 Munich,


GERMANY
Phone: +49-89-25 55 94 - 0
Fax:
+49-89-25 55 94 - 144
E-mail: info.muc@ilf.com

A m m a n S t r a t e g i c R e s e r ve T e r m i n a l for Petroleum Products


C a t h o d i c Protection
Specification

ILF-SPC-SRT-EL-810-0
07.11.2013

REVISION

7.11.2013 Approved

V.S.

P.B.

S. B.

4.10.2013 Issue for Review

V.S.

P.B.

S. B.

10.09.2013 Issue for IDC

V.S.

P.B.

S. B.

Prepared

Checked

Approved

Rev.

Date

Issue, Modification

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C a t h o d i c Protection
Specification

ILF-SPC-SRT-EL-810-0
07.11.2013

TABLE OF CONTENTS
1

GENERAL

1.1

Purpose of the Document

DEFINITION AND ABBREVIATION

2.1

Definition

2.2

Abbreviations

STANDARDS

ENVIRONMENTAL CONDITIONS

GENERAL REQUIREMENTS

5.1

Components and Equipment

5.2

Tagging

5.3

Description of Operation

5.4

Design requirements

5.5

Survey

EQUIPMENT

6.1

Rectifiers

6.2

Anodes and Anode Groundbeds

6.3

Test Stations

6.4

Reference Electrodes

6.5

Coupons

6.6

Distribution Boxes

10

REMOTE MONITORING

10

WIRING

10

CABLES AND CABLE LAYING

11

10

PAINTING

11

11

PRE-COMMISSIONING

11

12

COMMISSIONING

12

13

TESTS

13

14

ADDITIONAL INFORMATION

13

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C a t h o d i c Protection
Specification

GENERAL

1.1

Purpose of the Document

ILF-SPC-SRT-EL-810-0
07.11.2013

This specification defines the minimum requirements for the design, manufacturing, construction, installation, testing and commissioning of the terminal cathodic protection system for the new Amman Strategic Reserve Terminal for Petroleum Products.

DEFINITION AND ABBREVIATION

2.1

Definition
In the present document the following definitions were used. Their meaning is explained
in the table below.

2.2

Definition

Explanation

Client

MEMR - Ministry of Energy and Mineral Resources

Engineer

The engineering company entrusted with the project


management and construction supervision of the project
(ILF Beratende Ingenieure GmbH, Munchen).

Contractor

The company or group of companies entrusted by the


Client with Engineering, Procurement and Construction of
the project.

Terminal

The whole terminal within the limits defined on the Station


Layout Plan.

Abbreviations
Abbreviation

Explanation

BS

British Standart

API, NEC

American Petroleum Institute, National Electrical Code

IEC

International Electrotechnical Commission

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Specification

ILF-SPC-SRT-EL-810-0
07.11.2013

STANDARDS
The design, manufacturing, construction, installation, testing and commissioning of terminal cathodic protection systems shall be in accordance with the relevant codes, standards, rules and regulations as listed below, all in latest valid edition.
The following standards shall be applied, at least:
API RP 540

Electrical Installations in Petroleum Processing Plants

API RP 500

Explosion proof equipment in hazardous areas to suit area


classification.

94/9/EG (ATEX 95)

Equipment and protective systems intended for use in


potentially explosive atmospheres

EN 12954

Cathodic protection of buried or immersed metallic


structures

ANSI/API RP651

Cathodic protection of above ground petroleum storage


tanks.

BS 7561

Cathodic protection code of practice for land and marine


applications.

EN 14505

Cathodic protection of complex structures

EN 13509

Cathodic protection measurement techniques

IEC 60947

Low-Voltage Switchgear and Controlgear

As far as the energy provider or permits of other authorities require additional codes and
standards, respectively impose additional requirements, these are also part of the contract.
In the case of the conflict between the various codes, standards and order, the most
stringent of the requirements shall generally govern. The Contractor shall refer any such
conflict and any other matter to the attention of the Engineer and Clients, whose interpretation shall be final.
All conflicts between the requirements of this specification, contract documents, data
sheets, or drawings shall be referred to Engineer for clarification before proceeding with
the fabrication of the affected parts.

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Specification

ILF-SPC-SRT-EL-810-0
07.11.2013

ENVIRONMENTAL CONDITIONS
The cathodic protection system components shall be designed and constructed for continuous operation at full load under the climatic and environmental conditions as described in the specification Design and Construction of Power Supply Systems.

GENERAL REQUIREMENTS

5.1

Components and Equipment


It is required that all components and equipment are selected considering easy maintenance, simple and quick diagnosis and long maintenance intervals.

5.2

Tagging
All components, equipment and installations shall receive the respective tagging plates,
labels, etc., which have to be of extremely durable material resistant against the environmental conditions. Tagging plates or labels on fronts of enclosures shall be fixed with
screws.

5.3

Description of Operation
The terminal cathodic protection system shall increase the local ground potential in the
vicinity of underground metallic structures. The minimum potential shift shall be at least
the value of the free corrosion potential while impressed current is being applied. This is
equivalent to the decreasing the metallic underground structures potential.
Corrosion protection is achieved when the following criteria are achieved:

An ON potential equal to or more negative than UCu/CuSO4 = -1.2 V against the surrounding soil shall be achieved on the surface of metallic underground structures.

An ON potential equal to or more negative than UCu/CuSO4 = -0.8 V is acceptable in


the vicinity of reinforced concrete foundations, entries or earthing systems if test
probes or coupons are used for verification. At such test stations an OFF potential
of UCu/CuSO4 = -0.85 V or lower is mandatory.

While current is switched on a negative shift from the free corrosion potential by at
least 0.3 V indicates that probably sufficient current is entering the metallic underground structures.

The service life time of the terminal cathodic protection systems shall not be less than
forty (40) years. For anodes a life time of twenty five (25) years will be accepted.

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5.4

ILF-SPC-SRT-EL-810-0
07.11.2013

Design requirements
All underground steel pipes and other underground metallic structures of a station
(incl. grounding network, reinforcements, etc.) shall be protected by using a separate
terminal cathodic protection system.
The cathodic protection system shall mainly consist of the following parts:

rectifier unit for anodes,

single anodes,

anode distribution box,

minus connection on pipes and metallic structures,

potential measuring connections (including reference electrodes),

distribution boxes,

cables and cable connections.

In order to increase the negative pipe protective potential distributed anodes will be installed within the station. The anodes shall be fed via an anode distribution box
The potential test stations shall be placed at suitable locations within the station area.
5.5

Survey
A soil resistivity measurement shall be carried out within the station using the Wenner
four-pin method and/or any other approved measurement technique. The measurement
shall be included in a table. In addition to the measurements the following data shall be
recorded:

date,

measuring method,

soil conditions,

weather condition,

other special conditions.

EQUIPMENT

6.1

Rectifiers
All cathodic protection transformer/rectifiers shall be designed for indoor application installed in metal enclosed cabinets with hinged doors. The degree of protection for the

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ILF-SPC-SRT-EL-810-0
07.11.2013

cabinets shall be minimum IP42. All instruments shall be readable without the need to
open the door. Therefore, a glazed door with safety glass shall be used. A client approved locking system shall be delivered.
Variable potentiometer for calibration of the anode currents, power terminals as well as
terminals for anodes, reference cells, pipe connections and remote monitoring shall be
included in the cabinets.
The rectifier units will be fed from the 400/230 V 50 Hz bus of Secondary Power Supply
System.
The size of the rectifiers shall be proofed by respective calculation. The rated output current shall not be less than three (3) times the calculated end of life current requirements.
Rectifier units shall mainly consist of the following parts:

main switch (miniature circuit breaker),

leakage current switch,

isolation transformer according to EN 61558

control transformer, variable adjustable,

full wave silicon diode bridge,

surge protection devices (Leutron Typ: EnerPro 65V/12A-Tr or equivalent) to


protect against discharges via the underground structures

surge protection devices (Dehnguard D or equivalent) to protect against discharges via the power supply

overvoltage protection cascades,

Varistors against primary or secondary over-voltages

Variable potentiometer for each anode 25W, 150 Ohm

terminal strip for all cables individual terminal for each cable

To measure the ON/OFF potentials the rectifier units shall be equipped with an external
cyclical switch (interrupter). The interrupter module shall communicate and be controlled
via the station control system.
The transformer rectifier shall be able to operate in the following modes:

constant current,

constant voltage,

automatic control of pipeline protective potential.

Interrupter mode (ON/OFF)

Each unit shall be provided with the following measuring instruments:

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6.2

ILF-SPC-SRT-EL-810-0

supply voltage,

output voltage,

total output current,

protective potential (measured against a reference electrode).

07.11.2013

Anodes and Anode Groundbeds


The anode type and the number, dimensions and weights of anodes per groundbed shall
be selected in accordance with the calculations of the detail design.
Pre-packaged (min. 7 kg) silicon-iron (Fe-Si) container anodes with high-conductivity
coke breeze shall be used. Each anode shall have a factory assembled single core cable
with HDPE insulated stranded copper conductors and PVC jacket with a conductor size
of at least 1x10 mm.
The cable connections to cable-anodes shall be performed on site. The anode cables
shall be led to the distribution junction boxes. From the junction boxes the anodes shall
be connected the rectifier cabinet via multi-core conductors.

6.3

Test Stations
The potential test points shall consist of the following main parts:

6.4

two connections at each pipe and tank

measuring cable.

reference electrode.

Reference Electrodes
The permanent reference electrodes shall be of the Cu/CuSO4 type.
Each reference electrode shall consist of a terracotta vessel with inbuilt soft solid copper
wire and copper sulphate gel or solution filling. The reference electrodes are to be provided with minimum 10 m copper cable 1 x 10 mm. The cable connection point at the
electrode must be fully insulated and sealed with epoxy resin. Each electrode shall be
supplied with a backfill of a mixture from gypsum, bentonite and sodium sulphate.

6.5

Coupons
At critical areas external coupons shall be installed to measure the IR-free potentials.
The surface shall be A = 1 cm. The cable connection shall be1 x 10 mm and shall be
completely insulted.

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6.6

ILF-SPC-SRT-EL-810-0
07.11.2013

Distribution Boxes
Distribution boxes shall be installed outside of hazardous areas. Within the distribution
boxes all anode cables, reference cells and coupon cables shall terminate. Each terminal
shall be used for one (1) conductor only. For fixing of cables a suitable pull relief device
must be provided. The terminals shall be mounted on aluminum rails on plates.
For a clear identification of conductors regarding their measuring purpose a common
termination system shall be applied and all cables shall be correctly identified and labeled.

REMOTE MONITORING
For remote monitoring, at least the following signals into the station control system shall
be provided:
For each feeder station:

signal of rectifier summary alarm (potential-free contact),

protective potential (4-20mA),

transformer rectifier current (4-20mA)

For ON/OFF potential readings DCF-77 interrupter switch unit shall be provided.

WIRING
The wires shall be selected according to load, insulation level, function and operating requirements. The wires shall be adequately rated and equipped with fuses/circuit breakers
of adequate size.
The wiring shall be carried out solid and safe against damages. Wires shall be bundled
and fixed. The wiring shall be laid inside of wiring trays.
All circuits and auxiliary contacts including not used contacts for disconnecting devices
and relays shall be terminated on terminal strips. Terminal strips shall have a reserve for
future terminal expansion +10 % spare. If wires with different potential will be terminated
on one terminal strip the respective terminals shall be separated by means of isolating
plates. The termination of multiple stranded wires has to be carried out by means of multiple core cable ends.
Wires and terminals shall be marked durable and easy readable, corresponding to the
drawings.

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Specification

ILF-SPC-SRT-EL-810-0
07.11.2013

CABLES AND CABLE LAYING


All cables shall be one to five core cables with HDPE insulated stranded copper conductors
and PVC jacket. The nominal voltage of the cables shall be 0.6/1 kV. For feeder cables of
transformer/rectifiers cables with solid copper conductor may be used.
For the different applications the following cable sizes are recommended:

drain (negative) pipe connections

1 x 25 mm

spark gaps

1 x 25 mm

grounding connections

1 x 50 mm

anode groundbed (positive) connections

5 x 6 mm

cables for reference electrodes and test coupons

1 x 10 mm

cables for other measuring connections

2 x 2.5 mm

feeder cables of transformer/rectifiers

3 x 2.5 mm

multi-core cables from distribution boxes to integrated measuring box


12x25 mm / 24x2.5mm

For cable laying, labeling and further details, reference is made to the document Cable and
Cable Laying Specification.

10

PAINTING
All appropriate components and devices shall have a resistant, long term stable, high
quality painting. Damages, caused by transport, installation, cabling or commissioning
shall be repaired in a way, that the original quality is restored.

11

PRE-COMMISSIONING
After complete installation of all devices the terminal cathodic protection system shall be
tested to confirm satisfactory installation and operation of all equipment. In this course
the impressed protection current shall be adjusted.
During pre-commissioning the following measurements/checks shall be carried out (minimum requirements):

effectiveness of protection against touching of live parts (before switching on),

resistance measurements to earth of all anodes, between anodes and protected


structure, between protected structure and foreign structures

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Specification

ILF-SPC-SRT-EL-810-0
07.11.2013

potential measurements between protected structure and foreign structures, of free


corrosion potential at all measuring points

test of insulation joints,

The Contractor shall provide a detailed description and procedure for pre-commissioning
and shall submit to the Client.
All pre-commissioning results have to be recorded on standard forms and shall be submitted for approval.

12

COMMISSIONING
Not earlier than 2 to 3 months after pre-commissioning the commissioning of the terminal
cathodic protection system including required adjustments shall be carried out.
During commissioning the following measurements/checks shall be carried out (minimum
requirements):

current, voltage and potential of rectifiers,

adjustment of potential monitoring devices,

calibration of all currents and voltage

resistances of insulation joints,

ON/OFF potential at all test stations,

Interference between pipeline and foreign lines (if necessary connection between the lines via resistor).

Client shall provide a detailed description and procedure for commissioning and shall
submit to the Client .
All results shall be recorded on standard forms and shall be submitted for approval.
After commissioning a respective report shall be prepared which shall include all commissioning results. The report shall also include a discussion of the results giving conclusion.
The report shall contain as a minimum the following information:

measuring values of pre-commissioning,

measuring values of commissioning,

ON/OFF potentials and currents at all test point in both tabular and graphical
formats,

calculation of protection current average and of station piping coating resistance average,

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ILF-SPC-SRT-EL-810-0
07.11.2013

Information on critical points at the terminal cathodic protection system.

The Contractor shall brief the operation personnel in operation and maintenance during
installation, pre-commissioning and commissioning phase and during on-site training.

13

TESTS
All components of the terminal cathodic protection systems shall be tested in manufacturers workshop.
All tests required by the codes and standards as well as all manufactures tests have to
be performed. The rectifiers and other pre-assembled equipment shall be completely
tested in manufacturers workshop, for devices such as anodes, surge arrestors, cables,
heads of test posts, etc. a type test shall be performed.
The test program for the test of transformer/rectifiers and other pre-assembled equipment has to be submitted at least 3 weeks prior to start of the tests.
Detailed test protocols of all tests performed have to be submitted prior to shipment.

14

ADDITIONAL INFORMATION
For documentation requirements, shipping instructions, spare parts policy refer to document: Design and Construction of Power Supply Systems - Specification.

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