SPEC. No.

FS 4001
OFFSHORE FUNCTIONAL
SPECIFICATION FOR Rev. No. 3
DESIGN
CP SYSTEM FOR
SECTION OFFSHORE Discipline Elect
STRUCTURES Page 1 of 13

FUNCTIONAL
SPECIFICATION
FOR
CP SYSTEM FOR OFFSHORE STRUCTURES

PREPARED / REVIEWED APPROVED BY TOTAL NO. OF DATE REV.

REVISED BY PAGES
BY

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OFFSHORE FUNCTIONAL
SPECIFICATION FOR Rev. No. 3
DESIGN
CP SYSTEM FOR
SECTION OFFSHORE Discipline Elect
STRUCTURES Page: 2 of 13

Table of Contents

1. SCOPE................................................................................................................................. 3
2. CODES & STANDARDS ................................................................................................ 3
3. SITE CONDITIONS:........................................................................................................ 3
4. SCOPE OF SUPPLY.......................................................................................................... 3
5. TECHNICAL REQUIREMENTS ................................................................................... 4
5.1. General........................................................................................................................ 4
5.2. Design Criteria: ......................................................................................................... 4
5.3. Anode Material.......................................................................................................... 6
6. TESTING AND INSPECTION ...................................................................................... 6
7. ANODE DIMENSIONS AND PHYSICAL CHARACTERISTICS......................... 8
8. ANODE DISTRIBUTION:.............................................................................................. 8
9. MONITORING SYSTEM ............................................................................................... 9
9.1. General........................................................................................................................ 9
9.2. Reference Electrodes ................................................................................................ 9
9.3. Monitored Anodes.................................................................................................... 9
9.4. Monitoring panel .................................................................................................... 10
10. CABLING ..................................................................................................................... 11
11. SERVICE AFTER INSTALLATION ....................................................................... 11
12. SPARES:........................................................................................................................ 11
13. WARRANTY:............................................................................................................... 12
14. VENDOR DATA REQUIREMENTS ...................................................................... 12
15. CONFLICT : ................................................................................................................. 13
16. CERTIFICATION: ...................................................................................................... 13
17. PACKING AND TRANSPORATION:................................................................... 13

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 SPEC. No. FS 4001
OFFSHORE FUNCTIONAL
SPECIFICATION FOR Rev. No. 3
DESIGN
CP SYSTEM FOR
SECTION OFFSHORE Discipline Elect
STRUCTURES Page: 3 of 13

1. SCOPE

This specification defines the minimum requirements for the material selection,
design, manufacture, supply and installation of a sacrificial type cathodic
protection system with monitoring facilities (wherever required) for offshore
structures. The structures include all offshore structures like platform jackets,
clamp-on structures on existing platforms, flare or bridge support tripods, SPM
including PLEM and other appurtenances permanently attached to any of the
structure.

2. CODES & STANDARDS

2.1. Design and installation of the cathodic protection system shall be in

accordance with good marine engineering practice in corrosion protection and
compliance with the latest revisions of following Codes & Standards:

Det Norske Veritas: DNV RP B 401, DNV RP B 403

National Association of Corrosion Engineers:

NACE STANDARD RP 0176-03,
NACE STANDARD RP 0387-99,

American Petroleum Institute: API RP 5L

American Society for Testing and Materials: ASTM A36

National Electrical Code: NEC

National Electrical Manufacturers Association: NEMA

2.2. Electrical Design Criteria in Vol-II of Bid Package may also be referred.

3. SITE CONDITIONS:

All the equipment shall be designed to withstand the conditions specified in the
General Design Criteria enclosed in the bid package.

4. SCOPE OF SUPPLY

The scope of supply through this specification includes the following items:

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OFFSHORE FUNCTIONAL
SPECIFICATION FOR Rev. No. 3
DESIGN
CP SYSTEM FOR
SECTION OFFSHORE Discipline Elect
STRUCTURES Page: 4 of 13

i) Sacrificial type Anode materials for cathodic protection.

ii) Reference electrodes & monitoring anodes.
iii) Monitoring panel including all control & monitoring instruments /
devices (for Process Platform).
iv) Cables required along with cable glands and lugs, junction boxes,
filling compound, conduits etc.

The required details (quality and quantity) for above items are as indicated
below.

5. TECHNICAL REQUIREMENTS

5.1. General

Cathodic protection system shall be made up of anodes with a configuration

and anodic material composition suitable for use in seawater. All raw
materials finished products and components of the CP system and
monitoring assemblies specified herein shall be new and unused, of current
manufacture, of highest grade and free from all defects and imperfections
that could adversely affect the performance of the system.

5.2. Design Criteria:

5.2.1. The cathodic protection system for the Jacket structure shall be
designed in accordance with DNV RPB 401–1993 and the
requirements of this Specification.

5.2.2. For C.P. System design following current density and driving potential
shall be considered.
1. Current Density in sea water (initial) :130ma/m2
2. Current Density in sea water (average) : 107.65ma/m2
3. Current Density in sea mud : 43.05ma/m2
4. Driving potentials (initial and near end life) : 250 mV
5. Driving potential (mid life) :150mV

5.2.3. Design Life: same as the design of the platform specified elsewhere in
the bid package.

5.2.4. Cathodic protection method: sacrificial anodes

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OFFSHORE FUNCTIONAL
SPECIFICATION FOR Rev. No. 3
DESIGN
CP SYSTEM FOR
SECTION OFFSHORE Discipline Elect
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5.2.5. Coating breakdown factor shall be considered as per clause 6.4 of

DNV RP B401 for painted structures.

5.2.6. Surface Areas Definition for CP system design:

The system shall be adequately designed to protect all exposed steel

surface of the structure along with its various metallic components in
the submerged zone and in the splash zone area. The submerged zone
and splash zone for CP system design have been defined in Table – 4
of structural design criteria Part-II enclosed in the bid package.
The contractor shall, however, prepare a comprehensive list covering
all structural members/assemblies considered for cathodic protection
along with their individual surface area calculation and total surface
area calculation and submit it to Company, along with jacket drawings,
for review and approval. An allowance of 10% shall be added to the
calculated area during designing phase to account for the structural
design variations. Anode requirements shall be based on the above
details. The following factors shall also be taken into consideration-

5.2.6.1. Piles from mud line up to a depth of 30 meters shall be

considered.
5.2.6.2. Pile surface areas are to be calculated taking into account
apparent batter.
5.2.6.3. Internal surface area of the main pile is not required to be
considered.
5.2.6.4. For skirt piles, internal surface area is also to be considered as per
Clause 7.5.4 of DNV RP B401.

The estimated exposed surface area of the structure including the

structure below sea bed shall be indicated in the attached CP system
data sheet.

5.2.7. Current Load for Well casing & Tubing

Wherever it exists, a current drain of 5A shall be included for each

well to account for protection of buried portion of well casing and
tubing. However, surface area of conductor and conductor guide in
seawater shall be included in total surface area of the structures to be
protected by CP system. Proper electrical contacts shall be ensured
between conductor and the jacket structure.

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SPECIFICATION FOR Rev. No. 3
DESIGN
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SECTION OFFSHORE Discipline Elect
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5.2.8. Interference

Suitable arrangement to prevent interference in cathodic protection

system on bridge-connected structures shall be made by the vendor.
5.2.9. Clamp-on structures:

Vendor shall calculate the exact surface area based on structural

drawings and furnish details of the same. The surface area of all the
components as defined in section 5.2.3 shall be considered for cathodic
protection. External surface area only shall be considered for
conductors, conductor guide support framings, clamps including
stiffeners, stubs and anode clamps. Both external and internal surface
area shall be considered for conductor guides and conical plates. In
addition to the above, 10% contingency, especially for fasteners and
other fixtures of clamps, shall be included in total surface area to be
protected.
5.2.10. The complete surface area of PLEM shall be considered for cathodic
protection.
5.2.11. Submerged surface area and splash zone surface of SPM shall be
considered for cathodic protection.

5.3.Anode Material

Anodes shall be GALVALUM-III or Equivalent (Al-Zn-In) alloy suitable for

protection of steel in submerged marine environment. They shall not have any
mercury content. The potential of the sacrificial alloy material shall be (-)
1.08V or more negative referred to a silver/silver chloride reference electrode.
The Electro-chemical efficiency of anode material shall be minimum 2500
AH/Kg after four (4) days of operation as per DNV RP B 401.

6. TESTING AND INSPECTION

6.1. Anode Composition analysis:

Anode composition analysis shall be undertaken by methods agreed upon in
advance. Two samples from each melt shall be taken for chemical analysis.
The samples shall be taken in the beginning and at the end of casting from
the pouring string. Checking of closed circuit potential and practical mass
consumption shall be done for each 15 ton produced anodes. The test
samples may be separately casted or cut directly from an anode. Ampere-
hour capacity test shall be carried out be weight loss method only.

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OFFSHORE FUNCTIONAL
SPECIFICATION FOR Rev. No. 3
DESIGN
CP SYSTEM FOR
SECTION OFFSHORE Discipline Elect
STRUCTURES Page: 7 of 13

6.2. After casting, the inspection of the anodes shall be done to ensure that:

6.2.1. AH capacity of anodes shall not be less than the figures considered for
design i.e. no negative tolerance shall be permitted.
6.2.2. Closed circuit potential shall be within (+) 10 mV and (-) 50mV of the
guaranteed value. For example, for design value of (-) 1.08 volts,
anodes having closed circuit potential less negative than (-) 1.07 Volts
shall be rejected.
6.2.3. The anodes shall have minimum net weight (Gross weight minus core
weight) within a tolerance of + 2.0% to – 1.0%. However, overall
negative tolerance shall be 0% to ensure that is no short fall in total
alloy weight.
6.2.4. Dimensions shall be within tolerance limits indicated in the approved
drawings. No negative tolerance shall be allowed in standoff
dimensions.
6.2.5. At least one anode per delivery or at least 0.5 percent of the anodes
shall be subjected to destructive testing to check that the casting is to
an acceptable standard, each anode shall be cut at 3 of the most
relevant locations. The cut surface shall generally be free from visible
pores and slag/dross inclusions. The lack of bond or void between
anode core and anode material shall not exceed 5%.
As an alternate to a destructive testing, a non-destructive testing by
radiography may be used to check for lack of bond or slag/dross
inclusions if so permitted by the Company or its authorized
representative.
6.2.6. Anode to steel insert shall be checked for electrical continuity. The
resistance between the connector and the body of the anode shall not
exceed 0.005 ohm.
6.2.7. The anodes shall be free from mechanical defects like cracks,
shrinkages, excessive flash, surface projections, laminations, cold laps,
surface slag etc. as consistent with good casting practice. Criteria for
accepting these shall be as per NACE STANDARD RP 0387-99.
6.2.8. All the above Inspection / tests shall be witnessed by Company or its
authorized representative.
6.2.9. All anodes shall be delivered with material certificate from the Vendor
stating batch identification number and chemical analysis.

6.3. All work, materials, and equipments shall be subjected to inspection by

Company at all reasonable times. However inspection by the Company shall
not relieve the Vendor of his responsibility under terms of contract.

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OFFSHORE FUNCTIONAL
SPECIFICATION FOR Rev. No. 3
DESIGN
CP SYSTEM FOR
SECTION OFFSHORE Discipline Elect
STRUCTURES Page: 8 of 13

6.4. The monitoring system shall be inspected after completion of fabrication and
prior to load out. These checks shall include:

• Polarity checks on all monitored anodes.

• Insulation and continuity test of all cables.
• Calibration tests shall subsequently be carried out on all
instrumentation and reference electrodes.

7. ANODE DIMENSIONS AND PHYSICAL CHARACTERISTICS

Anode shall be standoff type. The steel core of the anode and stub pipes or
brackets provided for mounting the anode on the platform structure shall conform
to ASTM-A36 (for structural shapes) and API-5L Gr. B Seamless (for pipes) or
equivalent.

7.1. The core shall be of nominal 4 inch schedule 80 seamless steel pipe or
equivalent structural shape. Anode material shall surround the core.

7.2. Stand off-legs shall be of nominal 4 inch schedule 80 size. Stand off
separation between the underside of the anode alloy and the cathode surface
(member to be protected) should be in the range of 250 to 350 mm. Distance
between the two legs shall be less than the anode length. The free ends of the
legs shall be welded to the gusset plates superimposing the member.

7.3. For clamp-on structures, anodes shall be of bracelet-segmented type

8. ANODE DISTRIBUTION:

8.1. Anode distribution on the structural members of jackets shall be based on

advanced computer modeling techniques such as Boundary Element Method
(BEM) to ensure uniform current distribution. The contractor shall submit all
relevant details of the techniques used/ procedures adopted, datasheets,
results, drawings etc, for Company’s review and approval during detailed
engineering and prior to commencement of the installation of anodes over the
structural members.

8.2. Anode locations shall ensure early polarization of structures to provide

adequate protection at node welds. Anode for SPM chains and piles shall be
mounted on SPM whereas those for PLEM piles shall be put on PLEM itself.
Anode to be installed on PLEM shall be suitable for saline mud as well.

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SPECIFICATION FOR Rev. No. 3
DESIGN
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SECTION OFFSHORE Discipline Elect
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8.3. Clamp-on structures:

8.3.1. Anode distribution for clamp-on structures shall be based on the results
of survey carried out by successful bidder shall generally be located
on the structural members in direct proportion to the protected
surface area distribution.
8.3.2. Anode distribution shall ensure that the interference effects, with
already existing standoff anodes or adjacent anodes being installed,
are minimum.

9. MONITORING SYSTEM

9.1. General
Monitoring system shall be required only for the cathodic protection of
process platform jackets and shall be designed to provide the following as
minimum requirements:
a) The measurement of the effectiveness of the cathodic protection
system as judged by potential measurements.
b) The performance of the sacrificial anodes as judged by measurements
of current output of monitored anodes.
c) Cathodic protection system for unmanned well platforms, clamp-on
structures, Flare tripod, SPM, PLEM shall be unmonitored.

9.2. Reference Electrodes

9.2.1. 2 Nos of reference electrodes shall be provided on the Jacket, out of

which 4 will be used for vertical plane potential measurement and 8 for
horizontal plane potential measurement. The electrodes shall be
located in areas where the potential is expected to be least negative.
The vertical plane electrodes shall be installed at two different planes
with two electrodes in each plane and the horizontal plane electrodes
shall be installed in two different elevations with four electrodes in
each elevation.
9.2.2. The electrodes shall be of high purity (99.99%) Zinc to ASTM B418
Type 2. each reference electrode shall be supplied with sufficient cable
length to run between the selected location and the junction box.

9.3. Monitored Anodes

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9.3.1. The monitoring system shall also include four monitored anodes which
shall be located at two different elevations on the structure with two
anodes at each elevation.

9.3.2. The monitored anodes shall be identical to those supplied for the
structural protection system and have the same physical characteristics
but suitably modified so that current outputs can be electrically
measured at the monitoring panel. The anodic material of the
monitoring anodes shall be electrically insulated for those parts of the
anode core to be welded to the structure with an insulation resistance,
of not less than one mega ohm(when dry) and reducing to not less than
one thousand ohms(when wet). Prefabricated isolating joints with
suitable mechanical properties shall be utilized.

9.4. Monitoring panel

The monitoring panel shall be located in the switchgear room or other

suitable location in safe area. The panel shall be of sheet steel (14 SWG)
construction with an enclosure protection equivalent of IP-51 or NEMA-12.
The monitoring panel, as a minimum, shall contain the following;

a) Selector Switches, manually operated, one for each reference electrode

and monitoring anode.
b) Voltmeter with capability to measure the potential difference between
the structure and each of the reference electrodes.
c) Ammeter with capability to measure the current output of each of the
monitored anodes.
d) Built in Meter calibration facility for checking the calibration and
accuracy of the instruments.
e) Mimic diagram showing the platform jackets to be cathodically
protected shall be included on the front of the panel. Positioning of all
reference electrodes and monitored anodes shall be marked distinctly
on it. Different colours shall be used for marking structures, monitored
anodes and reference electrodes. The positions of reference electrodes
and monitoring anodes get illuminated when they are selected for
voltage or current readings respectively. LED displays may be used for
this purpose.
f) Recording unit provisions
g) Painting in accordance to Spec no 2005

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Power supply for the panel shall be provided by the contractor and the vendor
shall specify the total power required for the panel.

10. CABLING

All cabling from each reference electrode and monitored anode shall be brought to
a metallic waterproof junction box, mastic filled and mounted on the
jacket/walkway level in unclassified area. The cables shall be double insulated,
abrasion, ozone and weather resistant and suitable for total immersion in sea-
water. The cable shall be routed through a conduit and supported from the jacket
by welded bracket. The main raiser conduit shall be clamped at frequent intervals
for adequate supporting.

11. SERVICE AFTER INSTALLATION

11.1. The vendor shall provide necessary test equipments, material and services of
a corrosion specialist and carryout performance tests at the site after jacket
installation and verify that required protection level has been achieved.

11.2. The contractor shall carry out CP survey to ascertain the effectiveness of the
cathodic protection system provided for the jacket structure. The survey
shall be carried out after 60 days of the launching of jacket (and before 180
days maximum) to ensure that the structures are sufficiently polarized.

11.3. During detailed engineering, the contractor shall develop and submit
procedure for carrying out CP survey, for Company’s approval. However,
the survey procedure shall comply with the requirements of DNV standard
RP B-403. If the survey results show that the protection level is not
sufficient on any one or more than one location of the jacket member, the
contractor shall provide additional new anodes on all deficient locations so
as to raise the protection potential to required level and cost of all these shall
be borne by the contractor. The basis of redesign/redistribution and all
relevant back-up documents, as required by the Company, shall be made
available by the contractor for review and approval

12. SPARES:

12.1. Vendor shall provide spare parts needed for start-up. In addition, Vendor shall
furnish a separate priced list of recommended spares for two (2) years normal
operation and maintenance. Recommended spares shall take into account the

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OFFSHORE FUNCTIONAL
SPECIFICATION FOR Rev. No. 3
DESIGN
CP SYSTEM FOR
SECTION OFFSHORE Discipline Elect
STRUCTURES Page: 12 of 13

related factors of system reliability, effect of downtime upon production,

safety, cost of parts and availability of equipment service facilities.

12.2. All spares furnished by vendor shall be wrapped and packaged so that they
could be preserved in original as new condition under the normal conditions of
storage prevailing in India and shall be properly tagged and coded to facilitate
future identification. They shall be packaged separately, clearly marked as
"Spare Parts" and shipped along with main unit. Packing lists shall be
furnished so that the parts can be handled without uncrating, if required.

13. WARRANTY:

Vendor shall have final and total responsibility for the design and performance of
all equipments supplied and guarantee the equipment / anode for their design life.
Vendor shall warrant the equipments furnished by him and their performance in
accordance with this specification and `General Specification- Definition.(Spec
No. 1050)

14. VENDOR DATA REQUIREMENTS

Vendor shall furnish the following information relative to the anodes

14.1. Dimensional drawings of sacrificial anodes, monitored anodes and reference

anodes and supporting parts or accessories along with separate as well as
assembled drawings for their supporting parts and other accessories
14.2. Guaranteed minimum electrochemical value in ampere-hour per kg
14.3. Net, gross, and buoyant weight of anodes.
14.4. Minimum closed-circuit potential in volts.
14.5. Recommended means of anode support.
14.6. Anode alloying compositions (% age by weight and volume)
14.7. Testing method of anodes and details of the test procedure. The test shall
establish the guaranteed minimum electro-chemical value of the anode
material and its potential w.r.t. Ag/AgCl reference electrode under site
conditions.
14.8. Analytical information regarding the location of reference electrode (which
has to be located in least negative potential area.).
14.9. Calculation of anode quantity and weight based on current and weight basis
for the designated design life
14.10. Cable type /specification along with routine and type test certificates.
14.11. Type test certificate for monitoring panel (IP-51)

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14.12. Routine and type certificates for cable glands, junction boxes, pull boxes
etc.
14.13. Vendor shall confirm and provide guarantee for the design life (minimum)
for reference anodes with necessary back up calculation and other relevant
data.

15. CONFLICT :

In the event of conflict between this specification & other documents listed herein,
the following order of priority shall govern:
i). Basic Bid work
ii). Design criteria, drawings and data sheet (Whichever applicable).
iii). This specification .
iv). General Specification.
v). Codes & Standards.

16. CERTIFICATION:

All offered plug and sockets or those of similar design manufactured by same
vendor:
− Shall have been type tested by an authority approved by the company
− Shall have been in continuous satisfactory service on offshore for a
minimum period of two years.
− Shall be having current certification/approval/listing by an agency approved
by company or UL or FM.

17. PACKING AND TRANSPORATION:

The offered equipment along with their accessories shall be shipped to site packed
in wooden crates. They shall be wrapped with polythene sheets, before being
placed in the crates to prevent damage to finish. Crates shall have skid bottom for
handling.

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