Specification for Construction, Installation & Commissioning of CP Systems Version 1.

Petroleum Development Oman L.L.C.

UNRESTRICTED Document ID : SP-1129

September 1999 Filing key : xxxx

Specification for Construction,

Installation and Commissioning of
Cathodic Protection Systems

Keywords
Construction
Installation
Commissioning/testing/tests
Pipelines
Buried structures
Impressed current
Groundbed
Anodes
Transformer rectifiers
Junction box/connection box/bond box/distribution box
Test facility
Isolating couplings
Test post/test point
Cable connection
Road crossing

This document is the property of Petroleum Development Oman, LLC. Neither the whole nor any part of this document may be
disclosed to others or reproduced, stored in a retrieval system, or transmitted in any form by any means (electronic, mechanical,
reprographic recording or otherwise) without prior written consent of the owner
Specification for Construction, Installation & Commissioning of CP Systems Version 1.0

AUTHORISED FOR ISSUE

Signed :...........................................................
CFDH Materials & Corrosion
J.H.Gerretsen

Version No. Date Author Scope / Remarks

ERD 65-01 Aug/91 TTH/51 Original ERD
1 Sept/99 OTT/11 Updated and in new PDO format

INSTRUCTIONS TO USER

Make sure this is the latest issue of Specification. Refer to the EMDS on the PDO web for the last issue
date.

Where this Specification refers to DEPs and International Standards, it refers to the issues that were in-
use when the author wrote this Specification. Exceptions are references to specific issues. If you use
DEPs or International Standards with this Specification, make sure you use the latest issues.

Do not change this Specification without approval. Only the Custodian, the Corporate Functional
Discipline Head (CFDH) who owns this Specification, can give approval for changes. If you think the
Specification is not correct, write your comments on a copy of the User Comment Form. The form is the
last page of this Specification. Send the copy with your comments and personal details to OTE/21.

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Specification for Construction, Installation & Commissioning of CP Systems Version 1.0

Contents

1.INTRODUCTION .................................................................................................................................4
1.1.Applicability .....................................................................................................................................4
1.2.Language And Units Of Measurement..............................................................................................4
2. CONSTRUCTION AND INSTALLATION REQUIREMENTS .................................................5
2.1.External Cathodic Protection Systems..............................................................................................5
2.1.2.Power Sources ...........................................................................................................................5
2.1.2.1.Transformer Rectifier Stations............................................................................................................ 5
2.1.2.2. Solar Generator Stations .................................................................................................................... 5
2.1.3. Junction Boxes And Test Facilities.....................................................................................5
2.1.3.1.Junction Boxes and Distribution Boxes.............................................................................................. 5
2.1.3.2. Test Facility Types............................................................................................................................. 6
2.1.4. Isolating Couplings .............................................................................................................6
2.1.4.1. Isolating Joints................................................................................................................................... 6
2.1.4.1.1.Testing......................................................................................................................................... 6
2.1.4.1.2.Repairs......................................................................................................................................... 7
2.1.4.2.Insulated Flanges ................................................................................................................................ 7
2.1.4.2.1.Testing......................................................................................................................................... 7
2.1.4.2.2.Repairs......................................................................................................................................... 7
2.1.4.3.Isolating Spool Pieces......................................................................................................................... 8
2.1.5. Groundbeds.........................................................................................................................8
2.1.5.1.Vertical Anode Groundbed................................................................................................................. 8
2.1.5.1.1.Standard PDO Anodes (Non-cannistered) Installation................................................................ 8
2.1.5.1.2. Cannistered Anodes Installation................................................................................................. 8
2.1.5.1.3.Groundbed Completion and Testing............................................................................................ 8
2.1.5.2.Horizontal Anode Groundbed............................................................................................................. 9
2.1.5.3.Borehole Anode Groundbed ............................................................................................................... 9
2.1.5.4.Close Anode Groundbeds ................................................................................................................. 10
2.1.5.4.1.New Tank Base And Re-bottomed Tank Groundbed ................................................................ 10
2.1.5.4.2.Retrofit Groundbed Systems To Existing Tanks ....................................................................... 11
2.1.5.5.Buried Vessel And Buried Station Pipework Groundbeds ............................................................... 11
2.1.5.6.Sacrificial Anode Groundbeds.......................................................................................................... 11
2.1.6.Cable Installation.....................................................................................................................11
2.1.7.Cable to Structure Connections ...............................................................................................12
2.2. Internal Cathodic Protection Systems ............................................................................................12
2.2.1. Introduction ......................................................................................................................12
2.2.2. Sacrificial Anode Systems ................................................................................................12
2.2.3. Impressed Current Systems...............................................................................................12
3. COMMISSIONING ......................................................................................................................13
3.1. Introduction ..............................................................................................................................13
3.2. Pre-Commissioning Tests .........................................................................................................13
3.2.1. Isolating Couplings ...........................................................................................................13
3.2.2. Groundbed Tests...............................................................................................................13
3.2.3. Test Facility Tests.............................................................................................................13
3.2.4. Other Tests........................................................................................................................13
3.3. Commissioning Tests................................................................................................................13
3.3.1. External CP Systems (Impressed Current)........................................................................13
3.3.2. External CP Systems (Sacrificial Anode) .........................................................................14
3.3.3. Internal CP Systems (Impressed Current).........................................................................14
3.3.4. Internal CP Systems (Sacrificial Anode) ..........................................................................15
3.3.5. Test Instruments................................................................................................................15
3.4. Records.....................................................................................................................................15
4. APPENDIX A GLOSSARY OF DEFINITIONS, TERMS AND ABBREVIATIONS .............16
4.1 Standard Definitions .................................................................................................................16
4.2 Special Definitions....................................................................................................................16

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4.3 Abbreviations.................................................................................................................................17
4.4 References......................................................................................................................................17
5. APPENDIX B PIN BRAZING PROCEDURE QUALIFICATION DETAILS.........................19
5.1. Pin Brazing Procedure Qualification Details ............................................................................19
5.2. Tests on Connections ................................................................................................................19
6. USER COMMENT FORM............................................................................................................22

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Specification for Construction, Installation & Commissioning of CP Systems Version 1.0

1.INTRODUCTION
This Specification gives the minimum requirements for the construction, installation and commissioning
of cathodic protection systems for internal surfaces of tanks and vessels, the external surfaces of tank
bottoms, buried vessels, buried in-station pipework, buried flowline sections, interstation pipelines, main
transmission pipelines and well casings.
Marine facilities, internal surfaces of pumps, valves etc. internal surfaces of pipelines and temporary
cathodic protection systems are outside the scope of this Specification.
1.1.Applicability
If this Specification is applicable to the work that you do, you shall obey its instructions. You shall get
approval, in writing, from the Custodian, the CFDH who owns this Specification, before you use
procedures other than those that this Specification specifies.
This Specification is not applicable retroactively.
1.2.Language And Units Of Measurement
You shall use the English language and the International System (SI) units of measurement in all
documents and drawings; refer to ISO 31 and ISO 1000. Where the SI unit is a conversion of a
manufactured dimension, you can put the original dimension, in brackets, after the SI units. For example,
50mm (2in) pipe.

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Specification for Construction, Installation & Commissioning of CP Systems Version 1.0

2. CONSTRUCTION AND INSTALLATION REQUIREMENTS

2.1.External Cathodic Protection Systems
2.1.1. Introduction
This section defines the construction and installation requirements for equipment providing external
cathodic protection to the structures and pipelines as detailed in section1 of SP-1128, technical
specification for Cathodic Protection Design.
2.1.2.Power Sources
2.1.2.1.Transformer Rectifier Stations
Transformer rectifiers shall be connected to the power supply in accordance with the requirements of
ERD-63-01, Electrical Installation Practice.
Transformer rectifier compounds shall be provided with a plinth for mounting the transformer rectifier,
negative junction box and/or negative distribution box. The equipment shall be fastened to the plinth
using rag bolts or similar suitable fastenings. The plinth shall contain a cable duct for AC power supply
and DC cables. A sunshade shall be erected above the transformer-rectifier and associated equipment, all
in accordance with ERD-28-04.

Security fencing shall be erected all around the plinth at a distance of 1 metre. For T/R’s which are
located on-plot the fencing shall include a 2 metres wide double gate in the outer perimeter fence and a
single mangate at the rear of the compound. Similar facilities shall be provided for T/R’s which are
located off plot, except that the single mangate is not required. It shall be possible to lock gates using
padlocks.
The complete compound inside the security fencing shall be levelled and 50mm of gravel laid. Concrete
foundations and levelling shall be constructed such that the surface is 150mm above grade level.

2.1.2.2. Solar Generator Stations

The solar generator system shall be supplied complete with supporting framework, all in accordance with
Specification-SP-1130. A reinforced concrete foundation shall be constructed able to support the solar
generator, batteries and regulators according to the generator Manufacturer’s written recommendations.
The foundation shall be suitable to withstand the effect of the maximum prevailing wind forces on the
solar panel structure.
The concrete foundation shall be orientated such that solar panels, when installed, face due south.
A security fence shall be installed in compliance with the Company Standard Drawings at a clearance
distance of 2 metres from the edge of the foundation or structure, whichever is nearer. A double gate
with a clearance opening of 2m minimum shall be positioned on the east or west side of the compound to
allow vehicle access to the side of the panels facing south. It shall be possible to lock gates using
padlocks.
The complete compound inside the security fencing shall be levelled and 50mm of gravel laid. Concrete
foundations and levelling shall be constructed such that the surface is 150mm above grade level.

2.1.3. Junction Boxes And Test Facilities

2.1.3.1.Junction Boxes and Distribution Boxes
Junction boxes and distribution boxes shall be mounted on steel support frames as shown in SP-1136
Specification for Cathodic Protection Drawings STD-7-3008 and STD-7-3009. The frames shall be
stabilised in concrete.
Cables shall be run into the boxes using ducting and cable trays. On no account shall cables be clipped
direct to, or cast directly into the concrete.

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2.1.3.2. Test Facility Types

Test facilities shall be installed in accordance with the following drawings.
STD-7-3012- CP Test Point,Type 1,Potential Measurement Facility
STD-7-3003- CP Test Point,Type 2,Drain Point and Current Measurement Facility
STD-7-3007- CP Test Point,Type 3,Isolating Couplings Test Facility
STD-7-3004- CP Test Point,Type 4,Current Measurement Facility
STD-7-3005- CP Test Point,Type 5,Foreign Service Test Facility
STD-7-3016 -CP Test Point,Type 7,Buried Coupon Facility
STD-7-3017 -CP Test Point,Type 8, Cased road Crossing Test Facility
STD-7-3018 -CP Test Point,Combined Isolation / Drain Point Test Facility
STD-7-4001 Tank Farm Test Facility
STD-7-4002 Drain Vessel Test Facility
STD-7-4003 Tank Internal Anode Monitoring Detail

All cable to structure connections shall be in accordance with relevant section(s) of this specification.
All cable laying shall be in accordance with relevant section(s) of this specification.

2.1.4. Isolating Couplings

2.1.4.1. Isolating Joints
The monobloc isolating joint shall be welded into the pipeline at the specified location such that the joint
is not subjected to bending moments or stress.
Welding shall be in accordance with ERD-43-01 for on-plot locations or in accordance with the pipeline
welding procedures for transmission and interstation pipeline.
Welding shall be carried out such that the heat generated does not damage the insulating materials.
Manufacturer’s instruction with respect to welding shall be strictly followed.
Any damage to pipe coating during installation shall be made good by a method approved by the
Company.
2.1.4.1.1.Testing
a) Testing Prior to Installation
Following delivery of the isolating joint, the Contractor shall measure the electrical insulation resistance
with a 500V insulation tester and the result shall be greater than 4 M Ohm in air. The result shall be
approved by the Company before the joint is installed.
b) Testing After Installation.
All welds shall be checked by radiography or ultrasonics as specified by the Company.
After installation and with both sides of the joint earthed, the joint shall be tested by applying a DC
current to the pipeline on one side of the joint, such that the change in potential on that side of the joint is
not less than 250 mV in a negative direction. This may be achieved by the use of a permanent cathodic
protection system or by a temporary groundbed and DC supply.
On applying the current to one side of the joint, the potential on the other side shall not change or shall
change in a positive direction. A potential change in the negative direction shall mean the joint shall not
be accepted by the Company.

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Specification for Construction, Installation & Commissioning of CP Systems Version 1.0

2.1.4.1.2.Repairs
Isolating joints are factory assembled and repairs cannot be carried out by the Contractor. If a unit is
found to be faulty, it shall be returned to the Manufacturer.
2.1.4.2.Insulated Flanges
General Requirements
A pair of weldneck raised face flanges of the correct mating shall be welded into the pipe at the required
locations specifically for the purpose of cathodic protection isolation.
Welding shall be in accordance with Specification-43-01 for `on-plot’ locations or in accordance with
the pipeline welding procedure for transmission and interstation pipelines. In order to prevent damage to
the insulating material it is essential that the bolt or the flanges are exactly aligned, over sized bolts or
dowel pins shall be fitted at equal spacing around the flange to maintain alignment during welding.
Following welding the insulating gasket shall be inserted between the flange faces and then the insulating
sleeves shall be inserted into the bolt holes and checked for length and clearance. The bolts shall then be
passed through a steel washer, an insulating washer and then the sleeve in the flange. Insulating washers
shall then be fitted over the bolts next to the opposite flange, then a steel washer and the nuts installed.
The bolts shall be tightened up in accordance with Drawing STD-7-5001 such that an even stress is
maintained on the flanges faces.
When insulating existing flanges that are not exactly aligned, smaller diameter bolts of higher strength
shall not be used unless specific written approval is obtained from the Company.

2.1.4.2.1.Testing
After installation and termination of cathodic protection test cables, and with both sides of the flange
earthed, the flange shall be tested by impressing a DC current on one side of the flange, such that the
change in pipe to soil potential on that side of the flange is not less than 250mV in a negative direction.
This may be achieved by use of a permanent cathodic protection system or by a temporary groundbed
and DC supply.
During the test a Swain current clamp should also be attached to the pipe, within 0.3 m of the flange.
On applying the current to one side of the flange, the pipe to soil potential on the other side shall not
change or shall change in a positive direction. The current clamp shall not indicate a current flow during
the test.
A potential change in a negative direction means the flange shall not be accepted, unless the current
clamp indicates zero current flow.
Bolt to flange resistances shall be measured using a 500V insulation tester. Should any bolt to flange
resistance be less than 1 M Ohm the bolt shall be marked and the insulation repaired. If all bolt to flange
resistances are in excess of 1 M Ohm and the flange has not been accepted due to a negative change in
pipe-to-soil potential or current flow indicated by the current clamp meter, when tested as above, the
gasket shall be replaced. Repairs shall be in accordance with the following sub-subsection.
NB. Any electrical testing of insulated flanges shall take due cognisence of any mechanical testing of
the flange integrity using soapy water. Such tests may compromise the electrical integrity of the
insulation and should be avoided if possible or the flange thoroughly dried before electrical testing.
2.1.4.2.2.Repairs
Bolts showing low resistance to flange shall be removed and the insulating sleeves and washers replaced.
Should the gasket require replacement the flange shall be dismantled and re-assembled as per the
General Requirements sub-subsection above, using new insulating materials.
When repairing existing insulated flanges, bolts shall only be removed from, and replaced in, a line in
service if arrangements cannot be made to shut down the line, and in addition the following conditions
are met:
The flange has 8 bolts or more.

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Specification for Construction, Installation & Commissioning of CP Systems Version 1.0

Prior approval shall be obtained using the Permit to Work Procedure; refer PDO Safety Regulations.
Bolts shall only be removed and replaced one at time
Bolts shall be correctly tightened after replacement
Line shall not be subject to pulsating pressure.
Line shall not be blocked off and subject to a static pressure.
Line pressure shall not exceed maximum operating pressure.
Following satisfactory re-testing, the flanges shall be painted with non-conductive red paint.
2.1.4.3.Isolating Spool Pieces
Type A and B (See Drawing STD-7-5003) isolating spool pieces shall be installed and tested in
accordance with the requirements for insulated flanges (see above).
2.1.5. Groundbeds
2.1.5.1.Vertical Anode Groundbed
A vertical anode groundbed comprising PDO standard silicon-iron-chrome anodes in carbonaceous
backfill or pre-packaged cannister, shall be constructed in accordance with drawing STD-7-6001 at the
required locations. All critical dimensions shall be specified on this drawing.
The groundbed shall be constructed with a ring-main cable trench excavated 1200mm deep and 600mm
wide, to the length specified.
At the specified anode spacing, a nominally 250mm diameter hole shall be augered or drilled to the
specified depth.
2.1.5.1.1.Standard PDO Anodes (Non-cannistered) Installation
Carbonaceous backfill shall be poured into the bottom of each hole and compacted to achieve the
specified depth.
An anode complete with centraliser shall be carefully lowered down each hole, and supported centrally
in the hole, until carbonaceous backfill material has been placed around it. The anodes shall be lowered
into the holes using ropes; on no account shall the anodes be lowered using the cable tails. Carbonaceous
backfill shall then be packed around and over each anode to the specified height. Should the top of the
backfill column be lower than the bottom of the trench the remainder of the hole shall be filled with pea
gravel. Care must be taken when tamping the backfill not to damage the anodes. Broken or cracked
anodes shall be replaced.
2.1.5.1.2. Cannistered Anodes Installation
A cannistered anode assembly shall be carefully lowered by rope down each hole, using the provided
handle attached to the canister. On no account shall the assembly be lowered or supported using the
cable tail.
The annular space between the canister and the hole shall be filled with a saturated slurry of material
removed from that strata during the drilling / augering, continuing to give a minimum 300mm cover
above the top of the canister. The remainder of the hole shall be filled with pea gravel.
2.1.5.1.3.Groundbed Completion and Testing
After installation of the anodes and completion (including compacting) of the carbonaceous backfill, the
resistance of each anode to remote earth shall be measured by means of a low resistance earth meter. The
Contractor shall record and submit these resistance measurements to the Company prior to the next stage
of work.
The ringmain cable shall be laid on a 75mm bed of soft sand and care taken to ensure the cable has no
kinks or damage to the insulation or sheathing. The anode cable tails shall be spliced to alternate sides of
the ring main cable, using line taps, and the splices sealed with branched splice encapsulation kits in
accordance with the Manufacturer’s instructions. Each encapsulated splice shall be individually
inspected before backfilling. Any encapsulated splice found to be defective shall be rejected and
replaced.

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Specification for Construction, Installation & Commissioning of CP Systems Version 1.0

The splice between the positive feeder cable to the groundbed and the ring main shall be made in an
identical manner and the ring main cable shall not be broken to make this connection. The splice to
complete the ring main shall be made as above.
The ring main shall then be covered with a further 75mm of soft sand and tiled over its entire length. A
non-metallic breather pipe shall be placed over each anode, care shall be taken not to damage the anode
cables, and the entire groundbed shall then be backfilled with excavated soil and the breather pipes filled
with pea gravel.
Surplus excavated soil shall be used to form a windrow running the full length of the groundbed.
On completion of the groundbed installation, the Contractor shall construct and install groundbed
warning signs in accordance with Drawing STD-2-4704.
2.1.5.2.Horizontal Anode Groundbed
A horizontal groundbed comprising PDO standard silicon-iron-chrome anodes laid in carbonaceous
backfill, shall be constructed in accordance with drawing STD-7-6003 at the required location. All
critical dimensions shall be specified on this drawing.
The groundbed shall be constructed with a trench to the specified depth and 600mm wide, leaving a
cable step of width 300mm and height 300 mm for the specified length of the groundbed. All roots,
stones and rocks shall be removed from the trench.
A 150 mm deep layer of carbonaceous backfill shall be laid in the trench and tamped firmly into place.
Each anode shall then be centrally located in the trench at the specified spacing shown on the drawing,
and the anode cable tail taken to one side and positioned on the cable step.
A further 150mm deep layer of carbonaceous backfill shall then be laid by hand over the anodes and
along the trench, and tamped firmly. Over the anodes, a long plank of timber shall be used, and care
should be taken that no point load is applied over the brittle anodes. The plank shall be removed after
anode backfilling.
After installation of anodes and completion (including compacting) of the carbonaceous backfill, the
resistance of each anode to remote earth shall be measured by means of a low resistance earth meter. The
Contractor shall keep a record of these resistance measurements and make the results available to the
Company.
The ring main cable shall be laid along the step on a 75mm bed of soft sand, and care taken to ensure that
the cable has no kinks or suffers damage to the insulation and/or sheathing.
The anode cable tails shall be spliced to alternate sides of the ring main cable, using line taps, and the
splices sealed with branched splice encapsulation kits in accordance with the Manufacturer’s
instructions. Each encapsulated splice shall be inspected before backfilling, and any splice found to be
defective shall be rejected and replaced.
The resistance to remote earth of the entire groundbed shall then be measured and the result reported to
the Company.
The ring main shall then be covered with a further 75mm of soft sand and cable tiled over its entire
length. 200 mm of stone free soil shall be laid over the whole groundbed, the gravel columns installed,
and the remaining excavation backfilled with excavated soil.
Surplus excavated soil shall be used to form a windrow running the full length of the groundbed.
On completion of the groundbed installation the Contractor shall construct and install groundbed
warning signs in accordance with drawing STD-2-4704.
2.1.5.3.Borehole Anode Groundbed
A borehole groundbed comprising silicon-iron-chrome or mixed metal oxide coated titanium anodes in
carbonaceous backfill, shall be constructed in accordance with drawing STD-7-6004 at the required
location. All critical dimensions shall be specified on this drawing.
The first stage of the construction involves drilling and setting a minimum 250mm surface casing to a
depth of 5 metres. Drilling of the borehole shall then continue using a minimum 200 mm drill bit to the
depth specified or until the required depth below the water table is achieved.

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The surface casing shall be cut off 100mm above grade level and two semi-circular notches cut in the
casing to locate the anode support bar.
To maintain stability of the borehole a full welded steel casing complete with conical end fitting shall
(unless otherwise agreed by the Company) be installed to full depth. The section of this casing in the
active zone shall be drilled with 10mm diameter holes, in opposite 12 O’clock and 6 O’clock positions,
at nominally 1 m spacings.
Slotted non-metallic casings may also be used. Contractor shall submit details to company for approval.
If the borehole is not fully cased the anode assembly complete with centralisers and vent pipe shall be
installed within one hour of completion of drilling.
Prior to installation the anodes shall be laid out adjacent to the borehole and the anodes positioned to
achieve the correct spacing and active length. Anode cable tails and support ropes shall be separated and
fixed together with cable ties to ensure maintenance of position.
When using silicon-iron-chrome anodes the Contractor may consider using a frame to maintain anode
position within the borehole.
The Contractor shall submit a detailed procedure for the installation, to the Company, for approval.
Anodes shall only be lowered using polypropylene ropes of sufficient load bearing capacity. Under no
circumstances shall the anode cables be subject to stress.
When the anode ballast weight or assembly reaches the predetermined depth the ropes shall be secured to
the anode support bar.
Carbonaceous backfill (calcined petroleum coke only) shall then be pumped down the borehole to the
required depth. The volume of backfill required shall be calculated at the design stage. The backfill shall
be mixed with detergent and water to aid pouring and compaction. Once the backfill has compacted to
the specified depth the resistance to earth of the individual anodes and the whole groundbed shall be
measured by means of a low resistance earth meter. The Contractor shall keep a record of these
resistance measurements and make the results available to the Company prior to the next stage of work.
On acceptance of the groundbed the remainder of the hole shall be filled with pea gravel.
The borehole headworks shall then be completed taking care not to damage the anode cables. The anode
cables shall be adjusted to have minimum 30cm of slack before being secured to the anode support bar,
in order to avoid over-tensioning should the backfill settle. When the headworks are complete, the anode
cables shall be passed through the cable ducting and terminated in the anode junction box.
2.1.5.4.Close Anode Groundbeds
2.1.5.4.1.New Tank Base And Re-bottomed Tank Groundbed
A close anode groundbed comprising flexible polymeric anodes or mixed metal oxide ribbon anodes
shall be constructed in accordance with drawings STD-7-6005, STD-7-6006 or STD-7-6007 (as
applicable) below the new or re-bottomed tank base. All critical dimensions shall be specified on this
drawing.
The anode shall be laid in trenches to the specified depth and minimum practical width. All roots, stones
and rock shall be removed from the trench.
Unless recommended otherwise by the Vendor, the anodes shall be incorporated in a woven backfill
jacket of calcined petroleum coke.
The header cables or connection / conductor bars shall then be installed and fully encapsulated in
accordance with the Vendors instructions.
The groundbed shall be completed by backfilling with stone free material as used to construct the tank
foundation pad.
The anode connection cable(s) shall be routed beneath the tank ring beam and routed to the NJB, NDB
or T/R all in accordance with this specification
It is not required to measure the resistance to remote earth of close anode groundbeds.

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Specification for Construction, Installation & Commissioning of CP Systems Version 1.0

2.1.5.4.2.Retrofit Groundbed Systems To Existing Tanks

For tanks in operation which are to have CP applied, but which do not require re-bottoming, close anode
groundbeds shall be constructed in accordance with designs, procedures, specifications and drawings
developed on a case-by-case basis, considering the tank(s) diameter and other factors including tank
layout and accessibility for construction equipment.
Options may include, but are not limited to, use of canistered anodes installed angled below the tank
base, or installed vertically at a pre-determined depth around the tank circumference.
Wherever possible all such retrofit anode systems shall allow individual monitoring of, anode current
outputs and potentials beneath the tank base.
All such systems shall be subject to full Company review and approval prior to any site mobilisation.
2.1.5.5.Buried Vessel And Buried Station Pipework Groundbeds
Close anode groundbeds for buried vessels and station pipework shall be constructed in accordance with
designs, procedures, specifications and drawings developed on a case-by-case basis, considering number
of vessels, pipework layout etc.
Wherever possible all such systems shall allow individual monitoring of anode current outputs.
All such systems shall be subject to full Company review and approval prior to any site mobilisation.
2.1.5.6.Sacrificial Anode Groundbeds
Magnesium Anodes
Magnesium block anodes or magnesium ribbon anode shall be installed horizontally at a distance of 1.5
metres from the pipeline or flowline they are to protect, at invert level, all in accordance with the project
drawings.
Block anodes shall be installed in a pre-packaged cotton bag complete with backfill (see Specification-
SP-1130). Ribbon anodes shall be laid centrally in a backfill trench (of identical composition to that used
for pre-packaged anodes) of nominal cross-section 0.3m x 0.3m.
Magnesium anodes shall not be installed less than 2 metres from other buried metallic services which are
not protected, and on no account shall anodes be installed so that a foreign service lies between the
anode and the structure to which they are connected.
The anode cable tail shall be brought into the test facility or connected directly to an adjacent above
ground section of the structure as specified on a case-by-case basis.
Zinc Anodes
Zinc ribbon anode for protection of a pipeline within a sealed steel casing shall be secured to the pipeline
such that it cannot inadvertently come into contact with the casing. The anode cable(s) shall exit the
casing in such a way that they do not compromise the integrity of the casing end seals. A typical
arrangement is given in STD-7-3017.
2.1.6.Cable Installation
Cathodic protection cable shall be handled and laid with extreme care as damage to the insulation and/or
sheathing may result in premature cable failure. During installation the cable reel shall be supported such
that cable may be pulled from the reel without causing kinking or twisting. Cable runs incorrectly
installed shall not be accepted by the Company and shall be re-laid at the Contractor’s expense.
Cable runs shall be of one continuous length. Joints shall not be accepted except with the written
permission of the Company. All joints shall be clearly marked in the construction drawing provided by
the Company.
All cable joints shall be made using an approved splice and sealed using splice encapsulation kits.
Cables shall be laid generally in accordance with PDO standard drawing STD-4-0102-01, unless stated
otherwise.
The cable route shall be marked at 20m intervals and at direction changes, using cable route markers in
accordance with STD-7-7001.

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Cable route markers shall also be installed above all cable splices, joints and repairs and shall bear the
word “JOINT” cast in the concrete.
Damage to cable insulation or sheathing of all cables, including anode connection cables, shall be
reported immediately to the Company for inspection and assessment of the extent of damage.
All proposed repairs shall be implemented only after approval by the Company. Repairs shall be
undertaken by cutting out the damaged cable and splicing a new length of cable in its place. The cable
splice shall be sealed using splice encapsulation kits.
2.1.7.Cable to Structure Connections
Cable to structure negative connections to new installations shall be undertaken using welded pads, in
accordance with STD-7-2001 and 2003.
Cable to structure connections for potential measurement cables or low current carrying bond cables
shall be made by pin brazed threaded studs (As per STD-7-2002) or welded cable connection pads.
Cable to structure connections to live equipment shall be made by pin brazing, subject to Company
approval and issue of required work permits. Prior to any pin brazing on live equipment the braze area
shall be subject to UT examination to conform integrity of the pipe wall.
Prior to attachment of cable connection pads or pin braze studs the surface of the structure shall be
thoroughly cleaned by abrasive blasting or power wire brushing.
Welded connections shall be made in accordance with an approved welding procedure.
For pin brazed connections, brazing shall take place in accordance with the procedure given as Appendix
1, by a qualified operator.

2.2. Internal Cathodic Protection Systems

2.2.1. Introduction
This section defines the construction and installation requirements for equipment providing internal
cathodic protection to tanks and vessels
2.2.2. Sacrificial Anode Systems
Sacrificial anodes shall be securely bolted and tack welded to the steel supports welded to the tank or
vessel.
If hydro-testing takes place before internal coating, the anodes shall be wrapped in heavy duty
polyethylene to prevent undue wastage during hydro-testing. THE POLYETHYLENE SHALL BE
REMOVED ON COMPLETION OF HYDRO-TEST.
One anode in each tank shall be installed to allow external current monitoring, all in accordance with
STD-7 -4003. Cables shall exit the tank via a dedicated nozzle and coffadam arrangement. The tank
connection cable shall be made on the tank rims as for external CP systems, in accordance with drawing
STD-7-2003.
The anode support and exposed core shall be coated to the same standard as the internal coating of the
tank or vessel.
2.2.3. Impressed Current Systems
Anodes shall be tied to and suspended from the roof/deck hangers, by polypropylene ropes, such that the
anodes are immersed at all times. The use of floating anode arrangements may be considered on a case-
by-case basis.
Cables entry into the tank shall be suitably glanded. Anode header cables shall be run to ground level in
cable trays. They shall be routed (buried) to outside of the tank bond area and installed in anode junction
boxes such that individual current monitoring may be undertaken.
The negative cable shall be terminated on the rim as for external CP systems in accordance with drawing
STD-7-2003.
Cables between the tank and the transformer rectifier / NDB/NJB/AJB shall be installed in accordance
with the relevant section of this specification.

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The transformer rectifier shall be sited in a non-hazardous area and be plinth mounted.

3. COMMISSIONING
3.1. Introduction
This section specifies the minimum pre-commissioning and commissioning activities to be undertaken on
completion of installation of cathodic protection systems.
Generally the management of commissioning will take place in accordance with ERD-10-10. The final
acceptance and exception forms are also contained within ERD-10-10.
3.2. Pre-Commissioning Tests
Prior to commissioning the CP system, the Contractor shall complete construction and pre-
commissioning checks and submit the results on check sheets to the Company commissioning supervisor.
3.2.1. Isolating Couplings
Isolating joints, insulated flanges and isolating spools shall be tested for :
§ Insulation resistance,
§ Response to application of cathodic protection
All tests shall be as specified in the relevant section of this Specification.
3.2.2. Groundbed Tests
The following pre-commissioning tests shall be completed.
§ Individual anode and / or total groundbed resistance to remote earth tests on all types of
groundbed (except close anode groundbeds)
§ Confirm settled depth of calcined petroleum coke backfill in borehole groundbeds.
3.2.3. Test Facility Tests
The following pre-commissioning tests shall be completed:
§ Continuity of all cables with the structure or pipeline
§ Continuity of buried coupon cables and operation of reed switches
§ Open circuit potential of sacrificial anodes.
3.2.4. Other Tests
The following further pre-commissioning test(s) shall be undertaken as required:
Confirm isolation is achieved from common earthing system. The structure or pipeline shall not be in
contact with common earthing systems, e.g. by contact with reinforcing bar or other earthing, unless the
design makes due allowance for such contact.
Any other tests required by the Company to demonstrate that the installation works have been completed
in accordance with the specification.
3.3. Commissioning Tests
3.3.1. External CP Systems (Impressed Current)
Note: This section does not cover cathodic protection systems for well casings . For those application
detailed commissioning procedures shall be drawn up by the contractor and submitted to the company for
review and approval.
Record ‘natural’ structure to soil potential at the following:
§ All test facilities including buried coupons installed along pipeline routes and for buried
on plot piping.
§ At buried vessels using all of the test posts and buried coupons provided.

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§ At tanks using the buried coupons (if used) and monitoring duct provided, and at the test
stations provided around the tank circumference for potential measurement using portable
reference cells.
§ Energise the transformer rectifier/solar generator and record the minimum voltage and
current output from each. Measure and record the back emf of the groundbed / structure
circuit.
§ Reduce the transformer-rectifier / solar generator outputs and adjust the setting at each
NDB using the variable resistors, such that structure to soil potentials of, typically minus
1.0 to minus 1.5 volts (CP ON) are recorded at all test posts, test points and buried
coupons. (It should be noted that the successful achievement of full cathodic protection
shall be assessed by polarised, CP OFF, potentials. Experience indicates that in most
cases CP ON potentials in the stated range are sufficient to achieve the required CP OFF
criteria)
§ Where polarisation cells have been installed to mitigate induced AC potentials, AC
potentials shall be recorded prior to and after connection of the polarisation cells and
results reported to the Company.
§ Test the internal insulation effectiveness of isolation joints and insulating flanges in water
containing pipelines. With the CP system briefly interrupted the OFF potential of the
insulated structure or pipeline shall be measured and reported. If the measured potential
shift, as the CP system is switched on, is more than 20mV negative the Consultant shall
propose remedial measures to be employed.
§ Ten days after energisation record CP ON and (polarised) CP OFF structure to soil
potentials at all test locations. All power sources on the structure shall be synchronously
switched during this survey. Record all power source outputs and circuit back emf.
§ Perform interaction testing on all metallic services crossing or in close proximity to the
structures in accordance with BS 7361 ; Part 1. The effect of the existing systems on
pipelines which cross or are in close proximity to the new system shall also be assessed.
Where all or any part of a foreign structure is found to undergo a positive potential
change greater than 20mV, and the potential is more positive than minus 850mV when the
CP system is switched on, further action to mitigate stray current effects shall be
undertaken.
3.3.2. External CP Systems (Sacrificial Anode)
The following commissioning tests shall be undertaken:
§ Record ‘natural’ structure to soil potentials at all tests facilities on the pipeline or
flowline.
§ Connect sacrificial anodes to the structure or flowline and record potentials achieved.
Ten days after connection of anodes record CP ON structure to soil potentials and report any locations
where a value more positive than minus 1.0V (with respect to Cu/CuSO4 reference electrode) is
recorded.
3.3.3. Internal CP Systems (Impressed Current)
The following commissioning tests shall be undertaken:
§ Record ‘natural’ structure to electrolyte potentials by inserting a Ag/AgCl reference cell
into the tank.
§ Adjust output of transformer rectifier to achieve structure to electrolyte potentials of -0.90
to -1.45 volts with respects to a Ag/AgCl reference cell, record current required.
§ Record individual anode current outputs at AJB.
§ Repeat above two items after ten days to check polarisation effects.

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3.3.4. Internal CP Systems (Sacrificial Anode)

The measurement of natural structure to electrolyte potentials is not generally possible. Operating
potentials can only be measured on tanks fitted with access fittings and are not adjustable. The following
commissioning tests may be applicable, therefore:
§ Monitored anode current shall be recorded across the shunt installed in the test post.
§ Checks shall be made to ensure that protective polyethylene sheets have been removed
from hydro-tested tanks prior to commissioning.
3.3.5. Test Instruments
The instruments required to carry out the above pre-commissioning and commissioning tests shall be as
follows:
§ Potentiometric voltmeter having a minimum input impedance of 50 MOhms
§ Megger earth tester or equivalent
§ Insulation tester
§ Low resistance ammeter
§ Copper/copper sulphate or silver/silver chloride reference electrode.
§ Swain current clamp.

3.4. Records
On completion of all construction and installation works, all construction drawings shall be updated for
field modifications to the original design, to show the As-Built system, in accordance with ERD-00-05.
The Company shall be advised in writing along with appropriate field sketches of any field repairs to
groundbeds and main connecting cables.
The Company shall be provided with all data obtained during commissioning in the form of a
commissioning report. The report format and content shall be subject to Company approval.

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4. APPENDIX A Glossary of Definitions, Terms and

Abbreviations
The following terms and abbreviations used in this document, are defined below:
4.1 Standard Definitions
The list that follows tells you the meaning of some words in all Specifications:

Company: Petroleum Development Oman LLC

Contractor: The person or organisation that supplies

the company with services.

Vendor: The person or organisation that supplies

the company with materials and/or
equipment.

Discipline: A specific set of technical knowledge and

skills

Corporate Functional The person within the Company

Discipline Head: responsible for the discipline to which the
specification belongs. The CFDH
approves the Specifications that apply to
his discipline

User: The person or organisation that reads,

and uses the information, in this and
other Specifications

Shall: Indicates a requirement

Should: Indicates a recommendation.

May: Indicates a possible course of action.

4.2 Special Definitions

Cathodic Protection: Process to reduce or prevent corrosion of structures in contact with an electrolyte
by maintaining the flow of electrical current through the electrolyte into the surface of the structure being
protected. The flow of current into the surface of the structure results in a negative change in the surface
to electrolyte potential of the structure. When a critical surface to electrolyte potential is achieved the
structure surface is fully protected from corrosion. Cathodic protection can be achieved using impressed
current or sacrificial anode systems.
Structure: The electrically continuous steel plant or equipment to be protected using cathodic
protection. (Not inclusive of pipelines)
Foreign Structure (or Pipeline): A structure or pipeline which is either not Cathodically Protected or is
protected by another separate system.
Potential: Refers to the surface to electrolyte potential of a structure measured in Volts, with respect to a
reference cell, unless specifically stated otherwise.
Electrolyte: A liquid or the liquid component in a composite material in which electric current flows by
the movement of ions. For the purposes of this Specification electrolyte shall indicate either soil and/or
water.

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Drain Point: The point on a structure or pipeline to which the current return (negative) cable is attached.
“ON” Potential: Electrical potential measured while cathodic protection system is operating.
“OFF” Potential Or Instantaneous “OFF” Potential: Electrical potential measured within 100
milliseconds after the cathodic protection system has ceased operation and with no current flowing to or
from the structure.
Impressed Current: Method of providing cathodic protection by connecting the structure to a DC
power supply.
Sacrificial Anode: Metals and alloys with a more negative electrochemical potential than steel which are
connected to structures to provide cathodic protection. They are consumed during cathodic protection,
require periodic replacement and are typically alloys based on Aluminium, Zinc or Magnesium.
Main Transmission Pipeline: Pipeline which is part of PDO’s main oil or gas line system
Interstation Pipeline: Pipeline which is not part of PDO’s main oil or gas line system. Such lines are
generally less than 20km in length.
4.3 Abbreviations
AC: Alternating Current
CP: Cathodic Protection
DC: Direct Current
DP: Drain Point
FBE: Fusion Bonded Epoxy (Coating)
FRP: Fibre Reinforced Polymer
GRE: Glass Fibre Reinforced Epoxy (Coating)
ICCP: Impressed Current Cathodic Protection
NDB: Negative Distribution Box
NJB: Negative Junction Box
PCS: PDO Painting and Coating System (Refer to Specification-48-01)
PDO: Petroleum Development Oman
PE: Polyethylene (Coating)
PP: Polypropylene (Coating)
T/R: Transformer Rectifier

4.4 References
Shell Reference Documents
ERD-28-04 Standard Drawings and Requirements for Sunshades
ERD-43-01 Non-Destructive Examination (Amdts/Supp to ASME
B31.3)
SP-1136 Specification for Cathodic Protection Standard Drawings
ERD-63-01 Electrical Installation Practise
SP-1130 Specification for Cathodic Protection Materials and
Equipment
ERD-00-05 Handover and As-Built Documentation
Specification-10-10 Initial Start-up Procedure

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SP-1128 Specification for Cathodic Protection Design

International Standards
BS 7361:Part 1: 1991 Cathodic Protection Code of Practice for Land and Marine
Operations
ISO 31 Quantities and units
ISO 1000 SI Units and recommendations for the use of their multiples
and of certain other units

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5. APPENDIX B Pin Brazing Procedure Qualification Details

5.1. Pin Brazing Procedure Qualification Details

Prior to the commencement of any pin brazed cable to pipe connections the Contractor shall submit to the
Company Representative details of the proposed pin brazing procedures for qualification and approval.
These shall include, but not be limited to, the following:-
Complete details of the equipment to be used including brazing gun, battery, earthing device, grinding
attachment, brazing pins and contact medium.
Method of current control.
Coating repair procedure and specific materials to be used.
Details of the laboratory equipment to be used to carry out the tests defined below.
5.2. Tests on Connections
The Contractor's nominated pin brazing operator shall pin braze five threaded studs to a sample pipe of each
material and wall thickness to be employed on the Project. The connections shall be at least 100mm apart.
The connections shall then be subject to the following tests:-
Three connections shall be tested for mechanical strength by loading in the direction of lay of the cable. The
joint shall withstand a load of 100kg when tested on an approved tensile testing machine.
Two connections shall be sectioned, etched, subjected to metallographic examination. One section from
each connection shall be subject to copper penetration measurement and a Vickers hardness survey as
described in BS 427, using a 5 kg load, and the attached test result sheet completed. Intergranular copper
penetration of the pipe material should not exceed 0.5mm beyond the fusion line. For the hardness survey
the spacing between impressions on any one axis across the HAZ shall be 0.5mm. At least two impressions
shall be made in the parent material and fusion material on each axis. The maximum allowable hardness
shall be 350Hv (5kg).
The test programme shall be witnessed by the Company Representative and the results recorded by the
Contractor on the attached forms and submitted for approval. The results shall be in accordance with this
specification.
Pin brazing of cable connections on the pipeline shall not proceed until the Contractor has received written
approval of this pin brazing procedure and the test results.

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Pin Brazing Procedure Qualification Record

Company Name ____________________________________ Date ____________________

Operator's Name ____________________________________________________________
Test Connection No __________________________________________________________

EQUIPMENT
Manufacturer ____________________________________ Type ______________________
Equipment No ______________________________________________________________

BASE METAL

Pipe Diameter ___________________________________ Wall Thickness ______________

Coating ___________________________________________________________________
Method of Pre-Cleaning ______________________________________________________

BRAZING PROCESS AND TYPE OF ATTACHMENT

Cable Diameter ____________________________________________________________
Brazing Pin Type/Size
(i.e. Threaded / M8) ________________________________________________________

Current Used ______________________________________________________________

Volts _____________________________________________________________________
Duration _________________________ Secs
Signature of Operator ___________________________ Date ____________________
Signature of
Engineer's Representative _______________________ Date ____________________

Test Results
Sample No. __________________________________________________________________

Macro

Depth HAZ ___________________________________

Braze Penetration ______________________________
Hardness HV5

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Distance to Impression
from last impression
Hardness HV5

Axis A
Axis B

Pull Test
Load ______________________________________
Point of Failure ______________________________

Signature of Test Supervisor _________________ Date .________________

Signature of
Purchaser’s Representative ___________________ Date _________________

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6. USER COMMENT FORM

User Comment Form
If you find something that is incorrect, ambiguous or could be better in this Procedure, write your comments
and suggestions on this form. Send the form to the Document Control Section (DCS). They make a record of
your comment and send the form to the correct CFDH. The form has spaces for your personal details. This lets
DCS or the CFDH ask you about your comments and tell you about the decision.
Procedure Details Title: Issue Date:
Number:

Page Number: Heading Number: Figure Number:

Comments:

Suggestions:

User’s personal details

Name: Ref. Signature: Date:
Ind.:
Phone:
Document Control Section Actions
Comment Date: CFDH
Number: Ref. Ind.:

Recd.: To CFDH:
CFDH Actions
recd. Decision: Inits.: Ref. Date:

Date: Reject: o Ind.

Accept, revise at next issue: o
o
Accept, issue temporary amendment

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Comments:

Originator Date: Inits.: Document Date: Inits.:

Advised: Control
Advised.

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