SECOND AMC VISIT REPORT FOR CATHODIC

PROTECTION SYSTEM OF MOUNDED BULLETS AT

BPCL LPG BOTTLING PLANT, BANGALORE
By

KB Singh & Associates

Consultants Coatings & Cathodic Protection

Rev 0
14 Aug 2019

Reviewed By
Prepared By Anshul Jain Approved By Accepted
Rev & Date
Sanjaya Rath (NACE Certified CP K B Singh BPCL
Level 3)
 Second AMC visit report on cathodic protection
system of mounded bullets at BPCL LPG Bottling
plant, Bangalore
KB Singh and LPG Bottling plant,
Associates, Noida Bangalore

Contents
1. Introduction
2. International standards
3. Criteria for cathodic protection
4. Overview of the system
5. Status of CP system
6. Results
7. Recommendation

Annexure – 1
CP Monitoring Parameters- Old Mound
A. Transformer Rectifier Unit
B. Potential readings at REJB
C. Monitoring of Anode Groundbed
D. Monitoring of Cathode Junction Box
E. PSP at 12 o’clock position by portable Cu/CuSO4 reference cell
F. Isolation Joint testing
G. DC Decoupler testing
H. Initial condition of CP system

Annexure-2
CP Monitoring Parameters- New Mound
A. Transformer Rectifier Unit
B. Potential readings at REJB
C. Monitoring of Anode Groundbed
D. Monitoring of Cathode Junction Box
E. PSP at 12 o’clock position by portable Cu/CuSO4 reference cell
F. Isolation Joint testing
G. DC Decoupler testing

Page 2 of 16
 Second AMC visit report on cathodic protection
system of mounded bullets at BPCL LPG Bottling
plant, Bangalore
KB Singh and LPG Bottling plant,
Associates, Noida Bangalore

1. Introduction
BPCL has an operational LPG Bottling Plant at Solur, Bangalore. This plant has 2 mounds. Details of each mound are
mentioned below in the table:

No Description Old New

I Storage Capacity 300 MT 600 MT
Ii Diameter of Bullet (m) 5m 6m
Iii Length of Bullet (m) TL-TL 32.5 m 42.5 m
Iv Number of Bullets per mound 3 2
V Commissioned in 2003 2009
100% solid 100% solid elastomeric
Vi External Coating on bullet elastomeric airless airless sprayed
surface sprayed Polyurethane Polyurethane

ICCP system has been provided to protect these bullets against external corrosion. BPCL has awarded AMC
contract for CP system of both the mounds to M/s KB Singh and Associates (KBSA).

th th
Field visit has been made by Mr. Sanjaya Rath (KBSA) on 19 Sept. to 20 Sept 2019. During the visit CP system for
both old and new mounds has been inspected and improvement in health of cathodic protection of bullets has
been brought. This report provides monitoring data, status of cathodic protection, activities performed and
recommendations for improving corrosion protection of mounded bullets.

2. International standards

a. IS 8062: Recommended Practice for Cathodic Protection.

b. OISD –150 Standard.
c. NACE RP 0169- 2013 Standard Recommended Practice: Control of external corrosion of/on underground
or submerge metal piping system.
d. SP0285-2011, “Corrosion Control of Underground Storage Tank Systems by Cathodic Protection”

3. Criteria of Cathodic Protection

• A negative polarized potential of -850 mV (or more negative) with respect to saturated Cu/CuSO4
reference electrode. The polarized potential value shall be in range of -850 mVCSE to -1200 mVCSE or -0.250
V to +0.100 V with respect to Zn reference cell.
• A minimum of 100 mV cathodic polarization between the structure surface and a stable reference
electrode contacting the electrolyte. The formation or decay of polarization can be measured to satisfy
this criterion.

Page 3 of 16
 Second AMC visit report on cathodic protection
system of mounded bullets at BPCL LPG Bottling
plant, Bangalore
KB Singh and LPG Bottling plant,
Associates, Noida Bangalore

4. Overview of CP system

CP System Design Parameters:

No Description Old New

1 Number of TRU per Mound One One

2 AC Input Supply of TRU 240 V 240 V
3 DC Output Rating of TRU 50 V / 75 A 50 V / 25 A
4 Current Interrupter Availability Yes Yes
Manual / AVCC / Manual / AVCC /
5
Modes of Operation of TR unit Auto Auto
6 Number of Reference Cell in TRU 3 3
7 Total number of Anodes in Mound 8 8
8 Anode Strings are Dual Feed No No
9 No of AJB (Anode Junction Box) per Mound One One
No of CJB (Cathode Reference Junction Box) per
10.1
Mound One -
No of CRJB (Cathode Reference Junction Box)
10.2
per Mound - Three
No of REJB (Reference Electrode Junction Box)
10.3
per Mound Three -
11 No of EJB (Earthing Junction Box) in mound One One
12 No of Monolithic Isolation Joints per Bullet Three Three
2 No 2 No
13
No of Surge Diverters per Bullet with make Dehn EXFSL300 Dehn EXFSL300
14 One
No of DC Decoupler per Bullet One
15 Type of DC Decoupler, Rating and Make 5 KA Electrolytic 3.7 KA Solid state
type type
Make: Kirk Make: Dairyland
Engineering USA USA
No of permanent Cu/CuSO4 Reference Cell per 9
16
Bullet 9
17 3
No of Zinc Reference Cell per Bullet 3
No of Access Pits per Bullet for inserting
18
portable reference cell One at top One at top
19 Distance Between AJB/CJB to TR Unit Approx 100 m Approx 60 m
Page 4 of 16
 Second AMC visit report on cathodic protection
system of mounded bullets at BPCL LPG Bottling
plant, Bangalore
KB Singh and LPG Bottling plant,
Associates, Noida Bangalore

5. Status of CP system

Sr. New
Parameter Old
No

A. O/P Voltage and O/P DC Volt: 2.0 V O/P DC Volt: 7.23 V

Current
O/P DC Current: 0.13 A O/P DC Current: 2.18 A

B. Permanent Reference Bullet 1: All 9 No Cu/CuSO4 Bullet 4: 9 of 9 No Cu/CuSO4

electrodes meeting
protection criterion of - All 3 Zn All 3 Zn
0.850 VCSE Instant OFF. Bullet 2: All 9 No Cu/CuSO4 Bullet 5: 7 of 9 No Cu/CuSO4

All 3 Zn All 3 Zn

Bullet 3: All 9 No Cu/CuSO4 Bullet 6: All 9 No Cu/CuSO4

All 3 Zn All 3 Zn

C. PSP at 12 o’clock Yes Yes

position of MSV wrt
portable Cu/CuSO4
meeting NACE/OISD
criterion of -0.850 mVCSE
Instant OFF.

D. Anode strings Anode strings are working OK. 6 out of 8 anode strings are
taking current.

E. Electrical isolation Bullets are electrically isolated. Bullets are electrically isolated.

6. Results
a. In old mound Polarized PSP at all permanent reference cell locations of all 3 bullets (1, 2 and 3) is meeting
NACE/OISD criterion of -0.850 VCSE Instant OFF.
In New Mound polarized PSP of Bullet 4 and 6 is meeting NACE/ OISD criterion of -0.850 VCSE Instant OFF.
However in Bullet 5, 2 number reference cell locations are not meeting the criterion.

b. Anode strings for Old mound are OK.

2 Anode strings out of 8 in New Mound are not drawing CP current.

Page 5 of 16
 Second AMC visit report on cathodic protection
system of mounded bullets at BPCL LPG Bottling
plant, Bangalore
KB Singh and LPG Bottling plant,
Associates, Noida Bangalore

c. Bullets are electrically isolated in New as well as Old Mound.

d. Faulty meters for TR units have been replaced.

e. MIJ has been tested using Tinker & Rasor RFIT IJ tester. All MIJ has been found OK.

7. Recommendations
a. To investigate high current requirement of New Mound, it was suspected that MIJ is leaking current to
earthing. In this visit MIJ has been tested with IJ Tester and all MIJs are found OK.

We propose to check coating condition of bullet by making bell-hole on top of mound during our
next visit.

b. As anode strings A6 and A7 are not drawing any CP current anode to cable joint shall also be inspected
while doing excavation on top of the mound for coating inspection.

c. Spares required
- TR Unit cards for New Mound: 106

Page 6 of 16
 Second AMC visit report on cathodic protection
system of mounded bullets at BPCL LPG Bottling
plant, Bangalore
KB Singh and LPG Bottling plant,
Associates, Noida Bangalore

ANNEXURE-1

Operating parameters of CP System of New Mound

Page 7 of 16
 Second AMC visit report on cathodic protection
system of mounded bullets at BPCL LPG Bottling
plant, Bangalore
KB Singh and LPG Bottling plant,
Associates, Noida Bangalore

A. Transformer Rectifier Unit

Make Raychem RPG

Rating: 50 V / 75 A
Commissioned in 2009
Modes of operation Manual/AVCC/Auto
Input AC supply 240 V AC
Interrupter Yes
AC Voltage 243 V
AC Current 0.5 A
DC Voltage 7.62 V
DC Current 2.18 A
Mode of operation Manual
On: -3.164 VCSE
Potential at RE 1 Instant off: -0.960VCSE
On: -3.395 VCSE
Potential at RE 2 Instant off: -0.871 VCSE
On: -3.660 VCSE
Potential at RE 3 Instant off: -0.922 VCSE

Observation:

• TRU is kept operating in Manual mode due to faulty cards. Card 104 and 106 shall be replaced.

B. Potential Readings at REJB

REFERENCE MSV 4 MSV 5 MSV 6

ELECTRODE Instant
ON Instant off Instant off
NO. off ON PSP(VCSE) ON PSP(VCSE)
PSP(V) PSP(VCSE) PSP(VCSE)
PSP(V)
-3.618 -1.086 -3.544 -0.880 -4.100 -0.968
Cu/CuSO4 1
-3.901 -1.013 -3.226 -0.892 -4.028 -1.027
Cu/CuSO4 2
-3.935 -0.988 -3.704 -0.901 -4.101 -1.000
Cu/CuSO4 3
-3.705 -0.876 -3.686 -0.900 -3.809 -0.969
Cu/CuSO4 4
-3.768 -1.001 -3.642 -0.899 -4.327 -0.979
Cu/CuSO4 5
Cu/CuSO4 6 -4.071 -0.971 -2.791 -0.691 -3.886 -1.032

Page 8 of 16
 Second AMC visit report on cathodic protection
system of mounded bullets at BPCL LPG Bottling
plant, Bangalore
KB Singh and LPG Bottling plant,
Associates, Noida Bangalore

Cu/CuSO4 7 -2.641 -0.735

-3.229 -1.005 -3.806 -0.980
Cu/CuSO4 8 -3.575 -0.922
-3.857 -0.986 -4.382 -0.987
Cu/CuSO4 9 -2.641 -0.971
-3.900 -0.987 -4.005 -1.041
Zn RE 1 -2.639 +0.004
-2.821 -0.069 -3.203 -0.061
Zn RE 2 -2.503 +0.036
-3.039 -0.069 -3.187 -0.076
2Zn RE 3 -3.201 -0.168 -2.765 -0.027 -3.245 -0.046

Interruption cycle: 4 sec ON and 1 Sec off.

Criteria: Instant OFF PSP shall be more negative than -0.850 VCSE.

C. Monitoring of Anode Groundbed

Terminal No. mV Across Shunt Current in Amps

A1 3.1 0.41 A
A2 2.2 0.29 A
A3 2.5 0.33 A
A4 1.7 0.22 A
A5 3.3 0.44 A
A6 0 0
A7 0 0
A8 4.9 0.65 A
Total 17.7 mV 2.34 Amp

Shunt Rating: 10 A /75mV

Observation: Anode string A6 and A7 are not drawing any CP current.

D. Monitoring of Cathode Junction Box

Page 9 of 16
 Second AMC visit report on cathodic protection
system of mounded bullets at BPCL LPG Bottling
plant, Bangalore
KB Singh and LPG Bottling plant,
Associates, Noida Bangalore

Cathode mV Across Current in

MSV No
Connection Shunt Amps
C1 5.9 0.78 A
MSV 4
C2 3.7 0.49 A

C1 5.3 0.70 A
MSV 5
C2 0.1 0.01 A

C1 0.9 0.12 A
MSV 6
C2 5.4 0.72

Total 21.3 2.82 Amp

Shunt rating: 10 A /75mV

Observation: Cathode connection in all bullets is done with Loop in – Loop out arrangement.

E. PSP at 12 o’clock position by Portable Half Cell (Cu/CuSO4)

ON PSP(VCSE) INST. OFF(VCSE)

MSV 1 -3.780 -0.901
MSV 2 -3.885 -0.933
MSV 3 -4.009 -0.958

Observation: Instant OFF PSP of the bullets are meeting NACE/ OISD criterion of -0.850 VCSE Instant OFF.

F. Monolithic Isolation Joint Testing

Protected Side Unprotected Side

ON PSP (V) Instant off PSP (V) ON PSP (V) Instant off PSP (V)

MSV No 4

Liquid LPG -0.529 -0.541

-1.694 -0.621
Vapour in -0.529 -0.541
-1.694 -0.621
Vapor return -0.529 -0.541
-1.694 -0.621

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 Second AMC visit report on cathodic protection
system of mounded bullets at BPCL LPG Bottling
plant, Bangalore
KB Singh and LPG Bottling plant,
Associates, Noida Bangalore

MSV No 5

Liquid LPG -0.529 -0.541

-1.527 -0.640
Vapour in -0.529 -0.541
-1.527 -0.640
Vapor return -0.529 -0.541
-1.527 -0.640
MSV No 6

Liquid LPG -0.529 -0.541

-2.270 -0.707
Vapour in -0.529 -0.541
-2.270 -0.707
Vapor return -0.529 -0.541
-2.270 -0.707

Note: All PSP are wrt portable Cu/CuSO4 half cell kept at remote location.

Analysis: Both MSVs are electrically isolated.

G. Polarization Cell testing.

Dairyland USA make Solid State DC Decouplers has been installed for earthing of each bullet at
one point.

Voltage Across
S No Description
Polarization Cell
1 Bullet 1 1.341 V
2 Bullet 2 1.308 V
3 Bullet 3 1.616 V

Condition of SSD is OK.

Page 11 of 16
 Second AMC visit report on cathodic protection
system of mounded bullets at BPCL LPG Bottling
plant, Bangalore
KB Singh and LPG Bottling plant,
Associates, Noida Bangalore

ANNEXURE-2

Operating parameters of CP System of Old Mound

Page 12 of 16
 Second AMC visit report on cathodic protection
system of mounded bullets at BPCL LPG Bottling
plant, Bangalore
KB Singh and LPG Bottling plant,
Associates, Noida Bangalore

A. Transformer Rectifier Unit

Make Canana
Rating: 50 V / 75 A
Commissioned in 2004
Modes of operation Manual/AVCC/Auto
Input AC supply 240 V AC
Interrupter Yes
Parameter By Manual measurement
AC Voltage 230 V
AC Current 0.4 A
DC Voltage 2.0 V
DC Current 0.13 A
Mode of operation Manual
Potential at RE 1 On: -1.681 VCSE
Instant off: -1.261 VCSE
Potential at RE 2 On: -1.539 VCSE
Instant off: -1.186 VCSE
Potential at RE 3 On: -1.508 VCSE
Instant off: -1.138 VCSE

Observation: TRU is OK.

B. Potential Readings at REJB

REFERENCE MSV 4 MSV 5 MSV 6

ELECTRODE Instant
ON Instant off Instant off
NO. off ON PSP(VCSE) ON PSP(VCSE)
PSP(V) PSP(VCSE) PSP(VCSE)
PSP(V)
-1.477 -1.132 -1.488 -1.132 -1.510 -1.152
Cu/CuSO4 1
-1.356 -0.963 -1.365 -1.008 -1.350 -1.104
Cu/CuSO4 2
-1.298 -0.966 -1.395 -1.002 -1.390 -1.025
Cu/CuSO4 3
-1.598 -1.234 -1.554 -1.178 -1.406 -1.066
Cu/CuSO4 4
-1.444 -1.021 -1.250 0.858 -1.658 -1.226
Cu/CuSO4 5
Cu/CuSO4 6 -1.613 -1.202 -1.488 -1.084 -1.308 0.899

Page 13 of 16
 Second AMC visit report on cathodic protection
system of mounded bullets at BPCL LPG Bottling
plant, Bangalore
KB Singh and LPG Bottling plant,
Associates, Noida Bangalore

Cu/CuSO4 7
-1.518 -1.170 -1.548 -1.192 -1.537 -1.126
Cu/CuSO4 8
-1.452 -1.095 -1.435 -1.092 -1.630 -1.233
Cu/CuSO4 9
-1.586 -1.192 -1.396 -1.024 -1.438 -1.054
Zn RE 1
-0.510 -0.102 -0.446 -0.101 -0.541 -0.181
Zn RE 2
-0.645 -0.242 -0.538 -0.168 -0.607 -0.272
2Zn RE 3 -0.585 -0.208 -0.572 -0.163 -0.669 -0.252

Interruption cycle: 4 sec ON and 1 Sec off.

Observations: Instant OFF PSP with all permanent Cu/CuSO4 reference cells is meeting NACE /OISD
criterion -0.850 VCSE Instant OFF.

C. Monitoring of Anode Groundbed

Terminal No. mV Across Shunt Current in Amps

A1
0.6 0.12 A
A2
A3
0.0 0.00 A
A4
A5
0.0 0. 00 A
A6
A7
0.1 0.02 A
A8
Total 0.7 mV 0.14 Amp

Shunt Rating: 15 A /75mV

Page 14 of 16
 Second AMC visit report on cathodic protection
system of mounded bullets at BPCL LPG Bottling
plant, Bangalore
KB Singh and LPG Bottling plant,
Associates, Noida Bangalore

D. Monitoring of Cathode Junction Box

MSV No mV Across Shunt Current in Amps

C1 0.01 0.02 A

C2

C1 0.04 A

C2 0.2

C1 0.1 0. 02 A

C2

Total 0.04 mV 0.06 Amp

Shunt rating: 15 A /75mV

E. PSP at 12 O’clock position by Portable Half Cell (Cu/CuSO4)

ON PSP(VCSE) INST. OFF(VCSE)

MSV 4 -1.496 -1.086
MSV 5 -1.366 -0.987
MSV 6 -1.515 -1.086

Observation: Instant OFF PSP of the bullets are meeting NACE/ OISD criterion of -0.850 VCSE Instant OFF.

F. Monolithic Isolation Joint Testing

Protected Side Unprotected Side

ON PSP (V) Instant off PSP ON PSP (V) Instant off PSP
(V) (V)

MSV No 4

Liquid LPG -0.315 -0.315

-1.366 -1.075

Page 15 of 16
 Second AMC visit report on cathodic protection
system of mounded bullets at BPCL LPG Bottling
plant, Bangalore
KB Singh and LPG Bottling plant,
Associates, Noida Bangalore

Vapour in -0.315 -0.315

-1.366 -1.075
Vapor return -0.315 -0.315
-1.366 -1.075
MSV-2

Liquid LPG -0.315 -0.315

-1.358 -1.080
Vapour in -0.315 -0.315
-1.358 -1.080
Vapor return -0.315 -0.315
-1.358 -1.080
MSV -3

Liquid LPG -0.315 -0.315

-1.386 -1.088
Vapour in -0.315 -0.315
-1.386 -1.088
Vapor return -0.315 -0.315
-1.386 -1.088

Note: All PSP are wrt portable Cu/CuSO4 half cell kept at remote location.

Bullets are electrically isolated.

G. Polarization Cell testing.

Dairyland USA make Solid State DC Decouplers has been installed for earthing of each bullet at
one point.

S No Description Voltage Across

Polarization Cell
1 Bullet 4 1.205 V
2 Bullet 5 1.185 V
3 Bullet 6 1.184 V

Condition of SSD is OK.

Page 16 of 16