SP60-18 Rev3 Cathodic Protection

SPECIFICATION
SP-60-18 Revision 3

CATHODIC PROTECTION

VALIDITY OF SPECIFICATION
This document will be valid by directly printing the document from Sasol Intranet and
validated by a registered Sasol Intranet user by completing the table below.
Validity automatically expires 3 months after verification. Reinstatement of a document
takes place by verifying pertinence and completing the next line in the table. If the
document is found to be obsolete, it shall be destroyed or marked as such.
It is forbidden to use obsolete or expired documents.
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1 2003-12-12
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This Specification is protected by copyright and is the sole property of Sasol. The information is proprietary to Sasol and is for the sole use
of the identified project or defined scope of work. Any unauthorised use, disclosure or copying or any other means of duplication or
reproduction, is prohibited.
Copyright 2003. Sasol. All rights reserved.

SASOL SPECIFICATION SP-60-18

CATHODIC PROTECTION

Originator : (SIGNED)
DG ROSS
Reviewer : (SIGNED)
DFM GOODWIN
Approved by : (SIGNED)
JP NELL

Date : 16 MARCH 1988
ISSUE DATE: APRIL 1988
For interpretation of the Specification, the following person(s) can be contacted:
GH Mller, BAR Machado, J Piorkowski, T Erasmus
SUBSEQUENT REVISIONS
A Revision Description sheet is included to assist in identifying the changes.
Rev No Issue Date Proposed By Reviewed By Approved By Date
2 Aug 2000 DG Ross BAR Machado C Thirion 5 June 2000
3 Oct 2003 T Erasmus BAR Machado C Thirion 26 Nov 2003

This Specification is protected by copyright and is the sole property of Sasol. The information is proprietary to Sasol and is for the sole use
of the identified project or defined scope of work. Any unauthorised use, disclosure or copying or any other means of duplication or
reproduction, is prohibited.

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CATHODIC PROTECTION

TECHNICAL COMMITTEE OF SPECIFICATION SP-60-18, Revision 3

NAME DEPARTMENT AND / OR COMPANY
BERGH, G (Gerhard) Sasol Infrachem Water Systems
COOKE, JH (Jack) Electrical and Integrity, Natref
ERASMUS, T (Theuns) Electrical Engineering, Sasol Technology
HAYNES, GJ (Gerald) Sasol Technology Consultant
HOLLER, RK (Rolf) Electrical and Integrity, Natref
LOMBARD, ER (Sias) Electrical Engineering, Sasol Technology
MACHADO, BAR (Tony) Electrical Engineering, Sasol Technology
MLLER, GH (Grant) Electrical Engineering, Sasol Technology
OOSTHUIZEN, PC (Pieter) Sasol Oil
WILKINSON, W (William) Reliability, Sasol Synfuels

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REVISION SHEET
REVISION 3
Specification SP-60-18, Revision 2 is revised in its entirety.

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CATHODIC PROTECTION

FOREWORD
The first line of defence in the corrosion protection of metallic structures, whose external surfaces are
exposed to the electrolyte, unquestionably lies in the selection of suitable structural materials, as well
as the application of the correct coating system(s) to the correctly prepared metallic surface(s). This
must be given priority and be properly and adequately addressed in the early mechanical design phase
of any new process plant, transmission or distribution pipeline.
The application of cathodic protection shall be considered as a supplementary measure, unless
regulations state otherwise. The justification for installing cathodic protection shall be based on data
derived from cathodic protection surveys, corrosion surveys and / or operating records of similar
process plants, transmission or distribution pipelines located in similar environments. All of the
relevant economic, safety, environmental, legal and geographical factors shall be considered.
For this reason it is highly desirable that prior to any decision being taken to install cathodic
protection, an acknowledged cathodic protection design specialist should be commissioned to carry
out an initial cathodic protection and / or corrosion site / field survey. This is to gather the pertinent
data required to evaluate the need for cathodic protection and initiate and carry out any field test
programmes, required to determine data such as the Probable Performance Index (PPI) of the buried
structure and the soil resistivity measurements which will all serve as a basis for the cathodic
protection design. A written report must be submitted to SASOL, summarising findings and
recommendations. Should the recommendations favour the installation of cathodic protection, the
report shall include a conceptual design proposal, an order of magnitude cost estimate for the
installation, and an environmental, safety and economic justification for proceeding with the proposal.

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Subject to SASOLs review of the report and acceptance of the conceptual design proposal, the design
specialists scope of work should then be extended to cover:
a. The additional site survey in order to permit the preparation of a detailed cathodic protection
design complete with a detailed technical specification and bill of quantities. The latter shall
permit the procurement or a Request For Quotation (RFQ) document to be issued to enable
cathodic protection construction contractors to carry out the cathodic protection installation.
b. The necessary liaison with the engineering contractor of the process plant, transmission or
distribution pipeline which is to be cathodically protected, so as to ensure the inclusion of all
cathodic protection field installation details in the final plant / pipeline engineering drawings.
c. The site supervision, quality control and commissioning of the completed cathodic protection
system.

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PAGE
TABLE OF CONTENTS
PAGE
1 GENERAL.............................................................................................................................. 1
1.1 SCOPE........................................................................................................................ 1
1.2 LEGAL REQUIREMENTS........................................................................................ 2
1.3 ABBREVIATIONS .................................................................................................... 2
1.4 DEFINITIONS............................................................................................................ 9
1.5 PRECEDENCE......................................................................................................... 17
1.6 MATERIAL REQUIREMENTS .............................................................................. 17
1.7 GUARANTEE PERIOD........................................................................................... 17
2 REFERENCE DOCUMENTS............................................................................................ 18
2.1 SOUTH AFRICAN NATIONAL STANDARDS (SANS) AND SOUTH
AFRICAN BUREAU OF STANDARDS (SABS) CODES OF PRACTICE AND
SPECIFICATIONS................................................................................................... 18
AFRICAN BUREAU OF STANDARDS / INTERNATIONAL
ELECTROTECHNICAL COMMISSION (SABS IEC) SPECIFICATIONS.......... 21
AFRICAN BUREAU OF STANDARDS / INTERNATIONAL
ORGANISATION FOR STANDARDISATION (SABS ISO) STANDARDS....... 21
2.4 AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)
STANDARDS........................................................................................................... 22
2.5 AMERICAN SOCIETY FOR THE TESTING OF MATERIALS (ASTM)............ 22
2.6 AMERICAN PETROLEUM INSTITUTE (API) ..................................................... 23
2.7 NATIONAL ASSOCIATION OF CORROSION ENGINEERS (NACE)
RECOMMENDED PRACTICES............................................................................. 23
2.8 BRITISH STANDARDS INSTITUTION (BS) SPECIFICATIONS....................... 24
2.9 RAL DEUTSCHES INSTITUT FR GTESICHERUNG UND
KENNZEICHNUNG RAL-FARBEN................................................................... 25
2.10 DEUTSCHES INSTITUT FR NORMUNG (DIN)................................................ 25
2.11 INTERNATIONAL ELECTROTECHNICAL COMMISSION (IEC)
PUBLICATIONS...................................................................................................... 25
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2.12 INTERNATIONAL ORGANISATION FOR STANDARDISATION (ISO)
STANDARDS........................................................................................................... 25
2.13 SWEDISH STANDARDS INSTITUTION (SIS) STANDARDS............................ 26
2.14 SASOL SPECIFICATIONS, DATA SHEETS AND STANDARD DRAWINGS.. 26
3 CP SYSTEM REQUIREMENTS....................................................................................... 28
3.1 SPECIALIST CP CONSULTANT AND CP CONTRACTOR ............................... 28
3.2 ON SITE INVESTIGATIONS / SURVEY .............................................................. 29
4 CATHODIC PROTECTION DETAILED DESIGN REQUIREMENTS...................... 39
4.1 GENERAL CONSIDERATIONS ............................................................................ 39
4.2 COATINGS AND CP............................................................................................... 39
4.3 CHOICE OF CP SYSTEM....................................................................................... 41
4.4 DETAILED CP DESIGN CALCULATIONS.......................................................... 42
4.5 SPECIAL DESIGN CONSIDERATIONS ............................................................... 47
5 CONSTRUCTION, DRAWINGS, RECORDS AND COMMISSIONING.................... 48
5.1 CONSTRUCTION, TESTING AND INSPECTION............................................... 49
5.2 COMMISSIONING, AS-BUILT DRAWINGS AND RECORDS .......................... 51
5.3 SPARE PARTS......................................................................................................... 55
5.4 INSTALLATION, OPERATION AND MAINTENANCE MANUALS ................ 55
6 CP ACCEPTANCE CRITERIA ........................................................................................ 55
6.1 ACCEPTANCE CRITERIA..................................................................................... 55
6.2 ASSESSING THE IR FREE STRUCTURE-TO-ELECTROLYTE
POTENTIAL............................................................................................................. 57
7 OPERATION AND MAINTENANCE OF THE CP SYSTEM...................................... 59
8 CATHODIC PROTECTION MATERIALS AND THE INSTALLATION
THEREOF............................................................................................................................ 61
8.1 GENERAL................................................................................................................ 61
8.2 MANUAL TAP CHANGE AND AUTOMATIC THYRISTOR CONTROLLED
TRANSFORMER RECTIFIER UNITS ................................................................... 61
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9 ELECTRICAL CONSTRUCTION ................................................................................... 63
9.1 GENERAL................................................................................................................ 63
9.2 OUTPUT CONTROL............................................................................................... 65
9.3 METERS AND MONITORS ................................................................................... 66
9.4 SURGE PROTECTION............................................................................................ 67
9.5 WIRING AND BUSBARS....................................................................................... 68
9.6 COLOUR CODING AND LABELLING................................................................. 69
9.7 CABLE ENDS AND TERMINALS......................................................................... 71
9.8 EARTHING.............................................................................................................. 72
9.9 SPARES.................................................................................................................... 72
9.10 COMPONENT LAYOUT ........................................................................................ 73
9.11 AUXILIARY AC SUPPLY...................................................................................... 74
9.12 CABINET CONSTRUCTION.................................................................................. 74
9.13 COATING................................................................................................................. 76
9.14 INSPECTION AND TESTING................................................................................ 76
9.15 DOCUMENTATION................................................................................................ 78
9.16 GUARANTEE.......................................................................................................... 78
9.17 MANUFACTURER QUALIFICATIONS ............................................................... 78
10 CONCRETE PLINTHS ...................................................................................................... 78
11 CORROSION RESISTANT SILICON IRON ANODES ................................................ 79
11.1 GENERAL CONSIDERATIONS ............................................................................ 79
11.2 GENERAL ANODE DETAILS ............................................................................... 80
11.3 CHEMICAL COMPOSITION.................................................................................. 82
11.4 QUALITY CONTROL AND TESTING.................................................................. 82
12 TYPICAL IMPRESSED CURRENT ANODE INSTALLATION DETAILS............... 83
12.1 DEEP VERTICAL AND SHALLOW VERTICAL ANODE GROUNDBED
SYSTEMS................................................................................................................. 83
12.2 HORIZONTAL AND DISTRIBUTIVE ANODE GROUNDBED SYSTEMS....... 84
12.3 MIXED METAL OXIDE (MMO) / PRECIOUS METAL OXIDE (PMO)
ANODES .................................................................................................................. 85
12.4 ANODE DIMENSIONS AND TITANIUM SUBSTRATE GRADES.................... 86
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12.5 ANODE LOADING AND OPERATING PARAMETERS..................................... 88
12.6 ANODE CABLE CONNECTION............................................................................ 89
12.7 CHEMICAL AND PERFORMANCE TESTING OF ANODES............................. 90
13 IMPRESSED CURRENT CARBONACEOUS ANODE BACKFILL MATERIAL .... 91
13.1 INTRODUCTION AND GENERAL CONSIDERATIONS.................................... 91
13.2 CHEMICAL COMPOSITION.................................................................................. 92
13.3 PARTICLE SIZE DISTRIBUTION (PSD) .............................................................. 92
13.4 SHIPPING AND PACKAGING............................................................................... 93
14 CATHODIC PROTECTION CABLING.......................................................................... 93
14.1 INTRODUCTION .................................................................................................... 93
14.2 GENERAL PROPERTIES OF INSULATING COMPOUNDS .............................. 94
14.3 CABLE AND CABLE INSULATION COMPLIANCE.......................................... 95
14.4 CP CABLE REQUIREMENTS................................................................................ 96
14.5 CABLE INSTALLATION AND IDENTIFICATION............................................. 97
15 EXOTHERMIC WELDING / PIN BRAZING CABLE CONNECTION DETAILS ... 97
15.1 CABLE CONNECTIONS TO PIPES AND REPAIR TO COATINGS .................. 97
15.2 SURFACE PREPARATION.................................................................................... 98
15.3 PIN BRAZING / EXOTHERMIC WELDING......................................................... 98
15.4 TESTING.................................................................................................................. 99
15.5 WELD POWDER / CABLE COMBINATION........................................................ 99
15.6 PRECAUTIONS..................................................................................................... 100
15.7 REINSTATEMENT OF THE COATING SYSTEM............................................. 101
16 PERMANENT REFERENCE ELECTRODES.............................................................. 101
16.1 GENERAL CONSIDERATIONS .......................................................................... 101
16.2 MANUFACTURER QUALIFICATIONS ............................................................. 101
16.3 PERMANENT REFERENCE ELECTRODE (PRE) CONSTRUCTION ............. 101
16.4 PERMANENT REFERENCE ELECTRODE (PRE) STABILITY........................ 103
17 CATHODIC PROTECTION TEST POINTS................................................................. 103
17.1 INTRODUCTION .................................................................................................. 103
17.2 LOCATION OF TEST POSTS / STATIONS ........................................................ 104
17.3 TYPICAL CP TEST POSTS .................................................................................. 105
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18 SOLID STATE DC DECOUPLING DEVICES ............................................................. 108
18.1 INTRODUCTION .................................................................................................. 108
18.2 ELECTRICAL CONSTRUCTION ........................................................................ 109
18.3 ENCLOSURE CONSTRUCTION......................................................................... 111
18.4 INSPECTION AND TESTING.............................................................................. 111
18.5 DOCUMENTATION.............................................................................................. 112
18.6 GUARANTEE........................................................................................................ 112
18.7 MANUFACTURER QUALIFICATIONS ............................................................. 112
19 INSULATING FLANGE MATERIALS ......................................................................... 113
19.2 MATERIAL SPECIFICATIONS ........................................................................... 113
19.3 IDENTIFICATION / LABELS, OPERATING INSULATING FLANGE, NO
ATTACHMENTS TO PIPEWORK PERMITTED .............................................. 115
19.4 MONOLITHIC INSULATING JOINTS................................................................ 115
19.5 INTERNAL PIPE LINING FOR COOLING WATER SERVICE ........................ 116
20 HIGH POTENTIAL SACRIFICIAL MAGNESIUM ANODES (SOIL USE)............. 120
20.2 MAGNESIUM ANODE CHEMICAL COMPOSITION....................................... 121
20.3 HIGH POTENTIAL MAGNESIUM ANODE PHYSICAL PROPERTIES .......... 121
20.4 ANODE CABLE AND CABLE CONNECTION.................................................. 122
20.5 ELECTROCHEMICAL PROPERTIES ................................................................. 123
20.6 TESTING AND REVIEWAL................................................................................. 123
20.7 TYPICAL INSTALLATION DETAILS................................................................ 123
21 AC MITIGATION EARTH ELECTRODE.................................................................... 124
21.1 ZINC TUBE MATERIAL SPECIFICATION........................................................ 124
21.2 ZINC TUBE DIMENSIONS .................................................................................. 125
21.3 ZINC TUBE CHEMICAL COMPOSITION.......................................................... 125
21.4 HARDNESS MEASUREMENTS.......................................................................... 125
21.5 METALLOGRAPHY............................................................................................. 126

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1
1.1
1.1.1
a.
b.
c.
d.
e.
1.1.2
1.1.3
GENERAL
SCOPE
This Specification defines the minimum and mandatory requirements governing the design,
application, installation and commissioning of a Cathodic Protection (CP) system for the
following:
Pipelines, process, fire water, cooling water and utility piping, as well as pipes located
inside chambers;
Pipeline casings (cased crossings);
On-grade storage tank bottoms and the internal surface of storage tanks;
Well casings;
Water boxes of heat exchangers,
installed inside and / or outside the SASOL plant(s) battery limits.
In the event of any detail that is not fully addressed in this specification and that is warranted
to be carried out by the contractor, the work shall be performed in accordance with the
relevant applicable codes and best recognised engineering practices in the CP industry. The
contractor shall develop detailed specifications, procedures and method statements required
to perform the CP design during the engineering phase of work and this shall be submitted to
SASOL for review and approval prior to construction, supply and / or installation work.
The specification covers the general requirements of the CP system. CP may be achieved
through the use of Sacrificial Anode CP (SACP) or Impressed Current CP (ICCP).
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1.1.4
1.1.5
1.2
a.
b.
c.
d.
e.
1.3
AC interference mitigation may be achieved through the use of pipeline-earth grounding
systems, in conjunction with solid state DC decoupling devices. It must not adversely affect
or interfere with the CP system.
The details and extent of the plant or structure equipment required to be cathodically
protected, the site / locality and the meteorological data shall be both specified and supplied
by SASOL and / or the main contractor.
LEGAL REQUIREMENTS
The SASOL factories are subject to the statutory requirements of the following Acts and all
CP installations shall meet the requirements of these Acts:
The National Environmental Management Act (NEMA) - Act 107 of 1998;
The Occupational Health and Safety Act with Regulations - Act 85 of 1993;
The Mine Health and Safety Act - Act 29 of 1996;
The Minerals Act - Act 50 of 1991;
The National Water Act - Act 36 of 1998.
ABBREVIATIONS
The following CP abbreviations have been used:
A Ampere
A / m Ampere per metre square
AC Alternating Current
AFC Approved For Construction
A.hr / kg Ampere hours per kilogram (Electro-chemical Consumption Rate)
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Al Aluminium
API American Petroleum Institute
A.y Ampere-years
AQL Acceptable Quality Level
ASME American Society of Mechanical Engineers
ASTM American Society for the Testing of Materials
Br Bromine
BSI British Standards Institute
C Carbon
CD Current Drainage
CIP Close Interval Potential
COC Certificate of Compliance
CP Cathodic Protection
Cr Chromium
Cu Copper
CuSO
4
Copper Sulphate
Cu-Ti Copper - Titanium
DB Distribution Board
DC Direct Current
DCVG Direct Current Voltage Gradient
DIN Deutsche Institut fr Normung
ECTFE Ethyl Carbo Tetra-Fluoro-Ethylene
EPR Earth Potential Rise
ETFE Ethyl Tetra-Fluoro-Ethylene
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Ex Hazardous Classified Equipment
EXW Exothermic Welding
F Fluorine
FBE Fusion Bonded Epoxy
Fe Iron
Fe-Si Silicone Iron
FDU Forced Drainage Unit
GC Grounding Cell
g / ml grams per millilitre
GIS Geographical Information System
GPS Global Positioning System
H
2
SO
4
Sulphuric Acid
HDPE High Density Polyethylene
HMWPE High Molecular Weight Polyethylene
HVTL High Voltage Transmission Line / High Voltage Power Line
Hz Hertz
ICCP Impressed Current Cathodic Protection
ID Inner Diameter
IEC International Electrotechnical Commission
IJ Insulating Joint
IF Insulating Flange
IP Ingress Protection
IR Ohmic Voltage Drop
ISO International Organisation for Standardisation
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IrO
2
Iridium Oxide
kg kilogram
kg / m kilogram per cubic metre
kPa kilopascal
kV kilovolt
kV / mm kilovolt per millimetre
kW kilowatt
LCD Liquid Crystal Display
LMPE Low Molecular Weight Polyethylene
m metre
mA / m Milli-ampere per Square Metre
Mg Magnesium
mH Milli-henry
m Milli-ohm
mA Milli-ampere
MIC Microbial Induced Corrosion
Mil Thousandth of an Inch
MMO Mixed Metal Oxide
MMP Maximum Meter Point
MMWPE Medium Molecular Weight Polyethylene
Mn Manganese
Mo Molybdenum
MON Monitor
MOV Metal Oxide Varistor
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MPa Megapascal
mV Milli-volt
mV / C Milli-volt per Degree Celsius
NACE National Association of Corrosion Engineers
NDU Natural Drainage Unit
NDT Non Destructive Testing
NPS Nominal Pipe Size
OD Outer Diameter
OMM Operation and Maintenance Manual
OWS Oily Water Sewer
PC Printed Circuit
PCB Polycarbonate Based
PDF Portable Document Format
PE Polyethylene
pH Level of Acidity or Alkalinity
PIV Peak Inverse Voltage
PMO Precious Metal Oxide
PO Purchase Order
PPI Probable Performance Index
PPM Parts Per Million
PRE Permanent Reference Electrode
PSD Particle Size Distribution
psi Pounds Per Square Inch
P-TP Plant Test Post
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PTFE Poly-Tetra-Fluoro-Ethylene
PVC Poly-Vinyl-Chloride
PVDF Poly-Vinylidene Fluoride
QCP Quality Control Plan
Pub Publication
RE Reference Electrode
RFQ Request For Quotation
RMS Root Mean Square
RP Recommended Practice
R-TP Recording Test Posts
SAACE South African Association of Consulting Engineers
SABS South African Bureau of Standards
SACP Sacrificial Anode Cathodic Protection
SANS South African National Standards
SEM Scanning Electron Microscope
Si Silicon
SI System International
SIS Swedish Standards Institution
SP Specification
SPIR Spare Parts Interchange-ability Record
SRB Sulphate Reducing Bacteria
SS Stainless Steel
SS-DCD Solid State - Direct Current Decoupling Device
STDD Standard Drawing
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SWA Steel Wire Armour
Ta Tantalum
Ta
2
O
5
Tantalum Oxide
TDS Technical Data Sheet
Ti Titanium
TP Test Point / Test Post
TP-R Reference Monitoring Test Post
TRU Transformer Rectifier Unit
V Volt
+VE Positive Terminal
-VE Negative Terminal
XLPE Cross-linked Polyethylene
Zn Zinc
% IR Percentage Ohmic Voltage Drop
% Percentage
C Degrees Celsius
F Degrees Fahrenheit
micro
m micro metre
s micro second
.m micro Ohm metre (unit of measurement for resistivity)
Ohm
cm Ohm Centimetre
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1.4 DEFINITIONS
ANAEROBIC Oxygen deficient environment.
ANAEROBIC BACTERIA Also called sulphate reducing bacteria. A type of bacteria
which corrodes steel and is present only in the absence of
oxygen (anaerobic). When they are present, the protective
potential must be raised to -0,95 V.
ANODE DISTRIBUTION
CABINET
A steel cabinet containing a bulbar to which is joined the
anode cables as well as the main anode groundbed ring main
cable(s).
ANODIC GRADIENT Gradient arising in the soil due to the current flow through
the soil from the anode(s).
ANODE GROUNDBED An anode groundbed consisting of a number of impressed
current anodes joined to a common positive rectifier cable.
The anodes are encapsulated in coke to increase their life and
decrease the resistance to earth. The anode groundbed is on
average 100 m to 150 m long and a minimum of 2,5 m deep.
APPROVAL OR
APPROVED BY SASOL
Written agreement or authorisation by SASOL. All requests
for approval shall be submitted in writing and any proposed
deviation from the specified requirements shall be fully
explained and motivated.
ANODE (IMPRESSED
CURRENT)
Any buried or submerged metal (or graphite) which is
connected to the positive terminal of a transformer rectifier
and serves to introduce current into the earth. CP anodes
normally consist of a silicon iron alloy, containing 14% to
17% silicon, and measuring 1,1 m long and 0,075 m
diameter. Centrifugally cast tubular anodes have proven to
be the most reliable and effective anodes at SASOL.
Generally an anode is defined as any metal in which current
flows from it to the electrolyte.
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ANODE (SACRIFICIAL) A metal which is more electro-negative in potential than
steel and which when buried or immersed confers protection
to the latter when electrically connected to it. For buried
pipelines sacrificial anodes generally consist of magnesium.
ANODIC AND CATHODIC
AREAS
See Corrosion.
BONDING CABINET A steel cabinet used to bond two or more pipelines
electrically.
BYPASS CURRENT The current drained from a pipeline to a railway line, when
the latter is at very negative potential. Under such conditions,
the transformer rectifier temporarily shuts down.
CATHODE (IMPRESSED
CURRENT)
Any buried or submerged metal which is connected to the
negative terminal of a transformer rectifier. Generally a
cathode is defined as any metal in which current flow is
always from the earth to the cathode.
CATHODIC PROTECTION An active electrochemical method of corrosion protection in
which all areas of a metallic surface are rendered cathodic.
CLOSE POTENTIAL
SURVEY
A technique whereby the pipe potential is measured every
metre along the length of the pipeline.
COKE An electrically conducting form of carbon. It is used in
granular form to surround each individual anode in order to
form one long extended anode, termed the anode groundbed.
It decreases the resistance to earth and increases the life of
the individual anodes.
COKE BREEZE An inferior carbonaceous backfill material generally termed
metallurgical coke or coke breeze. It nominally contains less
than 85% fixed carbon and high amounts of sulphur and ash.
CONTINUITY BOND An electric cable welded to both sides of a potentially
insulating joint, such as a coupling or flange, in order to
ensure the electrical continuity.
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CONTRACTOR /
MANUFACTURER
Company engaged to perform the work covered by the
specification (successful supplier or bidder).
CORROSION An electrochemical process resulting in metal dissolution
and degradation. A buried or submerged metal forms anodic
and cathodic areas on its surface with consequent flow of
electric current between them. Corrosion occurs at the anodic
areas.
DATA SHEETS All necessary drawings, tabulations, sketches and relevant
documentation which SASOL will submit with a RFQ or PO,
to clearly indicate the technical, electrical and physical
requirements of the equipment, together with information
that is required to be submitted by the manufacturer.
DC DECOUPLING
DEVICE
A solid state device used for two main purposes. One is to
disconnect two metal systems, of which one is under CP and
the other is not, while at the same time permitting continuity
in any AC circuit, for example an earthing system connected
to a pipeline via this device. The other use is as a surge
arrester whereby it blocks DC voltages up to several volts,
but readily passes current at higher voltages (e.g. AC fault
currents and lightning). Its operation does not depend on the
moisture content of the soil, is easily inspected, tested and
more reliable than a polarisation cell or grounding cell.
DEEP WELL GROUND-
BED
One or more anodes installed vertically in a column, the top
most anode being at a nominal depth of 15 m or more below
the earths surface.
DRAIN POINT That part of the pipeline connected to the negative terminal
of the TRU.
EARTHING The technique of using a buried electrode in order to
decrease the voltage to earth of a particular structure.
ELECTRODE An electrode is a solid electrical conductor which discharges,
or picks up, current from an electrolyte.
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ELECTRODE
(REFERENCE
ELECTRODE [HALF
CELL])
The voltage difference between an electrode and the
electrolyte cannot be measured in absolute terms, but only
with respect to a special reference electrode, whose own
potential does not alter regardless of the solution in which it
is immersed. A reference electrode is also referred to as a
half cell. In CP of buried pipelines, a copper / copper
sulphate reference electrode (Cu / CuSO4) is used.
It consists of a copper rod in a saturated copper sulphate
solution, all housed in a suitable polymer housing and
possesses a porous plug at the bottom to permit current to
flow, enabling one to take potential measurements.
ELECTROLYSIS
(ELECTROLYTIC
CORROSION)
Electrolysis or electrolytic corrosion refers to the corrosion
caused by stray electric currents flowing in the ground. 1 A
flowing for 1 year corrodes 9 kg of steel.
ELECTROLYTE A medium, usually liquid, in which the flow of electric
current is by means of cations and anions. Typical
electrolytes are water and its solutions, acids, etc., and the
soil.
EXOTHERMIC WELDING The universal method of welding a copper cable to a steel
surface. The method is quick and simple and generates far
less heat than brazing or arc welding, which would otherwise
damage the coating and lining. Pin brazing / stud welding is
a newer and quicker method, which generates far less heat
than exothermic welding, but is very costly in comparison.
FORCED DRAINAGE
UNIT
A transformer rectifier using the railway line as the anode is
referred to as a forced drainage unit.
FOREIGN SERVICE A structure lying or buried in the ground belonging to
another owner. Typical examples are pipelines, cables,
railway lines and electricity pylons.
GALVANIC CORROSION A form of corrosion caused by one metal in electrical
contact with another and at different natural potentials or
separated in the galvanic series.
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HALF CELL Another name for reference electrode. See Electrode.
HOLIDAY A defect in the structure coating system also referred to as
coating defects.
HOLIDAY DETECTOR An instrument for detecting coating defects.
HYGROSCOPIC A material that has a high affinity for water.
INORGANIC Compounds composed of elements other than carbon. A few
simple compounds of carbon including carbon monoxide,
carbon dioxide, carbonates and cyanides, are generally
considered inorganic.
INSULATING JOINT /
FLANGE
A joint which is electrically insulating. An insulating flange
normally consists of an insulating gasket, insulating bolt
sleeves and insulating washers. An insulating joint is a
complete joint consisting of insulating epoxies embedded in
a spigot and socket type joint. An insulating joint nominally
cost six to eight times more than an insulting flange.
METAL OXIDE
VARISTOR
A metal oxide varistor is an electrical device used as a
voltage arrester. It has a high resistance at low voltages and
low resistance at high voltages.
MONOLITHIC JOINT Immovable (flange-less) electrical insulating fitting rated to
handle the operating pipe pressure.
NATIVE STATE Natural state or potential of a pipeline or structure.
NATURAL DRAINAGE
UNIT
A unidirectional bond from a pipeline to an electrified
railway line. It permits current flow only when the rail is at
negative potential and consists of one or more diodes, fuses,
surge arresters, etc. It is a passive device requiring no
external source of power.
NATURAL POTENTIAL Also called the corrosion potential. It is the potential of
steel buried in the ground without receiving current from an
external source.
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OVER PROTECTION When the pipe potential is too negative, the coating may be
damaged in the sense that it becomes detached from the steel
pipe, also referred to as cathodic disbondment. There is no
universal agreement as to what the maximum negative value
should be, but the most commonly accepted value of -2,5 V
is used, where no stray currents are present. This potential
must exclude the IR error associated with normal potential
measurements.
PIPE INVERT DEPTH Depth of ground cover from surface to the bottom of the
pipe.
PIPE OVERT DEPTH Depth of ground cover from surface to the top of the pipe.
PIPE POTENTIAL The voltage difference between a pipeline and a reference
electrode inserted in the ground (also known as pipe-to-soil
potential).
POLARISATION The change in metal potential upon passage of current. The
normal potential of steel in the ground is about -0,5 V and if
current enters it via the electrolyte the potential will become
more negative, say -1,0 V.
Polarisation can take place slowly over weeks or months, by
which the potential becomes even more negative and the
current required diminishes. The latter depends on the
coating quality.
POLARISATION CELL A DC electrolytic varistor / decoupling device. It consists of
two metal plates in a suitable electrolyte. The cell passes AC
at all voltages but blocks DC below a certain voltage, but
conducts above a certain voltage limit. By choosing different
metals and electrolytes a number of different blocking
voltages may be achieved. The steady state AC is generally
limited to 0,01% of the maximum surge current. The cells
need constant toping up and cleaning and are not as reliable
as a solid state device.
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PROTECTION LIMITS The limits in pipe potential between which a cathodically
protected pipe should operate. The lower limit is -0,95 V for
complete corrosion protection of the steel substrate, and the
upper limit is -2,5 V in order to avoid coating damage. The
value of -2,5 V is often impossible to adhere to in the
presence of stray currents.
PROTECTION
POTENTIAL
The minimum IR free pipe potential in order to achieve
protection. It varies from metal to metal. The protection
potential for steel ranges between -0,85 V to -0,95 V
depending on the oxygen content of the electrolyte.
RAIL RECORDING The potential of the rail (fluctuation) recorded over time.
REVIEWED/REVIEWAL A formal 5-day hold period on the planning schedule while
SASOL reviews / considers the relevant information or
proposed deviations; all communication to be confirmed in
writing
SILICON IRON ANODES See Impressed Current Anode.
SOIL AND PIPELINE
VOLTAGE GRADIENTS
The voltage gradients arising in the soil in the immediate
vicinity of coating defects, as the current flows (CP or DC
traction) to the bare steel (coating defect) through, the soil.
SOIL RESISTIVITY The specific electrical resistance of the soil. The lower the
resistivity, the higher the corrosivity of the soil. It is
commonly measured on site by a technique called the
Wenner Four method.
STRAY CURRENTS (DC) The flow of DC electric currents in the ground which follow
a course other than that intended. The most frequent cause of
DC stray currents is from electrified railway lines, and of a
fluctuating nature. Another source is that from adjacent CP
systems.
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TEST POINT Consists of a cable welded to the pipe or cleated to the
inside of a chamber wall and connected to an insulated
stainless steel stud protruding through the wall. It permits a
quick and vandal resistant method of measuring the pipe
potential. The potential measurement will however, contain
the IR error.
TEST POST A free standing post protruding about 0,6 m above the
ground and containing a cable welded to the pipe and
extending to the top in a suitable terminal. It permits the
ready determination of the On pipe potential at any
location.
TRANSFORMER
RECTIFIER UNIT
An electrical apparatus which converts AC voltages to low
DC voltages.
UNDER- PROTECTION When the pipe is only partially protected, which is indicated
by a potential of between -0,7 V to -0,85 V.
VIKING JOHNSON
COUPLING
A flexible coupling used to mechanically join two sections
of steel, plastic or concrete pipe materials.
VOLTAGE SURGES Also called voltage transients. A voltage, higher than
normal operating voltage, generally of short duration, which
enters the transformer rectifier or natural drainage unit
(NDU), either from the AC or DC side. It does great
damage unless measures are taken to contain it.
WENNER FOUR
ELECTRODE METHOD
A soil resistivity test method covered in ASTM G57,
utilising four electrodes spaced equidistant to one another.
The electrode separation distance equates to the average
depth measured in the soil. Current is injected into the outer
two electrodes and the potential drop is measured between
the inner two electrodes and the resistivity is then calculated.
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1.5 PRECEDENCE
Any conflict between the technical requirements stated in the RFQ or PO and the technical
requirements of this Specification shall be referred to SASOL for clarification. The
precedence of purchase documents is as follows:
a.
b.
c.
d.
1.6
1.7
The technical requirements specified in the RFQ or PO including terms, conditions
and legal requirements;
Data sheets;
This Specification;
Documents referenced in this Specification.
MATERIAL REQUIREMENTS
The material requirements shall detail all of the necessary drawings, tabulations, sketches,
technical data, materials specification and relevant documentation which will be issued with
a RFQ and / or PO.
The latter shall clearly indicate the technical, electrical, metallurgical and physical
requirements of any equipment, together with the information that is required to be
submitted by the manufacturer.
GUARANTEE PERIOD
The contractor shall guarantee the CP system for a 36 month period, which shall commence
from the date of commissioning.
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2 REFERENCE DOCUMENTS
Where reference is made to a code, specification or standard, the reference shall be taken to
mean the latest edition of the code, specification or standard, including addenda,
supplements and revisions thereto.
2.1 SOUTH AFRICAN NATIONAL STANDARDS (SANS) AND SOUTH AFRICAN
BUREAU OF STANDARDS (SABS) CODES OF PRACTICE AND SPECIFICATIONS
SANS 10086-1 / SABS 086 The installation, inspection and maintenance of
equipment used in explosive atmospheres Part 1:
Installations including surface installations on mines
SANS 10089-2 / SABS 089-2 The petroleum industry Part 2: Electrical
installations in the distribution and marketing sector
SANS 10108 / SABS 0108 The classification of hazardous locations and the
selection of apparatus for use in such locations
SANS 10121 / SABS 0121 Cathodic protection of buried and submerged
structures
SANS 10142-1 / SABS 0142-1 The wiring of premises Part 1: Low-voltage
installations
SANS 10199 / SABS 0199 The design and installation of an earth electrode
specifications
SANS 122 / SABS 122 Pressure-sensitive adhesive tapes for electrical
purposes (Metric units)
SANS 1700-7 /SABS 1700-7 Fasteners Part 7: External drive hexagon bolts and
screws Section 1 - 10: Hexagon head bolts - Product
grades A and B
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SANS 1700-14 / SABS 1700-14 Hexagon nuts Section 1: Style 1 - Product grades A
and B
SANS 1700-7-2 / SABS 1700-7-2 Fasteners Part 7: External drive hexagon bolts and
screws Section 2: Hexagon head bolts - Product
grade B - Reduced shank (shank diameter
approximately equal to pitch diameter)
screws Section 3: Hexagon head bolts - Product
grade C
screws Section 4: Hexagon head screws - Product
grades A and B
screws Section 5: Hexagon head screws - Product
grade C
SANS 1700-14-1 / SABS 1700-14-1 Fasteners Part 14: Hexagon nuts Section 1: Style 1 -
Product grades A and B
SANS 1700-14-2 / SABS 1700-14-2 Fasteners Part 14: Hexagon nuts Section 2: Style 2 -
Product grades A and B
SANS 1700-14-3 / SABS 1700-14-3 Fasteners Part 14: Hexagon nuts Section 3: Product
grade C
SANS 1700-14-4 / SABS 1700-14-4 Fasteners Part 14: Hexagon nuts Section 4: Hexagon
thin nuts (chamfered) - Product grades A and B
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SANS 32 / SABS EN 10240 Internal and / or external protective coatings for steel
tubes - Specification for hot dip galvanized coatings
applied in automatic plants
SANS 1411-1 / SABS 1411-1 Materials of insulated electric cables and flexible
cords Part 1: Conductors
cords Part 2: Poly-Vinyl-Chloride (PVC)
cords Part 3: Elastomers
cords Part 4: Cross-linked Polyethylene (XLPE)
cords Part 5: Halogen-free, flame-retardant materials
cords Part 6: Armour
SANS 1507-1 / SABS 1507-1 Electric cables with extruded solid dielectric
insulation for fixed installations (300 / 500 V to
1900 / 3300 V) Part 1: General
insulation for fixed installations (300 / 500 V to 1900
/ 3300 V) Part 2: Wiring cables
/ 3300 V) Part 3: PVC distribution cables
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1900 / 3300 V) Part 4: XLPE distribution cables
1900 / 3300 V) Part 5: Halogen-free distribution
cables
/ 3300 V) Part 6: Service cables
SANS 555 / SABS 555 Unused and reclaimed mineral insulating oils for
transformers and switchgear
SANS 1149 / SABS 1149 Flat and taper steel washers
2.2
2.3
SOUTH AFRICAN NATIONAL STANDARDS (SANS) AND SOUTH AFRICAN
BUREAU OF STANDARDS / INTERNATIONAL ELECTROTECHNICAL
COMMISSION (SABS IEC) SPECIFICATIONS
SANS 60079-10 / SABS IEC 60079-10 Electrical apparatus for explosive gas
atmospheres Part 10: Classification of
hazardous areas
SOUTH AFRICAN NATIONAL STANDARDS (SANS) AND SOUTH AFRICAN
BUREAU OF STANDARDS / INTERNATIONAL ORGANISATION FOR
STANDARDISATION (SABS ISO) STANDARDS
SANS 121 / SABS ISO 1461 Hot dip galvanized coatings on fabricated iron and steel
articles - Specifications and test methods
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2.4 AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME) STANDARDS
ASME B31.4 Liquid transportation systems for hydrocarbons, liquid petroleum gas,
anhydrous ammonia and alcohols
ASME B31.8 Gas transmission and distribution systems
2.5 AMERICAN SOCIETY FOR THE TESTING OF MATERIALS (ASTM)
ASTM A325 Standard specification for structural bolts, steel and heat treated, 120 /
105 psi minimum tensile strength
ASTM A694 Standard specification for carbon and alloy steel forgings for pipe
flanges, fittings, valves and parts for high-pressure transmission
service
ASTM B265 Standard specification for titanium and titanium alloy strip, sheet and
plate
ASTM B338 Standard specification for seamless and welded titanium and titanium
alloy tubes for condensers and heat exchangers
ASTM A518 Specification for corrosion resistant high silicon iron castings
ASTM B571 Standard practice for qualitative adhesion testing of metallic coatings
ASTM D149 Standard test method for dielectric breakdown voltage
ASTM D229 Standard test method for rigid sheet and plate material used for
electrical insulation
ASTM D293 Standard test method for sieve analysis of coke
ASTM D709 Standard test method for laminated thermosetting materials
ASTM D732 Standard test method for shear strength of plastics by punch tool
ASTM D785 Standard test method for Rockwell hardness of plastics and electrical
insulating materials
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ASTM D1248 Polyethylene plastic moulding and extrusion materials
ASTM D2000 Standard classification system for rubber products
ASTM D3222 Standard specification for unmodified Poly-Vinylidene Fluoride
(PVDF) moulding extrusion and coating material
ASTM E186 Standard reference radiographs for heavy walled (51 to 114 mm) steel
castings
ASTM G57 Method for field measurement of soil resistivity using the Wenner
Four Electrode method
2.6
2.7
AMERICAN PETROLEUM INSTITUTE (API)
API Std 620 Design and Construction of Large, Welded Low-Pressure Storage
Tanks
API Std 650 Welded Steel Tanks for Oil Storage
API RP651 Cathodic Protection of Aboveground Petroleum Storage Tanks
API RP1632 Cathodic Protection of Underground Petroleum Storage Tanks and
Piping Systems
API RP2003 Protection against Ignitions Arising out of Static, Lightning and Stray
Currents
NATIONAL ASSOCIATION OF CORROSION ENGINEERS (NACE) RECOMMENDED
PRACTICES
NACE RP0169 Control of external corrosion on under ground or submerged, metallic
piping systems
NACE RP0177 Mitigation of alternating current and lightning effects on metallic
structures and corrosion control systems
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NACE RP0186 Application of cathodic protection for well casings
NACE RP0193 External cathodic protection of on-grade carbon steel storage tank
bottoms
NACE RP0285 Corrosion control of under ground storage tank systems by cathodic
protection
NACE RP0286 Electrical isolation of cathodically protected pipelines
NACE RP0388 Impressed current cathodic protection of internal submerged surfaces
of steel water storage tanks
NACE RP0572 Design, installation, operation and maintenance of impressed current
deep groundbeds
NACE RP0575 Recommended practice for design, installation, operation and
maintenance of internal cathodic protection system in oil treating
vessels
NACE Pub10A190 Measurement techniques related to criteria for cathodic protection of
underground or submerged steel piping systems
2.8 BRITISH STANDARDS INSTITUTION (BS) SPECIFICATIONS
BS 171 Specification for power transformers
BS 1016 Method for analysing and testing of coal and coke
BS 1591 Specification for corrosion resisting high silicon iron castings
BS 1872 Specification of electroplated coatings on tin
BS 6001 (ISO 2859-1) Sampling procedures for inspection by attributes
Part 1: Specification for sampling plans indexed by acceptable quality
levels (AQL) for lot-by-lot inspection
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BS 7361 Cathodic Protection
Part 1: Code of practice for land and marine applications
2.9
2.10
2.11
2.12
RAL DEUTSCHES INSTITUT FR GTESICHERUNG UND KENNZEICHNUNG
RAL-FARBEN
RAL Specification for Colours for Identification, Coding and Special Purposes
DEUTSCHES INSTITUT FR NORMUNG (DIN)
DIN 30676 Design and application of cathodic protection of external surfaces
DIN 50918 Corrosion of metals, electrochemical corrosion tests
DIN 50925 Verification of the effectiveness of the cathodic protection of buried
structures
DIN 50929 Probability of corrosion of metallic materials when subject to corrosion from
the outside
INTERNATIONAL ELECTROTECHNICAL COMMISSION (IEC) PUBLICATIONS
IEC 60038 Standard voltages
IEC 60144 Degree of protection of enclosures for low voltage switchgear and control
gear
INTERNATIONAL ORGANISATION FOR STANDARDISATION (ISO) STANDARDS
ISO 2325 Method for analysing and testing of coal and coke
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ISO 2859-1 Sampling procedures for inspection by attributes
Part 1: Specification for sampling plans indexed by Acceptable
Quality Levels (AQL) For Lot-by-Lot inspection
ISO 8501-1 Preparation of steel substrates before application of paints and
related products
Part 1 to 3 and supplement 1994
ISO 13 623: 2000E CP monitoring plan
2.13
2.14
2.14.1
SWEDISH STANDARDS INSTITUTION (SIS) STANDARDS
SIS 05 59 00 Pictorial visual standards for surface preparation for the painting of steel
surfaces
SASOL SPECIFICATIONS, DATA SHEETS AND STANDARD DRAWINGS
Specifications
SP-40-3 Spare parts requirements
SP-50-6 Coating and wrapping of under ground steel pipe
SP-50-7 Design of under ground gravity sewers
SP-60-1 General electrical specification
SP-60-4 Low voltage switchgear and motor control centres
SP-60-10 Power and control cables rated 600 / 1000 V
SP-60-35 Earthing systems
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SP-60-37 Classification of hazardous locations and the selection of apparatus for use in
such locations
SP-60-47 Requirements for electrical engineering documentation
SP-90-32 Minimum requirements for SASOL engineering drawings
SP-90-37 End of job documentation deliverables
2.14.2
2.14.3
Data Sheets
E979 Spare Parts and Interchange-ability Record (SPIR)
Standard Drawings
STDD-6005CA Electrical CP general assembly G-026 to G-028
STDD-6005CB Electrical CP general assembly G-030
STDD-6005CD Electrical CP connection assembly G-034 to G-036
STDD-6005CN Electrical CP manual output transformer rectifier
STDD-6005CP Electrical CP details of thermit weld
STDD-6005CQ Electrical CP insulating flange
STDD-6005CR Electrical CP junction box test point
STDD-6005CS Electrical CP cabling at tanks located in tank farms
STDD-6005CT Electrical CP schematic diagram of variable voltage DC decoupler
STDD-6005CU Electrical CP encapsulating of anode head
STDD-6005CV Electrical CP electronic controller
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STDD-6005CW Electrical CP data logger post
STDD-6005CX Electrical CP potential test point details
STDD-6005CY Electrical CP insulating joint details
STDD-6005CZ Electrical CP high potential magnesium and cable connection details
3
3.1
3.1.1
3.1.2
3.1.3
CP SYSTEM REQUIREMENTS
SPECIALIST CP CONSULTANT AND CP CONTRACTOR
SASOL and / or the main contractor shall appoint a specialist sub-consultant in order to carry
out a detailed site survey, to permit the drafting of both a conceptual and detailed CP design,
should they be warranted. The detailed design shall only be carried out upon the reviewal of
the conceptual design by SASOL.
The design of the CP system shall be carried out by a SASOL approved consultant. The CP
consultant shall be completely independent as defined by the Southern African Association
of Consulting Engineers (SAACE). The main contractor shall assist the CP consultant with
drawings to permit the AFC drawings to be issued. The CP consultant shall prepare and
submit to the main contractor / SASOL a detailed list of all materials and equipment required
permitting the relevant RFQ document to be formulated.
The CP construction contractor shall install the CP field installation elements, concurrently
with the construction of the associated process plant and / or pipeline. The CP consultant
shall provide field engineering support and site supervision necessary to ensure the integrity
of the as-built CP installation. The CP consultant shall prepare a quality control plan for the
progressive checkout and acceptance of the CP installation and assist the main contractor in
its implementation.
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3.1.4 The CP consultant shall assist in the checkout, testing and commissioning of the installation
and the marking-up of AFC drawings to reflect the as-built status. He shall also submit a
final commissioning report in accordance with the requirements stipulated below.
3.2
3.2.1
a.
i)
ii)
iii)
iv)
ON SITE INVESTIGATIONS / SURVEY
The following surveys shall be carried out by the CP consultant prior to commencing with
the design:
Soil Corrosivity Survey
Distribution / transmission pipelines
Soil resistivity measurements shall be conducted nominally every 250 m along
the pipeline route in accordance with the Wenner Four Electrode Method, as
stipulated in ASTM G57 at pipe invert depth. Where corrosive areas are
encountered or at locations where temporary CP will be required or where it is
to be anticipated, measurements will be conducted every 50 m or as required.
Alternatively, an electromagnetic soil conductivity meter may be used, on long
remote pipelines. Measurements shall be carried out every 50 m at pipe invert
and overt depth.
Soil samples shall be taken at pipe invert depth or proposed burial depth along
the pipeline route nominally every 1000 m. The samples shall be analysed and
assessed in accordance with DIN 90529 Part 1 to 3, in order to determine the
PPI of the proposed or existing buried steel pipe.
The presence and probable magnitude of SRB shall be assessed every 1000 m
and / or at corrosive locations where the soil resistivity is less than 30 m.
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b. Petrochemical plants
i)
ii)
iii)
iv)
v)
3.2.2
a.
i)
ii)
Soil resistivity measurements shall be conducted accordance with the Wenner
Four Electrode Method, as stipulated in ASTM G57. The measurements shall be
carried out in a 50 m x 50 m grid section at a depth of 0,5 m, 1,5 m, 2,5 m and
3,5 m per grid section.
Soil samples shall be taken at pipe invert depth or proposed burial depth across
the site in accordance with BS 6001: Part1. The samples shall be analysed and
assessed in accordance with DIN 90529 Part 1 to 3, in order to determine the
PPI of the proposed or existing buried steel pipe.
The presence and probable magnitude of SRB shall be assessed per 50 m x
50 m grid section, but only where the soil resistivity is less than 30 m.
Where on-grade carbon steel storage tank bottoms are encountered, all of the
items described in Section 3, of NACE RP0193, shall be evaluated in full for
both new and existing tanks, in order to determine whether or not CP will be
required.
Redox measurements will not be carried out, as they are difficult to perform and
assess under normal site conditions.
Stray Current Survey
The presence and magnitude of DC traction stray currents shall be assessed
prior to installation of the pipeline and / or after installation of any transmission
pipeline. In the absence of a pipeline, rail recordings and pipe to soil and
pipeline voltage gradient recordings shall be conducted at the foreign service(s).
This, however, shall only be conducted upon approval from the foreign
service(s) owner.
On long transmission pipelines, the possible presence and magnitude of telluric
(magnetic interference effects from solar storms and flares) effects, shall also be
determined.
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iii) All foreign service(s) shall be identified, as well as foreign CP system(s) which
may influence (positively and / or negatively) the SASOL system. Where
possible, the GPS co-ordinates shall be obtained and the data entered into the
existing SASOL GIS. Operating data shall be obtained from the railway
authority, including the polarity, operating voltage and power of the overhead
catenary.
iv)
b.
i)
ii)
iii)
Where transmission pipelines are located in close proximity of HVTL, where
resistive and / or capacitive and / or inductive coupling may occur, tests shall be
conducted in order to determine the extent of the interference. All of the
relevant data pertaining to the supply authority shall be obtained, as well as the
soil resistivity at a depth in the vicinity of the HVTL towers representative of
pipe invert and overt depths along the affected pipeline route. All data relating
to the power line transpositions shall be obtained, as well as the distance
between the pipeline and HVTL, including angles of convergence, divergence
and all earthing (earth mat or point) details.
Petrochemical plants
Tests shall be conducted to determine whether the adjacent CP systems will
introduce any form of stray current into the new plant.
The tests shall include but not be limited to obtaining natural potentials with all
of the CP system(s) de-energised. Measurements shall also be obtained with the
neighbouring CP systems re-energised one-by-one. The neighbouring TRU(s)
shall also be pulsed at a 1,1 Hz frequency and the pipe potential signal (On -
Off) influence be recorded, mapped and modelled.
Once the above surveys have been carried out, definitive recommendations can
be made as to whether CP is required or not. A conceptual CP design report
shall be issued to SASOL for reviewal, should CP deemed to be required. As
soon as the conceptual CP design has been reviewed by SASOL, the following
additional tests shall be carried out.
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3.2.3
a.
i)
ii)
iii)
iv)
v)
vi)
Anode Groundbed Survey
General considerations
When designing and / or selecting to use ICCP, consideration must be given to the
proper use and selection of the anode groundbed(s).
The groundbed location shall be determined early in the design process because its
location may affect the choice of which groundbed type may be best suited to a
particular application. The following factors should be considered when choosing a
groundbed location:
Soil resistivity and moisture content;
Interference with other structures;
Electrical shielding by structures;
Availability of power supply and site accessibility;
Vandalism or other damage (e.g. operational damage);
Purpose of the groundbed and availability of Right-of-Way or servitudes.
Horizontal (conventional) anode groundbeds are normally used to distribute the
protective current over a broad area of the structure requiring protection. These are
frequently called remote groundbeds because the structure is outside the anodic
gradient of the groundbed caused by the discharge of current from the anodes to the
surrounding soil. They may be continuous or discrete in construction as detailed in
Figure 1 and 2.
FIGURE 1 SHALLOW CONTINUOUS HORIZONTAL ANODE GROUNDBED

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FIGURE 2 SHALLOW DISCRETE HORIZONTAL ANODE GROUNDBED

b.
i)
ii)
iii)
Anode Groundbeds
Distributed Anode Groundbeds (2,5 m to 15 m deep) are used to reduce the
potential for interference effects on neighbouring structures. They are also used
to protect sections of bare or poorly coated structure. They are extensively used
in congested areas where electrical shielding may or will occur, if other types of
groundbeds are considered.
Deep Vertical Anode Groundbeds ( 30 m deep) are remote to the structure by
virtue of the vertical distance between the anode and structure. Deep anode
groundbeds therefore achieve results similar to remote horizontal (surface)
groundbeds. A deep anode groundbed is an appealing choice when space is not
available for a horizontal groundbed or when the surface soil has a high
resistivity and the deeper strata exhibit low resistivity. They should however,
not be used where electrical shielding can occur in congested plant areas.
Shallow Vertical Anode Groundbeds ( 15 m but 30 m deep) are commonly
used where space is limited and shielding might occur, as well as to mitigate
costs associated with a distributive anode groundbed system as shown in
Figure 3.
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FIGURE 3: DISTRIBUTIVE, DEEP AND SHALLOW VERTICAL ANODE BED
ARRANGEMENT

c.
i)
ii)
Preference shall be given to remote horizontal continuous or discrete anode
groundbed systems. Where servitude and / or Right-of-Way problems exist,
deep vertical anode groundbed systems shall be employed.
Where horizontal anode beds are to be installed, the soil resistivity shall be
measured at 20 m intervals along the entire length of the active anode bed
length at the proposed anode installation depth.
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iii) Soil resistivity measurements shall also be conducted at two, three, four and
five times the equivalent depth of the proposed anodes, at the beginning, half
way to the centre, centre, halfway between the centre and end and end of the
proposed anode bed, using the Wenner Four Electrode Method, as per
ASTM G57.
iv)
v)
vi)
d.
i)
ii)
iii)
The minimum distance between the pipeline and anode bed shall be two and
half times the length of the anode bed.
Where deep vertical anode groundbeds are required, the soil resistivity shall be
measured at a depth of 2 m, 4 m, 8 m, 16 m, 32 m, etc., until the final depth of
the proposed deep vertical anode groundbed is attained, using the Wenner Four
Electrode Method, as per ASTM G57. The values will be rechecked upon
drilling of the bore hole.
The minimum burial depth of the vertical anode bed (i.e. excluding the active
length) shall be determined according to the resistivity data obtained from the
bore hole, but shall nominally be two and a half times the active length of the
bed.
Petrochemical plants
In uncongested areas, deep vertical anode groundbeds shall be the preferred
choice of anode groundbed systems.
In congested areas where electrical shielding can occur, only shallow vertical
and / or distributive anode groundbed systems shall be employed.
In both instances, the soil resistivity shall be measured at the active anode depth
of the proposed shallow vertical / distributive anode groundbed, using the
Wenner Four Electrode Method, as per ASTM G57. The values will be
rechecked upon the drilling of a test hole.
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3.2.4 Current Drainage (CD) Survey
a.
b.
c.
d.
e.
f.
g.
A CD test is conducted in order to calculate the total current required to confer
complete protection to the structure / pipeline. This is of utmost importance as the
current requirements determine the rating and number of TRUs required and the size
and rating of the anode groundbed(s). The current required is also used in order to
determine both the number and distribution (in conjunction with the soil resistivity
data) of the sacrificial anodes required.
This survey cannot generally be carried out on new structures / pipelines or during the
construction of a new process plant or during construction of new on-grade steel
storage tank(s), as construction schedules generally preclude such testing.
On existing pipelines and / or tanks the CD survey must be carried out.
During a CD survey, one essentially sets up a temporary CP system and injects a
known current into the structure(s) requiring protection via a suitable anode
groundbed. The latter may be a convenient fence or steel rods driven into the ground
and the former may be a portable DC power source such as a car battery, AC
generator connected to a rectifier bridge, etc.
The pipe potential is measured along the pipeline / structure before (natural potential),
and after injection of current (On potential). The current is adjusted until adequate
protection is achieved over a meaningful length of pipe or meaningful area of the
structure requiring protection.
It must also be appreciated that the On potentials of the structure / pipeline will also
vary as a result of temperature variations and due to the fact that the On potentials
also contain a voltage drop as a result of the current flowing through the soil /
electrolyte.
From the magnitude of current required and the length of pipe and / or surface area of
the structure protected and taking into consideration the abovementioned variations,
one may proceed towards preparing a CP design based on the current requirements.
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3.2.5
a.
b.
c.
Electrical Continuity Survey
This survey is generally conducted on old pipelines where the method of construction
may not be fully documented and on newly constructed OWS lines. The survey entails
measuring the voltage drop along the pipeline(s), with CP current flowing.
A break in electrical continuity is indicated by a voltage drop and complete electrical
continuity is indicated by a direct short measured between the two points with
current flowing in the pipeline as shown in Figure 4a and 4b.
This survey is obligatory, as any break in electrical continuity will result in corrosion
occurring downstream of the break.
FIGURE 4a and 4b: CONTINUITY BONDED CHAMBER / FLEXIBLE COUPLING
FIGURE 4a:

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FIGURE 4b:

3.2.6
a.
b.
c.
d.
Other CP Requirements

All other aspects pertinent to the installation of a CP system shall be addressed. These
include, but are not limited to the following:
Location of a suitable power source (public, plant and / or remote);
Location of river, rail and / or road crossing where casing will be required;
Location of test stations / points for CP, AC mitigation, foreign crossings, Insulating
Flanges (IF) or Insulating Joints (IJ);
Location of in-line valves, chambers, block valves, etc., etc., etc.
Once all of the above surveys have been carried out, a detailed CP design report will be
submitted to SASOL for reviewal.
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4 CATHODIC PROTECTION DETAILED DESIGN REQUIREMENTS
4.1
4.2
4.2.1
4.2.2
4.2.3
GENERAL CONSIDERATIONS
CP is perhaps the most important of all approaches to corrosion control. By means of an
externally applied electric current, corrosion may be reduced to virtually zero and the metal
surface may be exposed to a corrosive environment without any deterioration for an almost
indefinite period of time. CP is also one of the most economically viable methods available
in abating the corrosion process of submerged metallic structures.
COATINGS AND CP
Coatings (e.g. tape wrap systems, bitumen fibreglass, Fusion Bonded Epoxy (FBE), etc.)
applied to metal surfaces can be extremely effective in containing the corrosion of the steel
substrate in many environments.
However, no freshly applied coating is entirely free from defects and there will always be
small areas of steel which are exposed directly to the corrosive environment. It is possible to
reduce, but not eliminate these defects, by paying attention to workmanship. In practice it
becomes increasingly expensive to achieve fewer and fewer defects due to the need for high
quality inspection, detection and the repair of individual defects.
The coating provides the initial barrier against the corrosive environment and CP provides
protection at the coating defects. This apparently ideally complementary behaviour occurs as
a result of the low resistance path offered by the defects, as opposed to the high resistance
path offered by the coating.
A coating will deteriorate both chemically and mechanically during its lifetime. These results
in an increase in both the number of defects and the current required in order to protect the
newly exposed steel surface areas (defects).
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The defects will once again provide a low path of resistance and the CP current will flow to
it and provide protection, providing that it is of sufficient magnitude. This naturally implies
that the CP system must be designed such that it has sufficient reserve in order to provide the
necessary additional current.
4.2.4
4.2.5
In general, the choice of the coating system falls outside the scope of the CP Consultant.
However, the coating system must be compatible with the choice of CP utilised to protect the
structure.
Specification SP-50-6 must be complied with in full and any deviations must be reviewed by
SASOL prior to carrying out the work.
As a guideline, the protective coating system efficiencies should comply with the following:
COATING SYSTEM EFFICIENCY (%)
Three Layer FBE / Polypropylene > 98,5
FBE > 97,5
Polyethylene Tapes > 96
Cold Applied Mastics or Enamels > 95
Internal Pipe and Tank Linings > 94,5
Bitumen Fibre Glass Coatings > 92
External Epoxy Paint Coatings > 90
No Coating System 0

4.2.6 The pipeline shall be backfilled in accordance with ASME B31.4 / 8. This implies a selected
pipeline backfill material (size less than 9 mm) free from sharp objects, rocks, stones or any
other material which may damage the coating system. Pipelines located in the same trench
should nominally be separated by at least one and a half times the diameter of the largest
pipe, in order to prevent shielding.
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4.2.7 Where concrete encasement of the pipe is required, such as at river crossings, the reinforcing
steel shall be electrically isolated from the steel pipe. The pipeline shall be wrapped as per
Specification SP-50-6 prior to being concrete encased.
4.2.8
4.2.9
4.2.10
4.3
4.3.1
4.3.2
All buried pipelines when entering, passing through or leaving a chamber, reservoir, or any
concrete structure shall ensure a minimum clearance of 50 mm from the steel reinforcing and
the pipe or pipe puddle flange and shall be completely wrapped / coated as per Specification
SP-50-6 in the concrete covered section.
Pipeline sections which will be located inside chambers that may become flooded from time
to time or which will be continuously flooded, shall be wrapped / coated as per Specification
SP-50-6. Sacrificial magnesium anodes shall be employed to protect the pipeline or pipe
section in these chambers.
A DCVG survey shall be conducted on all transmission and distribution lines after
construction, in order to assess the condition of the coating subsequent to construction. The
pipeline construction contractor shall be responsible for the repair of all major defects
identified during the DCVG survey. Some 10 % of the defects will be exposed in order to
delineate defects and compare them to the DCVG % IR values prior to prioritising defects
for repair.
CHOICE OF CP SYSTEM
CP may be achieved by means of ICCP or SACP. The choice of which system to use shall be
based on both technical and economic factors.
ICCP utilises a TRU, which is supplied by a 230 V, 400 V or 525 V AC supply and produces
a low voltage direct current. The negative terminal of the TRU is connected to the structure
(tank / pipe), which becomes the cathode, and the positive terminal to an anode or a series of
anodes buried in the ground. This set-up is generally termed an anode groundbed.
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Current flows from the anode to the cathode through the electrolyte (soil or ground), and
provided it is of an adequate magnitude, protection will be attained.
4.3.3
4.3.4
4.4
4.4.1
a.
b.
c.
d.
e.
f.
g.
h.
i.
A SACP system does not need an external source of power. It exploits the difference in
potential of various metals in the galvanic series and generates its own voltage, much like a
battery. For example, magnesium possess a natural potential of -1700 mV and steel a natural
potential of -500 mV with regard to a saturated copper / copper sulphate reference electrode.
Therefore, the two combined will produce a driving voltage of approximately 1200 mV.
If the structure is subject to moderate to severe stray current influence, only ICCP will be
used. If stray currents are absent, the choice is essentially an economic one, which shall be
fully justified by the consultant.
DETAILED CP DESIGN CALCULATIONS
The design of the CP system shall be based upon, but not be limited to the following:
Native state corrosion potential readings and presence of Foreign services;
Soil resistivity along the pipeline route or in the plant area;
Soil chemical composition and level of the ground water;
PPI of the structure in contact / submerged in the electrolyte;
Structure polarisation characteristics (electrical shielding, proximity of other metallic
structures such as pipes in a common trench, earth mats, etc.);
Operating temperature;
Transient and / or stray currents (such as telluric currents, DC traction and HVTL
interference);
Coating damage factors as installed and for the design life;
Pipeline separation i.e. distance between pipes located in the same trench or in close
proximity.
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4.4.2 The electrical isolation of the structure requiring CP shall as a minimum be addressed as
follows:
a.
b.
i)
ii)
iii)
iv)
v)
4.4.3
4.4.4
Protected pipelines shall be isolated from other structures, such as above ground
processing facilities and / or loading / off-loading terminals, by suitable in-line
isolation components as per NACE RP 0286-97 or BS 7361, Part 1. Electrical
isolation of tanks shall comply with API RP 2003.
CP systems shall be electrically isolated from:
All electrical and instrumentation cable conduit and / or cable armouring and /
or Lead sheathing;
All reinforcing steel at chambers, piles, below grade wall and bunds, etc;
Steel casings at road and river crossings;
Structural steel supports including but not limited to pipe racking, cable racking,
steel ladders, I-beams, etc.;
Electrical earthing systems.
IFs / IJs shall be provided with protective devices should damage from lightning or high
voltage earth currents be possible. SS-DCD(s) shall be used and the enclosure suitably rated
to SANS 60079 / SABS IEC 60079 and SANS 10108 / SABS 0108. In very wet areas
(moisture content greater than 35% during all seasons) and upon reviewal from SASOL,
Copper Titanium grounding cells (Cu-Ti GC) shall be permitted.
Corrosion by stray currents shall be considered on the unprotected side of IFs / IJs where
low-resistivity electrolytes exist either internally and / or externally. Where the process fluid
has a resistivity of 100 cm, isolating spool pieces shall be installed in unlined piping to
prevent anodic corrosion at the unprotected side of the IF / IJ. The spool piece shall be lined
(internally coated) with an amine cured epoxy or process fluid compatible system. The latter
shall include for an IJ / IF at each end. The spool piece shall be of sufficient length to
prevent corrosion, but shall not be less than one metre or four times the pipe diameter which
ever is greater.
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In instances where this proves to be a problem, an internal ICCP or SACP system shall be
designed to mitigate corrosion on the internal pipe surface in the vicinity of an IF / IJ.
4.4.5
a.
b.
c.
4.4.6
a.
b.
Electrical continuity shall be provided across components, other than IFs / IJs which
increases the longitudinal resistance of the pipeline. The latter also implies the use of
multiple negative returns in congested plant areas.
Electrical continuity shall be achieved as follows:
All continuity bonds made to buried piping except across flexible joints (non-welded
joints, flanges, Viking Johnson couplings, etc) shall be brought above ground in
process areas. On transmission and / or distribution pipelines the bonds may be buried
or brought above ground depending on the number and risk of vandalism. In any
event, the locations must be identified for future testing;
The continuity bonds shall be carried out using two cables in parallel and suitably
sized to carry the current and any transient surges which may arise from time to time.
The insulation of the cable shall depend upon the prevailing environment;
Plant chambers shall be continuity bonded externally or internally. Externally shall be
the preferred method on new chambers as the risk of damage during normal operation
will be limited.
The earthing requirements shall be as follows:
The tanks shall possess individual earths and shall be connected to the main plant
earth via a SS-DCD, as per API RP 2003. The tank earth shall not be bonded directly
to the plant earth in order to mitigate interference and prevent the loss of protection at
the tank. The latter does not apply to discrete tank CP systems located between the
impervious layer (lining) and tank base;
The plant earth shall never be connected to the buried fire water, cooling water,
process piping, utility piping or any other buried metallic pipes which are cathodically
protected;
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c. In-line motorised pumps, valves, etc., which are connected to the plant earth shall be
electrically isolated from the buried pipeline via IFs / IJs. The latter may be required
on either side of the buried pipeline section. Continuity bonding will then be
conducted across the isolated valve, pump, section etc.
4.4.7
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
Design calculations, shall as a minimum be based upon the following data in the design
report:
Structure design life;
Applicable CP and other relevant standards. All design calculations and any
assumptions made during the preparation of the design. All assumptions will be
clearly stated;
Soil resistivity, soil corrosivity (PPI data) and the geological soil type survey data;
On-grade tank bedding / padding material, chemical composition, structure
dimensions, drainage, pH, chloride content, etc;
Current density requirements;
Calculations for type of coating and coating damage factors over the design and
project life;
Calculated current demand;
Protection against possible AC or DC electrical interference;
The mathematical modelling of steady state and fault current interaction between
pipelines and HVTL, including resistive, inductive and capacitive coupling and the
EPR in the vicinity of the HVTL earth mats, where applicable;
The rating and design of DC decoupling devices and earthing / grounding electrode
systems for AC mitigation, IFs / IJs, etc., where applicable;
Requirements for isolation;
Any other pertinent CP design criteria, including the location and description of all CP
equipment, bonding requirements between foreign services, test point facilities, valves
and other major pipeline structures, etc.
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4.4.8 For ICCP the design calculations shall also include:
a.
b.
c.
d.
e.
f.
g.
4.4.9
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
TRU design, including number, capacity / rating or the design of other DC power
source(s), should AC power be unavailable, e.g. solar stations;
Anode groundbed design, electrical capacity, expected operating temperature,
expected resistance, inter-anode spacing and the proposed cable installation protection
methods;
Protection requirements prior to the commissioning of the CP system. That is, the use
of temporary CP, where it is deemed to be necessary;
Cable runs, cable current carrying capacity and cable voltage drops;
Pipeline attenuation calculations, protective span of CP systems / stations, including
protective current span (distribution);
In plant environments, the mathematical modelling of soil data;
The mathematical modelling of current distribution from either or both distributive
and shallow vertical anode beds in plant environments.
For SACP systems the design calculations shall also include:
Anode performance in the design temperature range;
Anode weight and dimensions;
Anode material;
Anode efficiency in electrolyte (current and voltage output);
Anode utilisation factor;
Number of anodes;
Distribution of the anodes (distance relative to the structure (remote earth / localised
protection), current distribution to the structure and structure voltage attenuation;
Anode / cathode circuit driving voltage (initial and after cathode polarisation);
Structure resistance to remote earth;
Overall circuit resistance.
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4.5 SPECIAL DESIGN CONSIDERATIONS
4.5.1
a.
b.
c.
d.
e.
f.
g.
In addition to the design requirements already detailed and discussed above, the CP
consultants CP design shall also be based on the following:
The latest ICCP technology for all pipelines and plant structures;
The anode groundbed capacity shall exceed 125% of the design requirements;
The impressed current TRU or DC power supply unit shall exceed 125% of the design
requirements;
Continuous operation of the system for the specified design life of the structures to be
protected. This will generally imply a minimum continuous operation period of
20 years or longer, as specified by SASOL. The availability factor shall exceed 97,5%
for ICCP and 99,5% for SACP systems;
Acceptable range of structure to electrolyte potentials shall be as detailed in Section 6
of this specification;
The CP systems for on-grade storage tank bottoms shall incorporate a minimum of
two suitably rated negative cables installed within cable conduit from the tank centre
to the tank perimeter, as well as PRE installed within the tank foundation for potential
monitoring purposes.
The number of PREs shall comply with the following:
TANK DIAMETER NUMBER OF PRE
15 m 1
> 15 m but 25 m 2
> 25 m but 50 m 3
> 50 m but 70 m 4
> 70 m but 90 m 5
The PRE cables shall exit the tank perimeter via their own cable conduit.
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h. The tank centre negative connection is to ensure uniform distribution to the centre of
the tank, where shielding may occur, had the connection been made to the perimeter of
the tank.
i.
j.
k.
l.
m.
n.
5
The negative tank cables shall be exothermically connected to suitable steel lugs
welded to the bottom centre of the tank base. Mechanical joints shall not be permitted.
The cables and conduit shall be installed during construction and shall not be damaged
during welding and construction of the remainder of the tank base. Regular cable tests
shall be performed to ensure complete integrity.
The negative and PRE cables shall be terminated in a suitably rated enclosure(s)
outside the tank perimeter for future access.
The tank foundation mounds shall consist of fine grained, well compacted material.
Under no circumstances will Bitumen sand, oil filled sands, asphalt or asphalt and
Bitumen mixtures or compounds be permitted to be used as tank padding or as the
tank base material.
The CP Consultant shall be responsible for the accuracy of all field conditions and
data used to prepare the CP system design.
A list of materials and equipment required, including vendor, manufacturer, type, size,
model, quantity, warranty and all other pertinent technical documentation in order to
permit an RFQ to be issued for construction purposes shall be compiled by the CP
consultant.
CONSTRUCTION, DRAWINGS, RECORDS AND COMMISSIONING
Once the RFQ document(s) have been submitted by the various SASOL approved
contractors, the documents shall be evaluated by the CP consultant, in order to ensure full
compliance with the technical specification. Deviations will be evaluated technically and
commercially.
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5.1 CONSTRUCTION, TESTING AND INSPECTION
5.1.1
5.1.2
5.1.3
5.1.4
a.
b.
c.
d.
e.
All installation work shall be carried out in accordance with AFC drawings and
specifications.
No installation shall be undertaken unless the design and drawings have been duly reviewed
by SASOL.
The CP consultant shall prepare a QCP for the systematic monitoring of the installation of all
CP field equipment and piping details. The CP consultant shall be responsible for the
progressive inspection of all CP system details as each item is installed by the construction
contractor. The QCP shall be reviewed by SASOL prior to construction of the CP system.
Installation, checkout and acceptance of each detail must be properly coordinated to ensure
that no piping excavations are backfilled before the pipe coating has been Holiday tested and
the CP details have been checked, tested and passed by Inspectors. Inspection shall include,
but not be limited to the following details:
Continuity and cross bonds on all metallic pipelines, including cooling water, utility
water, fire water, potable water and chemical and oil water sewers;
Exothermic / pin brazed cable connections to the pipe or tank of all CP cables and
bonding conductors, and the reinstatement of protective coatings after completion of
each weld;
Installation of reference electrodes (cells) underneath tank bases and above pipe at
location of connection of rectifier negative cable to pipe;
Installation of sacrificial anodes, permanent or temporary;
Test post installation at location of reference electrodes (including termination of
electrode cables), rectifier negative cable, pipe monitor and pipe negative cable
connections to the test post;
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f. Impressed current anode groundbeds, including all associated cabling, coke backfill
material, anode installation, Perma-seal and graded sand installation where required
and applicable;
g.
h.
i.
j.
k.
5.1.5
a.
b.
c.
d.
e.
5.1.6
Transformer rectifier units and associated cabling;
Monolithic IJs or IFs;
DC decoupling devices or in approved locations grounding cells;
Surge diverters / lightning protection of transformer rectifier units;
Pipeline test posts / points, PRE test posts, bonding points, AC mitigation test points,
etc.
Full chemical and metallurgical data shall be obtained for all of the items listed below, as
detailed on the individual data sheets. The costs associated with these tests shall be for the
account of the CP manufacturer and / or CP construction contractor. Only SASOL approved
laboratories may be used and other proposed laboratories must be approved by SASOL prior
to their use:
Sacrificial magnesium anodes;
Impressed current anodes (silicon iron or precious metal oxide (PMO) / mixed metal
oxide (MMO) anodes);
AC mitigation grounding electrodes;
Impressed current anode backfill material;
The outer sheath of cables where PVDF is used.
The CP consultant shall provide field engineering and supervisory support to the
construction contractor, to ensure that all CP installations are in accordance with AFC
drawings and design specifications.
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5.1.7 A SASOL appointed inspection authority shall also monitor the application of wrapping and
coatings to pipelines and tank bottoms, to ensure their adequacy and compliance with
Specification SP-50-6 and may witness all Holiday testing of wrappings and coatings to
confirm their integrity before final acceptance. These QCP data sheets shall be made
available to the CP consultant.
5.1.8
5.2
5.2.1
5.2.2
5.2.3
The CP consultant shall monitor the QCP relating to the preparation of tank foundation
mounds to verify compliance with requirements of Paragraphs 4.5.1 (f) to (l) of this
Specification.
COMMISSIONING, AS-BUILT DRAWINGS AND RECORDS
The consultant shall supervise the testing, commissioning and setting up of the complete CP
system. Appropriate measurements of structure to electrolyte (soil) potential shall be taken
at all of the various test points, to verify that the system is functioning in accordance with
design and that the protection criteria as set out in Section 6 are complied with in full.
Prior to energising or switching-on, a complete mechanical and electrical inspection shall be
carried out in order to ensure that the installation is fully compliant with the specification and
to ensure that all cables are firmly and correctly connected. Particular caution shall be
exercised when confirming that the correct polarity of all DC cabling has been affected.
After the system has been certified to be both mechanically and electrically compliant, the
initial switch-on of the protection shall be carried out. The measured structure to soil
potentials will continue to change (become more electro negative) for some 3 to 6 months
and test will have to be made at intervals until full protection has been achieved (polarisation
of the structure).
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5.2.4 In the setting up of the system, adjustments shall be made to the flow of the protective
current at all test points in the system so as to achieve stable operation with potentials at all
points on the protected structure. The values shall be more negative than the minimum
values specified in Section 6 of this Specification and where stray currents are absent,
protective potentials should not be more negative than 2500 mV.
5.2.5
5.2.6
a.
b.
c.
d.
e.
The consultant shall make a comprehensive analysis of the measured potentials and provide
a schedule of test points at which future routine test measurements can be conveniently
taken, to confirm continued satisfactory operation of the CP protective system. These points
and the testing requirements will be submitted in a detailed OMM, which will be submitted
together with the CP commissioning report.
The consultant shall submit a final commissioning report, summarising the results of all tests
made and listing all measured values of structure to electrolyte potentials and the protective
CP currents recorded during commissioning and testing. The following shall as a minimum
be included in the commissioning report:
Native State potential measurements shall be conducted at all structures test points,
including cased, thrust bored and / or jacked crossings;
Groundbed continuity and the maximum, minimum and average output values,
including resistance, current and voltage data;
Sacrificial anode connections, the maximum, minimum and average output values,
including resistance, current and voltage data at all installation points. Potential
measurements shall be conducted at points remote from the anodes (if possible);
Pipeline continuity data, at all in-line flexible couplings, valves, pits, chambers, etc.;
As Left energised settings including On and IR free measurements;
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f. Final Balanced, On and IR free potential measurements and the current
distribution along the protected structure. 24 hour recordings, using a 10 second
sampling rate shall be used in all DC traction stray current environments. Eight
equally spaced On and IR free potential measurements shall be conducted around
all of the tank peripheries, as well as at the tank centre and other permanent PREs
buried under the tank, where applicable;
g.
h.
i.
j.
5.2.7
a.
b.
c.
d.
e.
f.
Current output and operating parameters of internal CP equipment for vessels, tanks
and treaters;
Evaluation of any electrical interference effects and their resolution, including the
cross-bond potentials, the magnitude and direction of current at each location. 24 hour
recordings, using a 10 second sampling rate shall be used in all DC traction stray
current environments;
Operating parameters of AC mitigation equipment (where applicable), including AC /
DC current flow and AC / DC potentials;
Operating parameters of any DC decoupling devices, IF(s) and / or monolithic IJ(s)
including hazardous classification certification where required.
The contractor in association with the CP consultant shall also provide as-built drawings of
the installation, which shall include, but not be limited to the following:
Size, type and location of positive and negative cables;
Date, dimension, type and location of anodes (sacrificial and / or impressed anodes);
AC input, DC output, make, model, serial number and capacity of the TRU(s);
The TRU number in the SASOL system (if designated);
Legal land description, where servitudes, and / or Rights-of-Way have been
acquired;
Vendor drawings of the TRU(s) and any other relevant equipment, including but not
limited to the SS-DCD(s), monolithic IJs / IFs test points, etc., where applicable;
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g. Ex rated equipment shall be supplied with the applicable accredited test certificates
relating to the area classification and level of protection where it may be installed;
h.
i.
j.
k.
l.
m.
n.
5.2.8
5.2.9
5.2.10
Material safety data sheets for all components;
Metallurgical laboratory analysis of the coke backfill, impressed and / or sacrificial
anodes and protective outer cable sheath, where applicable;
The TRU AC supply point, including the AC supply schematic and all relevant wiring
diagrams, cable schedules and junction box schedules;
Test points location, including PREs, cross-bonding facilities to Foreign services,
valves, chambers and all other relevant locations required in order to accurately
monitor the efficacy of the CP system;
Location of all pipeline insulators and their associated surge protection devices;
The capacity, type and location of AC voltage mitigation equipment;
COC as per the requirements of SANS 10142 / SABS 0142.
The consultant shall include in the report the schedule of test points developed in accordance
with the above section of this specification, together with a listing of the potentials recorded
during commissioning to serve as a basis of comparison for further (repeat) tests which
SASOL shall carry out every 3 months, 6 months, and 12 months after commissioning to
ensure that the system operates effectively over the 36 month guarantee period.
The commissioning report shall also include a summary of all design calculations and related
design formulae employed, as well as design data such as, surface area of protected
structures, current density allowances, anode bed resistance, anode current output (for both
impressed current and sacrificial systems), anode consumption rates and life expectancy, etc.
The consultant in association with the contractor, on completion of commissioning of the CP
system, shall submit to the main contractor three copies of all CP drawings, to reflect the as-
built status of the system.
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The main contractor shall then check the drawings relating to the as-built status for
submission to SASOL with the relevant End-of-Job documentation. All drawings shall
comply with the requirements of Specification SP-90-32.
5.3
5.4
6
6.1
6.1.1
SPARE PARTS
Data Sheet E979, in accordance with Specification SP-40-3, shall be submitted for all
equipment supplied for the CP system. Spare parts list shall include parts location diagrams
or drawings and prices of all parts which the manufacturer recommends for the first two
years of operation.
INSTALLATION, OPERATION AND MAINTENANCE MANUALS
The manufacturer of each component of equipment shall furnish installation, operation and
maintenance manuals as specified on the data sheets.
CP ACCEPTANCE CRITERIA
ACCEPTANCE CRITERIA
The following criteria as indicated in the table below, shall be employed in order to verify
both the performance and efficacy of the CP system(s) and / or where applicable, any AC
interference mitigation system(s). The efficacy of the CP system shall be evaluated by
recording the structure to electrolyte potentials. Potentials will only be considered to be valid
if the IR error or voltage drop associated with the structure-to-electrolyte potential
measurements has been eliminated, or can be technically shown to be negligible.
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STRUCTURE ENVIRONMENT
ACCEPTANCE
CRITERIA
Cu / CuSO
4
RE
Potential (V DC)
Medium Type
Resistivity Range
(m)
Temp
(C)
Oxygen
Max
(3)
Min
(4)

40 Aerobic -0,850
> 40 Aerobic -0,950
Water / Low Resistivity
Electrolytes
(1)

0 100
65 Anaerobic -0,950
> 100 1000 -0,750
High Resistivity Sandy
Electrolytes
(2)

> 1000
65 Aerobic
-0,650
High Resistivity
Electrolytes
(5)

> 100 65 Anaerobic -0,950
-2,500
NOTES:
1.
2.
3.
4.
5.
6.1.2
To be used for all resistivity design ranges.
These values may only be used where documented high resistivity induced
measurement shifts can be attained.
The protection potential criteria shown apply to the metal-medium interface and the
values correspond to IR free values.
Minimum values only attainable in the absence of DC stray current influence and
where low alloy steel has been employed.
High resistivity soils / electrolytes where water stagnates / collects in pipe trench
(rocky areas) and where MIC can occur. The protection potential criteria shown apply
to the metal-medium interface and the values correspond to IR free values.
For AC mitigation systems, the system shall be considered effective, if the measured steady
state (50 Hz) AC voltage on the structure is less than 15 V at all locations along the structure.
The SS-DCDs shall also block the DC current until the preset voltage (design DC blocking
voltage) threshold is exceeded.
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6.1.3 Under fault conditions, the maximum step and touch potentials as specified in SANS 10199 /
SABS 0199 shall be met in full at all exposed AC mitigation and CP test points. Under fault
conditions the induced structure voltages shall also be less than the structure coating
breakdown voltage, so as to prevent damage to the coating system.
6.2
6.2.1
a.
b.
c.
i)
ii)
ASSESSING THE IR FREE STRUCTURE-TO-ELECTROLYTE POTENTIAL
General Considerations
One of the perennial problems of CP is how to measure accurately the structure (tank /
pipeline) potential. Traditionally this is done by measuring the potential with the
current switched on and the reference located above the pipe or along the tank
periphery. The correct method is to place the RE right next to a bare location of pipe
(coating defect) so as to eliminate the IR drop due to current flow between the RE and
pipe.
This is problematic since as a general rule the location of the defect is not known and
even if it were, it would be laborious and time consuming to dig a hole down to the
pipe to measure the potential. The potential measurement is even more complex for
large diameter flat bottom storage tanks.
There are a number of techniques which can be used to measure the true structure
potential, free of voltage drop errors:
One of these is to measure the instant off potential. With this method, the CP
current is turned off. The instant the current is turned off, the potential due to
the IR drop is removed but the polarised potential decays over a period of time.
It must be noted that this technique cannot be used if stray currents are present;
Another method which may be employed in order to measure IR free
potentials, is the potential versus voltage gradient technique and coupon off
potential, as described in DIN 50 925;
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iii) A technique which overcomes many of the disadvantages of the instantaneous
off technique is the measurement of the coupon off potential. This involves
burying a steel coupon (which behaves as a defect in the pipeline coating) at
each test point. Instead of turning off the CP to the structure, the CP to the
coupon is interrupted, and the potential measured at the instant of interruption.
The method may be subject to errors, for example, if the structure contains
coating defects of substantially larger size than the coupon and if the coupon is
close to a defect;
iv)
v)
A PRE station is another means of minimising IR components in potential
measurements. This basically consists of a permanent reference electrode
combined with a standard man made coating defect (bare steel area) to
simulate a coating defect. The coating defect, which is to be utilised as part of
the PRE should be constructed in accordance with DIN 50 918. It is buried
with the structure and backfilled with the same material.
The probe is oriented so that the plate experiences the equivalent electric field
to that which applies to the other entire pipeline coating defects. The potential
is measured between the man made defect and the reference electrode located
within the centre of the defect so there is no soil voltage gradient. This satisfies
all the requirements for accurate measurements as well as permitting a
comparison with the conventional potential measurements;
Other more complex techniques, include waveform analysis, whereby the
polarised structure potential is measured using the unsmoothed full-wave
rectified waveform of the TRU.
The preferred method is iv) where stray currents are present and iv) or v) in plant
environments where stray currents are not a problem. Consultants may also provide
details of other techniques or test methods, which may be employed in order to
determine true potentials (IR error corrected / free) and these proposed techniques
and / or methods shall be subject to reviewal by SASOL.
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6.2.2 Distribution and Transmission Pipelines - Stray Current Conditions
The true (IR free) potential of pipeline structures which are located in stray current
environments should preferably be determined as follows:
a.
b.
6.2.3
a.
b.
7
IR free PREs should be installed at regular intervals along the pipeline route to
permit ostensible IR free measurements;
Intensive voltage gradient / pipe potential measurements as stipulated in DIN 50 925.
Other techniques which contractors wish to use must first be reviewed by SASOL prior to
commissioning.
All Structures - Environments with No Stray Currents
The true (IR free) potential of pipeline structures which are located in non stray current
environments, should preferably be determined as follows:
IR free PREs should be installed at regular intervals along the pipeline route to
permit ostensible IR free measurements;
Instant Off measurements shall be obtained by pulsing the TRU(s). This may be
achieved by interrupting multiple TRUs using GPS interrupters or interrupting single
TRUs one at a time, with all other TRUs de-energised for testing.
Other techniques which contractors wish to use must first be reviewed by SASOL prior to
commissioning.
OPERATION AND MAINTENANCE OF THE CP SYSTEM
After complete construction of the CP system and commissioning, the system will be
required to be monitored by SASOL during the guarantee period.
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A complete and concise operation and maintenance manual (OMM) will be issued with all of
the relevant hand-over documentation. The OMM shall include but no be limited to the
following:
a.
b.
i)
ii)
iii)
iv)
v)
vi)
vii)
c.
d.
A CP monitoring plan based on ISO 13623:2000 (E);
The CP monitoring plan shall include regular monthly monitoring of CP test point(s)
installed at the following locations:
Road, rail and river crossings;
Insulating joints / couplings;
Pipelines running parallel to or crossing high voltage cables;
Changes in CP methods;
Valves and other major pipeline structures;
Crossing of other pipelines or major metallic structures with or without CP;
Test stations located approximately every kilometre along transmission and
distribution pipelines and test stations located in and around process plant areas,
in order to enable CP measurements and demonstrate the effectiveness of the
CP for the entire pipeline route;
The impressed current CP rectifiers will be monitored twice monthly to verify that the
rectifiers are energized and functioning as designed;
Sacrificial anode locations shall be tested bi-annually and inspected monthly or as
required, based upon the risk of vandalism and theft.
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8 CATHODIC PROTECTION MATERIALS AND THE INSTALLATION THEREOF
8.1
8.2
8.2.1
a.
b.
c.
d.
e.
f.
g.
h.
i.
GENERAL
The CP materials to be used, as part of the CP installation shall conform to the requirements
stipulated below. An equivalent item shall imply complete technical compliance or better,
than that specified. The alternative equivalent material / item shall be reviewed by SASOL
prior to its use.
MANUAL TAP CHANGE AND AUTOMATIC THYRISTOR CONTROLLED
TRANSFORMER RECTIFIER UNITS
Power supplies for ICCP systems are required to generate the DC current required in order to
confer protection. TRUs are the most common power sources for ICCP systems. Each
Manufacturer may offer a perplexing array of options regarding their TRU. The most
commonly noted options are offered in the following areas:
Enclosure Type : 316SS, 3Cr12 or mild steel, IP66, etc.;
Cooling type : Air cooled (convection or forced) or oil cooled;
Control type : Manual (tap change, variac) or automatic;
Rectifying element : Thyristor or diodes;
Circuit type : Constant voltage, current and / or potential;
AC input : Single phase or three phase (400 or 525 V);
DC voltage should be limited to 50 V (max);
DC amperes typically ranges from 10 A to 350 A;
Colour, configuration, type of meters, etc.
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8.2.2 Great inefficiencies may result if the entire CP system is not designed with the power supply
in mind. The essential function of a TRU is to supply a DC between the structure to be
protected (the cathode) and the anode / anode groundbed system. The TRU negative
terminal is connected to the cathode and the positive to the anode. In all instances, the
current must flow from the anode to the cathode via the electrolyte (soil / ground).
8.2.3
a.
b.
c.
d.
8.2.4
For safety and technical reasons, 525 or 400 V AC mains voltage has to be stepped down to
at most 50 V DC while simultaneously increasing the output current to as much as 150 A,
depending on the application.
In order to provide a better appreciation of the conditions in which TRU have to operate, the
following should be kept in mind:
The external load is resistive, but it is not generally constant. Seasonal fluctuations in
the moisture content of the ground can result in the total loop resistance changing by a
factor of three or more;
Rectifiers are subject to frequent and severe lightning and other electrical transients
and surges, originating from the use of high quality dielectric pipe coatings;
The overall reliability of the TRU is of great importance since the protection conferred
on the pipeline is directly dependent on it. In plant areas, the monitoring and
maintenance may be infrequent due to plant operating and maintenance constraints;
The TRU is often required to operate outdoors. The internal temperature may be
capable of reaching in excess of 60C unless steps are taken to vent the heat.
Automatic TRUs are required to maintain the output current constant at a preset value. A
manual control TRU is one where only the output voltage remains constant and the current
and pipe potential varies according to the prevailing circuit resistance.
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9 ELECTRICAL CONSTRUCTION
9.1
9.1.1
9.1.2
9.1.3
9.1.4
9.1.5
GENERAL
The rectifiers shall meet the requirements of all applicable electrical and safety codes.
The rectifier shall be capable of operating at a continuous full rated output in ambient
temperatures between 10C and +60C.
The TRU is to comprise a step down, double wound transformer requiring a 525 V / 400 V
supply, and a rectifier bridge to produce the required DC output. The maximum DC output
voltage may not exceed 50 V. A typical schematic / wiring diagram is shown in Standard
Drawing STDD-6005CN. This is only a type drawing and bidders must supply their own
drawings with the RFQ documents.
The transformer shall be double wound and continuously rated in accordance with BS 171.
Single wound (auto) transformers are not permitted except as a means of controlling the
primary current of the main double wound transformer. The transformer shall have an earth
screen between the primary and secondary to intercept voltage transients, and insulation on
the primary shall be able to withstand 10 kV (due to atmospheric pollution causing
flashovers) between phases, and between phases and earth. The transformer shall have a
minimum efficiency of 95% and regulation shall be no greater than 3% (for not stressing the
electronic components) from no load to full rated load.
The transformer shall have suitable taps on the primary or secondary winding, connecting to
Brass terminals for coarse selection of the voltage. These shall have an insulating cover in
order to prevent accidental contact with the live circuit. The voltage taps shall be equivalent
to 33,3%, 66,6% and 100% of the rated DC voltage.
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9.1.6 Protection against current surges shall be provided by means of a circuit breaker or fuses.
The circuit breaker shall be of the thermal or 100% magnetic type and located in the primary
circuit before the power transformer. The circuit breaker must engage / disengage all phases
of the AC supply and be capable of completely isolating the TRU except the 16 A 230 V
switch socket. A second circuit breaker with thermal overload protection shall be installed
between the power transformer and the rectifier bridge to protect the diodes.
9.1.7
9.1.8
9.1.9
9.1.10
A fuse is to be positioned in the negative DC leg. The fuse must not only be capable of
failing on a short circuit, but also when the output current exceeds the rated current by 40%
and such that no part of the circuit is damaged.
A 0,5 mH choke capable of continuously carrying 125% of the full load current is to be
included in the positive and negative DC legs immediately before the output terminals.
The rectifier bridge shall consist of six silicon diodes (manual units) or six silicon thyristors
(automatic units) connected for full wave rectification. The diodes and thyristors to be used
shall be derated to 50% of the manufacturers published rating and have a PIV of 1600 V
(RMS). Diode / thyristor packs or equivalent are not permitted in applications where the DC
output current is rated at 75 A or above. Above 75 A, discrete rectifier devices shall be used.
The diodes / thyristors shall be rated for continuous operation at 120C and are to be
mounted on aluminium heat sinks suitable for the type of cooling specified. The diodes /
thyristors are to be screwed onto the heat sink using a heat conducting paste which shall
exclude moisture. Care must be taken not to exceed the diode / thyristor manufacturers
torque value when screwing in the diodes.
The three phase crest values shall not exceed 10 % of the DC value at full rated load i.e.
output ripple voltage. At maximum output, the heat sink temperature and ambient
temperature difference shall not exceed 35 C above ambient operating conditions.
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9.1.11 A one-to-one ratio (mVA) shunt (accuracy of at least MMP 25 %) is to be located on the
negative leg with the measuring cables terminating at two 3,5 mm female socket banana
terminals under the DC ammeter. The shunt rating shall be at least 120 % of the maximum
rectifier output current rating.
9.1.12
9.2
9.2.1
9.2.2
a.
b.
In parallel with the negative cable, a monitor cable shall be connected to the pipeline and
connected to the monitor terminal. This cable shall not carry current and is to be used only
for the measurement of the structure potential.
OUTPUT CONTROL
Manual Tap Change Transformer Rectifier Units
For manual tap change transformer rectifier units only, the output voltage shall be adjusted
using 150 A DC rotary tap switches (depending on the TRU full load current capability) or
equivalent and shall allow for at least 16 ranges for output current adjustment i.e. 4 coarse
and 4 fine switch settings.
Automatic Thyristor Controlled Transformer Rectifier Units
The control circuit shall control the firing of the thyristors and perform the following
functions:
Maintain output current constant at a preset value;
Have a current limit facility at a specified value of output voltage.
All the above functions shall be carried out by one control card. All the connections to the
control card are to be by means of plug-in ribbon cables.
The TRU must have a ready mounted spare control card such that in the event of a failure of
the primary control card, the ribbon cable may be disconnected and connected to the spare
card.
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The current limit facility shall be adjustable from 0% to 100% of current output via a
suitable potentiostat and the knob must be set against a graduated scale marked 0 to 10,
with 10 the maximum output of the TRU.
In the constant current mode, the feed-back signal is to come from 3 current transformers
installed on each phase of the mains supply.
In atmospherically polluted areas all control circuitry not contained in an oil tank is to be
sealed in an enclosure rated IP64 minimum.
9.3
9.3.1
a.
b.
c.
d.
e.
9.3.2
9.3.3
METERS AND MONITORS
The TRU shall include the following meters:
DC voltmeter for measurement of output voltage;
DC voltmeter for measurement of pipe potential - press to read;
DC milli-voltmeter (ammeter) connected to the shunt and graduated to the shunt
rating;
DC hour-off meter (to record no DC output hours);
AC voltmeter for measurement of AC supply voltage sequentially between phases.
The pipe potential voltmeter is to be digital with a minimum input impedance of 10 M, and
a LCD. The height of the digits shall not be less than 12,5 mm with an accuracy of MMP
1%.
The pipe potential voltmeter shall be connected to the pipe monitoring terminal and the
reference electrode terminal. The pipe monitoring terminal shall not be connected to the
pipe terminal.
All other meters are to be analogue.
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9.3.4 The analogue meters shall be 96 mm2 with an accuracy of 2% at maximum output and 25C.
The meters shall be compensated to a maximum of 0,85% error over 100C for temperatures
other than 25C.
9.3.5
9.3.6
a.
b.
c.
d.
e.
9.3.7
9.3.8
9.4
9.4.1
All meters shall be discreet, sealed and flush mounted.
The meters shall be labelled as follows:
DC output voltage;
Reference potential;
DC output current;
DC hour-off;
AC Voltage.
Two differently coloured captive terminal sockets (female banana jacks) must be located
beneath each of the output voltmeter, output ammeter and reference voltmeter, to enable one
to check that the meters are reading correctly, with the exception of the AC voltmeter. The
value of the shunt must also be indicated below the ammeter e.g. 100 mV 100 A.
The 3,5 mm banana socket connected to the pipe must also be indicated for the potential
voltmeter. The DC hour-off meter shall indicate the time the DC current has not been
flowing. It shall be capable of detecting a current as low as 1 % of rated current.
Manufacturers are to submit the details of the DC hour-off meter circuit during the RFQ
stage.
SURGE PROTECTION
Indoor type lightning arresters shall not be permitted.
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9.4.2 Moving away from the rectifier bridge towards the output terminals, surge protection will be
sequentially installed as follows:
a.
b.
9.4.3
9.5
9.5.1
9.5.2
Two 280 V 40 kA @ 8 / 20 s MOVs in series are to be connected between the
positive and negative legs. Between the latter two MOV devices, a connection to the
earth bar is to be made via another 280 V 40 kA @ 8 / 20 s MOV. Next to the above
a 550 V 40 kA @ 8 / 20 s MOV, in parallel, is to be connected between the positive
and negative legs. See Standard Drawing STDD-6005CV.
This shall be followed by a 0,5 mH choke in the negative leg (pipeline) and a 0,5 mH
choke in the positive leg (anode) rated at 125% of the full rated load current (output
current) of the TRU.
On all long transmission and distribution pipelines, the negative leg (pipeline) of the DC
output shall be connected to a suitably rated earth via a solid state DC decoupling device, in
order to permit transient, steady state induced AC and DC fault currents to be diverted from
the pipeline directly to earth.
WIRING AND BUSBARS
Wherever possible, flexible multi-strand cable is to be used, the copper conductors
insulation values shall be adjusted to compensate for the internal temperature rise of the unit,
given the ambient operating temperature range. Joints or splices in any wiring will not be
permitted. Not more than two conductors shall be connected to any one terminal, with the
possible exception of anode header cables. All conductors shall be numbered at both ends
with reference to the schematic and wiring diagram supplied.
All conductors excluding bus bars shall be routed in trunking. Bus bars shall be tinned
copper. The latter shall be tinned after cutting, forming and drilling. Tinning shall be in
accordance with Grade Sn6C of BS 1872. Bulbar joints shall be bolted.
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9.5.3 Bolted bulbar joints shall be tinned after cutting, forming and drilling and treated with
petroleum jelly or a similar water repellent paste prior to assembly. Bolted joints shall be
provided with spring washers.
9.6
9.6.1
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
9.6.2
9.6.3
9.6.4
9.6.5
COLOUR CODING AND LABELLING
The following colour coding should be adhered to:
Metal cabinets : Signal Yellow: RAL 1003;
Positive electrical cables : Red;
Negative electrical cables : Black;
Earth cables : Green-Yellow;
Electrical supply cables (1
st
phase) : Red;
nd
phase) : Yellow;
rd
phase) : Blue;
Cable for reference electrode : Red;
Electrical warning signs : Black on Yellow background;
Monitoring cable : Black.
Power transformer secondary cables shall be grey and have an approximately 30 mm heat
shrink sleeve at either end, the colour is to be red, yellow or blue as appropriate to the phase.
If bus bars are used on the power transformer secondary, they are to be insulated by means
of a correctly coloured heat shrink sleeve per phase.
All components and / or component assemblies shall be labelled.
Labels shall cross reference to the circuit diagram.
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9.6.6 Labels shall be of the engraved sandwich Traffolyte type with black letters on a white
background, except the positive output label which shall be in white letters on a red
background. Alternatively aluminium silk screen labels may be used.
9.6.7
9.6.8
9.6.9
a.
b.
c.
d.
e.
9.6.10
9.6.11
9.6.12
Labels shall be in upper case letters with a height of 6 mm for component labels and 10 mm
for output terminal labels.
At Natref, all metal cabinets shall be painted according to the highest voltage colour and
other voltages be indicated as per individual colour code via a 40 mm diameter dot.
Output terminals shall be labelled as follows:
+VE GROUNDBED;
-VE PIPE;
PIPE MON;
RE;
EARTH.
Labels shall be fixed by means of screws or pop rivets such that they shall not dislodged
during the life of the unit. Screws and rivets are to be Brass or Aluminium. Cable tags shall
be plastic.
Cables shall be identified by means of permanently marked ferrules with black lettering on a
white background. Ferrules shall be slip-on-type and matched to the size of the cable.
Ferrules shall be situated so as to read right way up on a horizontal cables and from lug to
insulation on vertical cables.
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9.7 CABLE ENDS AND TERMINALS
9.7.1
9.7.2
9.7.3
a.
b.
c.
9.7.4
9.7.5
9.7.6
9.7.7
9.7.8
9.7.9
Cables shall be terminated at each end by means of lugs.
Control cable lugs shall be pre-insulated by means of heat shrink sleeves.
Power cable lugs shall be insulated by means of heat shrink sleeves or slip-on rubber shrouds
colour-coded as follows:
AC: Red, Yellow or Blue according to phase;
DC Positive (Groundbed / Rail): Red;
DC Negative (Pipe): Black.
All terminals shall be suitably labelled and be completely accessible after completion of all
wiring.
Terminals on power connections shall be provided with lock nuts and / or spring washers.
Output terminals shall be fully insulated from the metal of the housing and shall comprise of
Brass bolts, each provided with nuts, lock nuts, washers and tinned Copper cable lugs
suitable for the specified cable size.
The negative terminal shall be M10 and the positive terminal M16.
Separate terminals size M6 shall be provided for the pipe monitoring cable, and reference
electrode cable.
A 10 mm diameter hole shall be drilled in the earth bar in order to facilitate the connection
via a lug to the earth cable.
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9.8 EARTHING
9.8.1
9.8.2
9.8.3
9.8.4
9.9
a.
b.
c.
d.
The surge diversion units shall be connected to the common earth incorporating the primary
AC supply earth, transformer screen and the transformer rectifier housing.
Earthing shall be carried out in accordance with Specification SP-60-35.
All electrical circuits shall be floating with respect to earth.
An additional dedicated earth may be required at each TRU location on transmission /
distribution pipelines, where a high incidence of transient surges, steady state induced AC
and / or AC fault currents occur. The earth would be connected to the pipe via a SS-DCD
and directly to the incoming AC earth and / or TRU earth.
SPARES
The following minimum spares are to be supplied with the TRU in accordance with
Specification SP-40-03:
Fuses: three of each type and rating used;
Diodes: two of each type and rating used;
MOV: five of each type and rating for R-C networks;
Spark gap: one of each type and rating used and one for the SS-DCD.
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9.10 COMPONENT LAYOUT
9.10.1
9.10.2
Convection Cooled
The transformer, choke and rectifier bridge shall be housed in the bottom of the cabinet and
the meters at the top.
All components are to be mounted such that they may be easily removed for repairs and also
for in-situ repair work. The surge protection devices shall be mounted as close as possible
to the item requiring protection.
Particular attention shall be taken to ensure that the heat is efficiently dissipated and that the
heat of one component does not interfere with the operation of adjacent devices. The spares
detailed in Paragraph 9.9 shall be located on the inside of one of the large doors.
Oil Cooled
All transformers, chokes, rectifier devices, heat-sinks, and any other devices requiring oil
cooling to maintain safe operating temperatures at ambient conditions, are to be placed in an
enclosure containing an adequate volume of insulating (less than 50 ppm PCB) mineral oil to
SANS 555 / SABS 555. All connections through the wall of the oil tank are to be effected
through sealing bushes of the correct electrical and hydraulic pressure rating.
In applications where atmospheric pollution or excessive humidity pose a threat to the
operation of the components, this configuration may be specified even though devices may
be adequately cooled by means of natural convection.
All oil cooled equipment shall be maintenance free, i.e., totally enclosed and sealed. No oil
testing, purification or topping up shall be necessary.
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However, under exceptional circumstances and upon SASOLs reviewal, the oil tank may be
designed to accommodate an adequate volume of oil and to provide ease of access to
components for maintenance purposes (bolted tank cover). The tank is to be suitably
constructed to withstand the pressure of the specified volume of oil and is to be fitted with a
sealable filler tube, a drain valve and a sight-glass for determining oil level indicating
maximum and minimum permissible levels. A breather pipe with a silica-gel desiccant
element is to be fitted to the highest point of the oil-tank.
9.11
9.12
9.12.1
9.12.2
9.12.3
9.12.4
AUXILIARY AC SUPPLY
The TRU shall be provided in the front and back with a standard 230 V single phase 5 A
(1 kW) 3-point plug for providing power to auxiliary devices.
CABINET CONSTRUCTION
The cabinet shall be manufactured from 2 mm thick 3Cr12 steel. It shall be suitably designed
to prevent ingress of dust and rain (at least IP55). The cabinet shall be of sufficient size to
allow easy access for servicing and maintenance.
The housing shall allow for adequate ventilation of the heat-sinks and power elements
(natural convection cooled). It should be borne in mind that as the units generally stand in
the open sun, the internal temperature may reach 60C.
Insect proofing shall be bolted to the inside of the cabinet where the cabinet is open to the
atmosphere.
Cabinet doors shall be sealed by means of closed cell expanded rubber or approved
equivalent.
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9.12.5 Cabinet doors shall be provided with door stays to hold the door open during servicing and
maintenance.
9.12.6
9.12.7
9.12.8
9.12.9
9.12.10
9.12.11
All external welds shall be continuous seam welds. Stitch or tack welding is not permitted.
Cabinets shall be provided with channel section bases and lifting lugs suitably designed to
prevent distortion during transport, handling and installation.
The cabinet base shall be 3Cr12 steel.
The cabinets shall be provided with a bottom plate which shall incorporate a removable
gland plate. The gland plate shall be manufactured from 304 L SS and the entire assembly is
to minimise the ingress of moisture from the ground.
The cabinet must be so designed that there are no inherent moisture traps.
The following information (as a minimum) is to be hard stamped onto the manufacturers
nameplate attached to the inside of the cabinet door:
Owner :
Type of equipment offered : e.g. CP transformer rectifier
AC rating :
DC rating :
Serial No. :
Date of manufacture :
Fault level :
Manufactured to specification :

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9.13 COATING
9.13.1
9.13.2
9.13.3
9.13.4
9.14
9.14.1
9.14.2
Manufacturers shall submit a complete specification relating to the coating system they
intend using, prior to coating the cabinets.
The colour shall be Signal Yellow (RAL 1003), in accordance with RAL-FARBEN.
Application shall be by means of electrostatic spray and the coating systems shall be from
one manufacturer only. The TRU cabinet case shall be finished with two coats of corrosion-
resistant primer and an outdoor environment-resistant finish (fusion bonded polyester or
equal). The coating shall not chalk in sunlight.
Manufacturer must include in their proposed specification, details relating to the surface
preparation and painting. This must be accompanied with full details, record of past
performance and a two year guarantee. The successful contractor may only use his coating
system upon reviewal from SASOL.
INSPECTION AND TESTING
The tests detailed below shall be carried out at the manufacturers works.
All the components shall pass the stipulated tests and the tests shall be carried out in the
presence of SASOL. The manufacturer will issue a test certificate on completion of the tests
and it shall be signed by SASOL. All of the testing shall be carried out at the manufacturers
expense.
The cabinet and AC input, the DC output and cabinet and the primary to secondary sides of
the main transformer shall withstand a 1 kV insulation test.
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9.14.3 Efficiency tests shall be conducted at 10% and 100% of the maximum current and at the full
rated voltage.
9.14.4
9.14.5
9.14.6
9.14.7
9.14.8
9.14.9
The TRU shall operate for 24 hours continuously at maximum current and voltage output
with all the doors closed or until the temperature is stable for a period of not less than
3 hours. Where the temperature continues to rise after 24 hours, the testing shall continue
until the temperature becomes stable.
In the event of the TRU being constructed on a chassis for use inside a Durasafe, the heat
sink temperature shall be recorded.
The ambient, internal cabinet and heat sink temperatures shall be plotted against time. The
temperatures shall be logged by means of a digital data logger at a sampling rate of 1 value
every 15 minutes. The test shall be terminated when there is no further increase in the
temperature difference between the ambient and heat sink temperature. The maximum
temperature difference between the latter two shall not exceed 40C.
Maximum permissible internal temperature under any circumstance shall be 65 C.
The insulation test described in Paragraph 9.14.3 above shall be repeated immediately on
conclusion of the temperature test run.
SASOL may call for other pertinent tests in order to prove compliance with the specification.
The construction contractor shall supply a COC upon installation.
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9.15 DOCUMENTATION
The TRU shall be supplied with the following items, which are to be mounted to the inside
of the front door:
a.
b.
9.16
9.17
10
A removable circuit diagram attached to a 2 mm thick aluminium sheet. The latter
shall then be encapsulated in clear epoxy resin;
Two hard copies and one electronic (PDF format) copy of the Operation and
Maintenance Manual (OMM) shall be supplied to SASOL.
GUARANTEE
The equipment shall carry an unconditional three year guarantee.
The only exceptions shall be for damages arising from vandalism, mechanical damage,
external fire and flooding.
MANUFACTURER QUALIFICATIONS
Rectifiers shall be supplied only by manufacturers pre-qualified by SASOL.
CONCRETE PLINTHS
10.1 Concrete plinths shall be installed at the transformer rectifier unit, anode cabinet and
potential monitoring cabinet.
10.2 The plinth shall be reinforced with steel or hot dipped galvanised steel in corrosive
environments and shall have a strength equal to 25 MPa and installed a minimum of 0,5 m
above ground.
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10.3 The plinths shall have a square concrete surround 75 mm thick (25 MPa), the size of the
surround shall be based upon the site and whether a transformer rectifier unit, anode cabinet
or potential monitoring cabinet is to be installed.
10.4 All plinths shall be buried a minimum of 0,3 m in the ground.
10.5 The TRU plinth shall have a minimum clearance of the open cabinet door width plus an
additional 0,5 m at the front and the back of the cabinet for access.
10.6 All the plinths shall be installed with two 100 mm diameter 2 m long PVC conduits for cable
entry. There shall be two separate conduits for the AC and DC cables.
10.7 The plinths shall be coated with a concrete bonding liquid and then painted with white (or
SASOL required colour) road marking paint.
11
11.1
11.1.1
CORROSION RESISTANT SILICON IRON ANODES
Iron containing a high silicon percentage was developed in the early 1900s. The cast
material was extremely hard and brittle and was first seriously considered for impressed
current anode application in the early 1950s. It was introduced as an anode material in
1954. A subsequent modification to the alloy in 1959 produced better anode performance
characteristics. This alloy consisted of the addition of 4,5% chromium and this anode
material has been widely used and accepted in industry. High silicon chromium cast iron is a
solid, non-porous material. This alloy consists of a matrix of Silica-ferrite in which the
majority of the carbon is in the form of graphite flakes at grain boundaries. Adding
chromium results in the elimination of the graphite. The standard metallurgical composition
of silicon iron anodes conforms to ASTM Standard A518-86 Grade 3.
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11.1.2 This alloy is cast by several methods including sand mould casting, chill-casting, and
centrifugal casting; the latter results in the most stable and homogenous structure. A variety
of anode shapes and sizes are available. The most common anode shapes are cylindrical
tubes and solid bars in lengths up to 2,13 m and diameters ranging from 25,4 mm to 150 mm,
weighing up to 127 kg.
11.1.3
11.1.4
11.1.5
11.2
11.2.1
11.2.2
Each silicon iron anode is normally provided with an individual cable of varying length.
Silicon iron anodes are provided in both end-connected and centre-connected configurations.
The solid bar anodes are cast with a hole at one end to accommodate a connecting cable.
Centre-connections are used for cylindrical tube shapes. There have been numerous methods
and procedures for connecting cable to cast iron anodes. The most common connector for
solid anodes is a poured and tamped lead connection in the cast hole. Centre-connected
anodes utilise a one or two piece lead assembly attached to the interior centre of the anode.
High silicon cast iron anodes are widely used in under ground applications in both shallow
and deep groundbeds. Although the performance is improved with coke breeze, its use is not
critical. This material is also widely used in freshwater and saltwater environments.
The performance of cast iron as an anode is dependent upon the formation of a layer of
silicon dioxide on the surface of the anode. Oxidation of the alloy is necessary to form this
protective film. Silicon-chromium cast iron is highly resistant to acid solutions and it does
not perform particularly well in alkaline environments.
GENERAL ANODE DETAILS
The silicon iron anodes shall be centrifugally cast tubular anodes and manufactured in
accordance with ISO9002. ISO 9002 certification shall be required.
The anodes shall typically have an external diameter of 71 mm and an internal diameter of
55 mm, and be nominally 1071 mm long.
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11.2.3 The anode shall possess a steel terminal which shall be located centrally within the walls in
order to ensure that the anode is consumed uniformly and to ensure that a balanced spread of
current is achieved throughout its length.
11.2.4
11.2.5
11.2.6
11.2.7
11.2.8
11.2.9
11.2.10
The cable insulation shall be as per the requirements specified in Section 14 and the capacity
shall be determined in accordance with the current requirements, the associated voltage drop
and tensile strength required to adequately support the anode during installation. The
minimum cable length shall be detailed in the bill of quantities and an additional 2 m of slack
shall be supplied with each anode.
The entire connection area, with the exception of the top and bottom 150 mm shall be filled
with hot (85 C) pourable bitumen.
The top and bottom 150 mm shall be filled with Hydrochloric acid (10 % solution) resistant
two pack epoxy. All proposed equivalent epoxies shall be submitted to SASOL for reviewal.
Great care must be taken to ensure that the cable insulation is not damaged by the lead
caulking. Care must also be taken to ensure that the bitumen covers the entire cable
connection.
The anode connection and encapsulation shall be suitable for continuous use in wet and / or
submerged conditions for the duration of 20 years.
Care must be taken not to damage the cable insulation during transport, storage and
installation. If there is any sign of damage, the entire anode and cable shall be replaced.
The anodes shall be free from defects which may impair the anode performance. The anode
shall be free from internal porosity, blow holes, cracks or inclusions. The level of defects
present shall not exceed ASTM E186 (Volume II) Level 1 / 2.
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11.2.11 The manufacturer shall submit the pertinent documentation required in order to verify the
level of defects present. The weight of the anode without cable and epoxy, shall be a
minimum of 14 kg and possess a minimum density of 7,0 g / m.
11.2.12
11.3
The anode life shall be 70 A.y minimum as determined for use without coke.
CHEMICAL COMPOSITION
The anode composition shall be in accordance with ASTM A518-86 Grade 3 as indicated in
the table below:
ELEMENT
PERCENTAGE BY WEIGHT
(%)
Silicon (Si) 14,20% to 14,75%
Carbon (C) 0,70% to 1,10%
Manganese (Mn) 1,5%
Molybdenum (Mo) 0,2%
Copper (Cu) 0,5%
Chromium (Cr) 3,35% to 5%
Iron (Fe) Balance
11.4
11.4.1
11.4.2
QUALITY CONTROL AND TESTING
An analysis certificate shall be provided of the batch from which the anodes were cast.
SASOL shall witness that the resistance of the cable to anode connection does not exceed
0,004 . This shall be conducted at the factory.
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11.4.3 Type test certificates shall be submitted at the time of RFQ. These shall give details of the
life of the anode, including the Ampere-years / kg, when tested in a steel drum containing
10% sodium sulphate solution.
11.4.4
11.4.5
11.4.6
11.4.7
12
12.1
12.1.1
A minimum of one week prior to installation, an anode shall be selected and tested for
capacity (A.y), porosity and other tests deemed pertinent by SASOL.
Anodes shall not be dispatched to site prior to testing and / or without the reviewal of
SASOL.
During installation of the anodes, SASOL reserves the right to select a percentage of
anode(s) at random, as stipulated in BS 6001 Part 1, for inspection and testing. A full set of
chemical and metallurgical tests shall be carried out in order to ensure complete compliance
with the specification. The testing shall be for the contractors account.
Great care must be taken to ensure that no damage occurs to the silicon iron anodes during
storage, transport and / or installation. Any broken anodes are to be replaced by the
contractor and all associated costs shall be to his account.
TYPICAL IMPRESSED CURRENT ANODE INSTALLATION DETAILS
DEEP VERTICAL AND SHALLOW VERTICAL ANODE GROUNDBED SYSTEMS
Upon completion and testing of the bore, the anodes shall be installed as follows:
A predetermined amount of coke will be poured into the bore hole and allowed to settle prior
to installation of the first anode. This shall ensure that the bottom anode is resting on a layer
of pitch coke.
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12.1.2 Anode centralisers shall be employed where it cannot be guaranteed that the anode will
ostensibly be located in the centre of the coke column.
12.1.3
12.1.4
12.1.5
12.1.6
12.2
12.2.1
12.2.2
12.2.3
Anodes shall be lowered on an individual basis and coke poured into the bore hole in order
to ensure that the anode is centrally surrounded by the pitch coke and the correct anode
separation is achieved. If MMO / PMO anodes are used, the coke must be pumped.
No cable joints are permitted in these systems.
Upon installation of the top anode (last one), the cables shall be located inside a plastic high
density polyethylene (HDPE) pipe, which shall protect the outer insulation sheath. Graded
washed river sand with a particle size distribution of 0,5 mm to 3,5 mm shall be poured into
the anode bed to a depth of 1,5 m below the surface. The top 1,5 m of the anode bed (bore
hole) shall be sealed with Bentonite or a equivalent.
The anode tails shall be terminated into a suitably rated DC distribution cabinet / enclosure.
Inside process plant areas, cognisance shall be taken of the area classification, environment,
type and rating of enclosure required.
HORIZONTAL AND DISTRIBUTIVE ANODE GROUNDBED SYSTEMS
Anodes shall be pre-packed in 300 mm diameter, 2 m long and 1,5 mm (minimum) spirally
welded galvanised steel canisters.
The anode shall be centrally located inside the canister and encapsulated in pitch coke.
Anodes located inside the canisters shall be lowered into the typically 2,5 m deep horizontal
trench or lowered into the augured vertical distributive hole, on an individual basis. Coke
shall be poured around the canister and augured hole to ensure that there are no voids. This
is generally not required when installing the anode and canister in the horizontal trench.
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12.2.4 Anode canisters filled with pitch coke shall be used in order to ensure that the correct anode
separation is achieved, in horizontal anode beds. This is not required in vertical distributive
systems.
12.2.5
12.2.6
12.3
12.3.1
The anode tails shall be hydraulically crimped to the ring main cable via a suitably sized
T-ferrule. The T-ferrule shall be wrapped with self-vulcanising tape and the entire
connection be placed into a T-shaped cable splicing kit. The ring main cable shall be joined
in a similar fashion to the positive DC header cable. All cable connections shall be inspected
by SASOL prior to backfilling.
Cable warning tape shall be placed along the entire length of the horizontal anode bed at the
required burial depth. This is typically 550 mm below grade outside the SASOL factory
limits. All cabling located inside the SASOL factory shall be installed as per Specification
SP-60-01. The relevant inspection shall be carried out during the cable installation as
stipulated in the SASOL cable installation specification.
MIXED METAL OXIDE (MMO) / PRECIOUS METAL OXIDE (PMO) ANODES
The MMO and PMO anodes covered in this specification will be limited to tubular, mesh
and wire anodes. The MMO / PMO anode shall ostensibly consist of an electro-catalytic
iridium oxide (IrO
2
) and tantalum oxide (Ta
2
O
5
) coating on a titanium (Ti) substrate. The
coating shall be applied by an automated coating process in order to maximise
reproducibility, coating uniformity and consistency. Manual application is not permitted. The
loading requirements shall be carried out in accordance with the manufacturers proprietary
data in order to achieve the stipulated requirements in soils, backfill, fresh, brackish and
seawater applications.
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12.3.2 The MMO / PMO operating voltage shall not exceed 50 V for soil and 9 V for sea water
applications. The latter assumes that no Halide pollutants are present such as fluorine (F) or
bromine (Br). Where deleterious pollutants are to be expected, the precise soil and ground
water chemistry shall be determined, prior to the use of any MMO / PMO anodes. The
anode manufacturers maximum current output for the various anode configurations and
dimensions shall not be exceeded under any circumstances. The anode current output
parameters shall be submitted during the tender stage.
12.4 ANODE DIMENSIONS AND TITANIUM SUBSTRATE GRADES
The titanium anode substrate shall comply as detailed below, for the various anode
configurations. A chemical data sheet shall be supplied with the anodes confirming
compliance to the substrate material.
ANODE
CONFIGURATION
TITANIUM SUBSTRATE
MATERIAL
COMMENTS
Tubular ASTM B338 Grade 1 or 2 - Seamless Installation depth > 100 m
Tubular ASTM B338 Grade 1 or 2 - Welded Installation depth < 100 m
Mesh (Diamond) ASTM B265 Grade 1 or 2 All installation depths
Wire ASTM B348 Grade 1 or 2 All installation depths
All configurations Ti as above and 50 m of metallic
Tantalum*
Severely polluted
environments
Note: *tantalum (Ta) to be electroplated onto titanium substrate.
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The following anode dimensions shall apply:
ANODE
CONFIGURATION
DIMENSIONS
(mm)
CAPACITY COMMENTS
500 to 1000 x 25 x 1,6
(length x nominal bore x
wall thickness)
160 A.y
500 to 1000 x 19 x 1,6
wall thickness)
120 A.y
Installation depth
> 100 m and seawater
applications
500 to 1000 x 25 x 0,9
wall thickness)
160 A.y
Tubular
500 to 1000 x 19 x 0,9
wall thickness)
120 A.y
Installation depth
< 100 m
Mesh (diamond) 1200 x (6 x 4) x 40 x 1
(length x diamond mesh
x width x wall thickness)
60 A.y All installation depths
l x 1,5
(length x cross section)
0,5 A / m @ 20
years
l x 3,0
1,0 A / m @ 20
years
Wire
l x 3,2
1,07 A / m @
20 years
All installation depths
Strip l x 6,35 x 0,635
length x width x
thickness
0,017 A / m @
50 years
All installation depths
Alternative dimensions may only be considered upon reviewal by SASOL.
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12.5 ANODE LOADING AND OPERATING PARAMETERS
12.5.1
12.5.2
The minimum operating life of the anodes shall be 20 years. Manufacturers shall ensure that
a 10% safety factor is applied to the coating loading, in order to ensure that the required life
is met. The maximum rated output is to be based on the fact that the anodes will be
encapsulated in Corr-Carb pitch coke or an equivalent calcined petroleum coke. Other
carbonaceous backfill materials are not suitable, nor permitted to be used with MMO / PMO
anodes.
The following guidelines are to be used for anodes based on a current output of 100 A / m
for calcined petroleum / pitch coke, fresh and brackish environments:
ANODE DATA
MAXIMUM RATED
OUTPUT AMPERE
MINIMUM
LIFETIME
TUBULAR
500 mm x 25,4 mm x 1,6 / 0,9 mm 4,0 20 Years
1000 mm x 25,4 mm x 1,6 / 0,9 mm 8,0 20 Years
500 mm x 19 mm x 1,6 / 0,9 mm 3,0 20 Years
1000 mm x 19 mm x 1,6 / 0,9 mm 6,0 20 Years
MESH (DIAMOND)
1200 mm x (6 x 4) mm x 40 mm x 1 mm 3,0 20 Years
WIRE
1000 mm x 1,5 mm 0,5 20 Years
1000 mm x 3,0 mm 1,0 20 Years
1000 mm x 3,2 mm 1,07 20 Years
STRIP / RIBBON
1000 mm x 6,35 mm x 0,635 mm 0,017 50 Years

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12.6 ANODE CABLE CONNECTION
12.6.1
a.
b.
c.
12.6.2
a.
Tubular Anodes
The cable connection shall meet the following minimum standard requirements for the
tubes. The anode wire shall be attached internally in the longitudinal centre of the
tubular anode by means of titanium wedge, which will be forced fitted into the
centre of the tube. The tube is to be crimped in the centre prior to coating in order to
ensure a tight forced fit.
The end of the anode wire will be stripped and soldered using low temperature silver
solder or it shall be hydraulically crimped into the designated half of the Ti wedge.
Heat shrink shall be applied to seal the end of the wedge where the cable exists. The
entire tube shall then be filled with a hydrochloric acid (10 % solution) resistant epoxy
resin. The resistance of the completed cable to anode connection shall not exceed
0,001 .
The cable size to be used for the anode positive cable connection shall be stipulated by
the engineer. All positive anode cable insulation shall be PVC / HMWPE in non-
polluted environments and PVC / HMWPE / PVDF insulation in polluted or seawater
environments. The minimum thickness of each layer of the insulation shall be 2 mm.
No cable joints will be permitted under any circumstances in the buried or submerged
portions of the positive anode cable. The minimum cable to anode breaking strength
shall be 1175 kg for the 25 mm OD tubular anode.
Mesh and Wire Anodes
The cable connection shall meet the following minimum requirements for both wire
and mesh anodes. The anode wire shall be attached internally in the longitudinal
centre of the tubular polymer connector, using a stud which has been welded to the
mesh or wire. The wire or mesh anode with the attached stud shall be coated with a
MMO / PMO coating.
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b. The end of the anode wire will be stripped and hydraulically crimped onto the MMO /
PMO coated stud. Heat shrink shall be applied to seal the cable joint. The entire
tubular polymer connector shall be filled with a hydrochloric acid (10% solution)
resistant epoxy resin. The resistance of the completed cable to anode connection shall
not exceed 0,001 .
c.
12.7
12.7.1
12.7.2
The cable size to be used for the anode positive cable connection shall be stipulated by
the engineer. All positive anode cable insulation shall be PVC / HMWPE in non-
polluted environments and PVC / HMWPE / PVDF insulation in polluted or seawater
environments.
The minimum thickness of each layer of the insulation shall be 2 mm. No cable joints
will be permitted under any circumstances in the buried or submerged portions of the
positive anode cable. The minimum cable to anode breaking strength shall be 105 kg
and 25 kg for the mesh and wire anode respectively.
CHEMICAL AND PERFORMANCE TESTING OF ANODES
A specified number of anodes will be randomly selected from the batch to be supplied and
tested as detailed below. The anodes for testing will be selected as per BS 6001, Part 1 and
ISO 2859-1.
The anodes will be tested by an accredited third party laboratory, in order to confirm
compliance with the specification. The third party laboratory must be approved by SASOL.
TEST MINIMUM REQUIREMENT / TEST METHOD
Test Solution 10% by volume sulphuric acid (H
2
SO
4
)
Test Temperature Less than 50C for duration of the test
Test Current Density 20 kA / m
2
minimum
Test Duration Minimum of 36 days at the specified current density
Coating Adhesion Test Coating adhesion : ASTM B571
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TEST MINIMUM REQUIREMENT / TEST METHOD
X-ray / NDT The tubular anode shall be X-rayed in order to ensure that
bubbles are not contained within the epoxy sealant
Metallurgical and SEM
Analysis
Anodes will be sectioned and the MMO / PMO coating
verified
13
13.1
IMPRESSED CURRENT CARBONACEOUS ANODE BACKFILL MATERIAL
INTRODUCTION AND GENERAL CONSIDERATIONS
Carbonaceous backfills include various coke products produced from coal, tar (pitch cokes),
bitumen (petroleum cokes) and graphite granules. The coke is in essence the solid residue
left from coal after its volatile constituents have been driven off by heating in the absence of
air and as such, coke is amorphous. This also implies that any metallurgical coke contains
significant amounts of sulphur, ash and volatiles. The ash also generally entraps the heavy
metals, such as lead, cadmium, mercury, copper, zinc, etc., which would not be
environmentally acceptable. The effective resistivity of the soil surrounding an electrode
(anode) is confined to the immediate region of the anode; it is therefore common practice to
reduce the local resistance by using these so-called backfill materials. The backfill being a
conductor carries a measure of the current, reducing to some extent, the consumption rate
of the anode. Therefore, the essential purpose of the carbonaceous backfill is to lower the
anode / soil interface resistance, increase the current capacity by increasing the effective
anode area and thus prolonging the anodes life.
The backfill must also allow for the egress of anodic gases during its normal operation and
be as environmentally safe and friendly, as possible.
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13.2 CHEMICAL COMPOSITION
Preference shall be given to Sasol Carbo-Tar pitch coke (Corr-Carb : Product code 3397).
However, calcined petroleum cokes may be permitted, providing that it is fully compliant
with the technical specification. The manufacturer must be an ISO 9002 or equivalent
accredited organisation. Alternatives will only be permitted to be used upon reviewal from
SASOL. The following shall apply:
CHEMICAL COMPOSITION OF IMPRESSED CURRENT ANODE BACKFILL
MATERIAL CORR-CARB
ELEMENT / COMPOUND SPECIFICATION TEST METHOD
Fixed Carbon 99,5% Minimum
ASTM D5373 / D3172
100 % - (% Ash + % Volatiles)
Sulphur 0,25% Maximum ASTM D4239
Ash and Volatiles 0,50% Maximum
Ash : ASTM D4422
Volatiles : BS 1016: Part 4
Moisture 0,15% Maximum ASTM D3173
Resistivity (1000 kPa) 550 m Maximum Alusuisse C109
Bulk Density 1000 kg / m Maximum ASTM D527

13.3
13.3.1
PARTICLE SIZE DISTRIBUTION (PSD)
The particle size distribution (PSD) of the impressed current anode backfill material is a very
important variable and shall vary according to the anode material and burial depth.
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13.3.2 The PSD shall be determined in accordance with ASTM D293 or BS 1016 Section 110.2.
The following shall apply:
PARTICLE SIZE DISTRIBUTION (PSD) (ASTM D293)
ANODE TYPE ENVIRONMENT
BURIAL
DEPTH
MAX, PSD MIN, PSD
MMO / PMO Soil / Brackish < 15 m 100% < 1,0 mm 5% < 0,5 mm
MMO / PMO Soil / Brackish > 15 m 100% < 1,5 mm 5% < 0,5 mm
MMO / PMO Soil / Brackish > 50 m 100% < 2,0 mm 5% < 0,5 mm
Graphite All All 100% < 3 mm 5% < 0,5 mm
Silicon Iron
Anode
All All 100% < 3 mm 5% < 0,5 mm
13.3.3
13.4
14
14.1
14.1.1
Technical motivations for the use of other PSDs will be considered by SASOL, should the
above values not suffice.
SHIPPING AND PACKAGING
The material shall be supplied in 20 kg polypropylene bags and no more than 52 bags shall
be placed onto each pallet. Upon approval from SASOL, the material may also be supplied
in one ton bulk bags. Paper bags may not be used as packaging, unless the material is to be
used within 10 working days and / or will not be damaged by rain prior to use.
CATHODIC PROTECTION CABLING
INTRODUCTION
The CP cable insulation should be based on the environmental requirements; therefore the
best insulating material for the application should be selected. The selection may involve the
examination of various different performance properties.
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14.1.2 The choice of materials for cable design in order to satisfy any given combination of
installation and environmental conditions can often be more critical than the electrical
requirements.
14.1.3
14.1.4
14.1.5
14.2
14.2.1
a.
b.
c.
d.
14.2.2
These insulation materials can generally be split into thermoplastic and thermoset materials.
Thermoplastic materials soften and flow when heated and usually possess a definitive
melting point. The material will become firm again upon cooling. These materials can be
moulded and shaped with a heating and cooling process and the process can be repeated.
Extrusion of melt flow polymers on wire is an example of this type of material.
Thermoset are soft and pliable during one stage of the processing, can be moulded and
extruded at this state after which they are set or cured, usually at a higher temperature. After
the setting or curing process (cross linking) is complete, they cannot be softened by
reheating, hence the heat and solvent resistance properties are improved over thermoplastic
materials.
GENERAL PROPERTIES OF INSULATING COMPOUNDS
The primary insulation material is the most important of the cable material for overall
performance reasons. The following must be considered:
Voltage dielectric for higher voltage charge at the conductor surface;
Heat resistance in high temperature environments;
Low temperature flexibility;
Toughness for cut-through, abrasion and burial (crush) resistance.
Insulation compounds serve an electrical function first. Secondary properties consider the
environmental factors.
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Environmental factors include, but are not limited to the following:
a.
b.
c.
14.2.3
a.
b.
c.
d.
e.
f.
g.
14.3
14.3.1
14.3.2
14.3.3
Fire resistance;
Ultra-violet resistance (weather ability);
Chemical resistance.
Some of the insulation compounds available include, but are not limited to:
Poly-vinyl-chloride (PVC);
Polyolefins;
Polyethylene (PE):- low (LMPE), medium (MMPE) and high density (HMWPE);
Polypropylene;
Cellular polyolefins;
Non-halogen compounds;
Fluorocarbons (PTFE, PVDF, ECTFE, ETFE).
CABLE AND CABLE INSULATION COMPLIANCE
CP cables shall be insulated and rated for voltages up to 600 V / 1000 V and shall possess
stranded copper conductors in accordance with SANS 1507 / SABS 1507 or ASTM B-8. The
cable conductor size and cable voltage drop shall be calculated in accordance with SANS
10142-1 / SABS 0142-1.
For insulated CP cables, the PVC insulation Type S5 shall comply with the requirements
stipulated in SANS 1507 / SABS 1507 and SANS 1411 / SABS 1411.
For insulated CP cables, the HMWPE insulation Type I, Class C, Category 5 grades 8-5 shall
comply with the requirements stipulated in ASTM D1248.
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14.3.4 In exceptional corrosive environments, fluorocarbon insulation shall be provided. For
insulated CP cables, the PVDF insulation shall comply with the requirements stipulated in
ASTM D3222.
14.4
14.4.1
CP CABLE REQUIREMENTS
Table 14.4 shall be used when selecting DC cables for CP. The insulation layers are
specified from the inner layer (conductor surface) to the outer layer (environment).
TABLE 14.4 CP SINGLE CORE CABLE REQUIREMENTS
CABLE DETAIL
INSTALLATION
ENVIRONMENT
INSULATION
LAYERS AND TYPE
INSULATION
COLOUR
Direct sun PVC / HMWPE Red
Partial sunlight PVC / HMWPE Red
Soil (non-polluted) PVC / HMWPE Red
Positive DC
Soil (polluted) PVC / HMWPE / PVDF Red
Direct sun PVC / HMWPE Black
Partial sunlight PVC / HMWPE Black
Soil (non-polluted) PVC / HMWPE Black
Negative DC
Soil (polluted) PVC / HMWPE / PVDF Black
Soil (non-polluted) PVC / HMWPE Green-Yellow AC Mitigation
Earthing
Soil (polluted) PVC / HMWPE / PVDF Green-Yellow
Sacrificial Anodes Soil (non-polluted) PVC / HMWPE Red
Soil (non-polluted) PVC / HMWPE Black Pipe Monitor
Soil (non-polluted) PVC / HMWPE Red Reference Electrode
Soil (polluted) PVC / HMWPE / PVDF Red
Soil (non-polluted) PVC / HMWPE Black Corrosion Coupons
Above ground PVC / Al / PVC White CP Instrumentation
(single / multi-core)
Below ground PVC / Al / PVC /
HMWPE
White
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PVDF = Poly-Vinylidene Fluoride (ASTM D3222)
14.4.2
a.
b.
14.4.3
14.5
15
15.1
a.
b.
In certain instances, where CP installations are conducted outside the SASOL plant battery
limits, multi-core power cabling is required, such as:
Positive DC header cable: 4 Core x # mm PVC / PVC / SWA / PVC
AC Feeder cable: 4 Core x # mm PVC / PVC / SWA / PVC
The cross sectional area of the positive DC header cable core size shall be determined by the
contractor.
CABLE INSTALLATION AND IDENTIFICATION
All cables shall be installed as per Specification SP-60-01. Cables shall be identified as per
Specification SP-60-10.
EXOTHERMIC WELDING / PIN BRAZING CABLE CONNECTION DETAILS
CABLE CONNECTIONS TO PIPES AND REPAIR TO COATINGS
Unless otherwise specified all cable connections to the pipe are to be by means of thermit
(exothermic) welding. This applies equally to the negative cable from the rectifier,
continuity and cross bonding cables, test post cables, DC decoupling device cables, etc.
Exothermic welding is not permitted if any of the following conditions are present:
The pipeline wall thickness is less than 3,0 mm or severe corrosion has occurred and
the wall thickness is unknown;
The pipeline is lined internally and contains no product or is partially filled with
product (can only be welded when filled);
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c. Live gas distribution / transmission pipelines.
In these instances, cables shall be connected by means of pin brazing.
15.2
15.2.1
15.2.2
15.3
15.3.1
a.
b.
c.
d.
SURFACE PREPARATION
The area where the pin / thermit welding is to take place shall be thoroughly cleaned to
provide an area slightly larger than the graphite mould (approximately 50 mm x 50 mm).
All traces of petroleum mastic, concrete, Bitumen coating, primer material or any other
matter shall be removed and the surface shall be brushed with a steel wire brush, in order to
ensure that the surface complies with St3, ISO 8501-1, Part 1 to 3 and Supplement 1994 as
part of the surface preparation. Prior to making the weld, the area shall be roughened using a
coarse file or an angle grinder. Always ensure that the steel surface is dry.
PIN BRAZING / EXOTHERMIC WELDING
Exothermic welding will be performed as follows:
The end of the double insulated cable shall be bared for a distance of 25 mm;
A retaining cap shall be placed in the bottom of the mould and the weld powder
poured into the mould;
The weld powder shall be covered with the starting powder and some simultaneously
sprinkled on the lip of the mould. The cable shall be placed on the pipe and the mould
squarely pressed down firmly over the cable. It shall be ensured that the mouth of the
mould is turned away from the welding operator;
The lid shall be closed, and the starting powder ignited with a flint gun and the weld
allowed solidifying. The mould shall be removed and the residue cleaned out in
preparation for the next weld.
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15.3.2 Pin brazed connections will be performed as follows:
a.
b.
c.
d.
15.4
15.4.1
15.4.2
15.4.3
15.5
The end of the double insulated cable shall be bared and connected to the appropriate
lug using a hydraulic crimping tool;
The crimped cable shall be placed against the cleaned steel surface;
The appropriate power setting shall be selected for the cable and the trigger of the pin
brazing gun pressed down firmly. It shall be ensured that the correct setting, pin
brazing consumables and lugs have been selected prior to brazing;
The pin brazing gun shall be removed from the cable connection and any residue
cleaned from the brazed connection.
TESTING
After the above procedure has been carried out, a number of welds shall be tested by
SASOL, by striking the exothermic weld with a 2 kg hammer. Should any movement occur
the cable shall be re-welded and re-tested.
The pin brazed connection shall be gently tugged. Should any movement occur the cable
shall be re-welded and re-tested.
If deemed necessary by SASOL, additional welds / pin brazed connections will be tested
especially where failures have occurred.
WELD POWDER / CABLE COMBINATION
The powder / cable combinations specified in Table 15.5 shall be used. It must however be
noted that in the case of ASME constructed pipelines, all of the stipulated ASME
requirements shall be complied with in full. The latter requirements imply that no powder
(charge) size shall exceed 15 g.
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TABLE 15.5 WELD POWDER / CABLE COMBINATIONS
CABLE SIZE (mm
2
)
TYPE OF MOULD /
WELD
POWDER SIZE
10 Single entry 25 g
15.6
a.
b.
c.
d.
e.
f.
g.
h.
PRECAUTIONS
While exothermic welding and pin brazing are generally safe procedures, certain precautions
should nevertheless be exercised:
Ensure that the powder, mould and surface to be welded are perfectly dry;
Do not weld in areas where water is close to the welded area;
Prior to welding ensure that the retaining metal disc fits properly in the welding
chamber and that it prevents the powder from partially or wholly falling through to the
bottom, prior to ignition;
Ensure that the correct mould, consumables and pin brazing settings are used. Do not
attempt to use moulds past their design life or force a cable into an incorrect mould;
When welding, wear appropriate eye protection, welding gloves and protective
clothing. Always ensure that the mouth of the mould is away from the body of the
operator. Hold feet back from the mould;
Centre the mould over the pipe, holding it steady during welding. Use exothermic
putty on small bore pipes, in order to prevent liquid copper from escaping through the
base of the mould and damaging the coating system and / or the operator;
Use only a pistol type igniter, matches and / or cigarette lighters are not permitted;
Follow all SASOL permit conditions prior to and during the exothermic and / or pin
brazing operation;
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15.7 REINSTATEMENT OF THE COATING SYSTEM
The pipeline coating shall be reinstated in accordance with Specification SP-50-6 to the
satisfaction of SASOL.
16
16.1
16.1.1
16.1.2
16.2
16.3
16.3.1
PERMANENT REFERENCE ELECTRODES
The PRE shall consist of a long lasting permanent copper / copper sulphate reference
electrode located next to a bare steel coupon, which shall permit the measurement of
substantially IR free potentials in accordance with DIN 50925.
The PRE shall be installed at pipe invert depth and shall be placed in the same soil as the
pipeline, that is, the probe will be exposed to substantially identical forces acting on the
exposed areas of the pipe. Similarly, it shall be located under flat bottom storage tanks and
exposed to the same forces acting upon the tank.
PREs shall be supplied only by manufacturers pre-qualified by SASOL.
PERMANENT REFERENCE ELECTRODE (PRE) CONSTRUCTION
The ion entrapment membrane must be manufactured from a graded sintered silica carbide
material which is tubular in section and design; the minimum wall thickness shall be 5 mm.
The 25 micron () graded density ion entrapment membrane shall be manufactured from a
pure grade of silica carbide powder.
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16.3.2 The solid steel coupon whose internal diameter is slightly larger than tubular ion entrapment
membrane shall be located around the periphery. The steel coupon may be bare or coated in
order to regulate the size of the defect. The defect size shall be determined by the CP
consultant. The steel coupon shall be completely isolated from the ion entrapment membrane
and copper sulphate gel. Manufacturers shall submit details with the RFQ detailing their
method of isolation.
Two 2,5 mm
2
double insulated flexible copper cables shall be connected to the steel coupon
by brazing or silver soldering. The one cable shall be a monitor cable and the other the
negative cable. The negative cable shall be connected to the pipe via a suitably rated shunt,
located on the printed circuit board inside the test post in order to measure the current flow to
the steel coupon. The monitor cable shall permit the measurement of the coupon potential.
These cables shall be external to the PRE.
16.3.3
16.3.4
16.3.5
16.3.6
16.3.7
The permanent copper sulphate reference electrode shall comprise of a solid chemically
etched and annealed copper rod. The copper rod shall be manufactured from 99,9% pure
copper and shall be at least 10 mm in diameter and 150 mm long.
A single 2,5 mm
2
double insulated flexible copper cable shall be connected to the copper rod
by brazing or silver soldering. The cable connection shall be completely encapsulated in acid
and alkaline resistant epoxy.
The gel shall be manufactured from a chemically inert inorganic and hygroscopic gel and
analytically pure copper sulphate. The electrode shall contain a minimum of 250 m of
copper sulphate gel. Contractors shall indicate the type of gel they intend to use during the
submission of their RFQ.
The overall physical dimensions shall not exceed 100 mm in diameter and 450 mm long,
excluding the length of the cable. The top PRE outer casing shall be polypropylene or
equivalent, in order to withstand the forces due to the expansion and contraction of the soil
resulting from variation in its water content.
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16.3.8 Contractors shall submit all of the pertinent details and drawings pertaining to the PRE they
intend using. SASOL shall review the use of the proposed PRE.
16.4
16.4.1
a.
b.
16.4.2
17
17.1
17.1.1
17.1.2
PERMANENT REFERENCE ELECTRODE (PRE) STABILITY
The PRE shall possess a minimum operating life of 10 years, operating with the stability
detailed below:
The stability of the probe shall be 5 mV / C at a load not exceeding 50 mA / m
2
;
The operating temperature shall be 0C to 57 C.
Both the potential and current drawn by the probe shall be conveniently measured at the test
point. Details of the PC board pertaining to the latter measurements shall be submitted to
SASOL for reviewal. Each PRE shall posses an individual serial number and shall be
supplied with a calibration certificate.
CATHODIC PROTECTION TEST POINTS
INTRODUCTION
There are several CP Test Post types available. Test posts are used in order to monitor the
efficacy of a CP system and / or to ensure the correct operation of a CP system, e.g. where
anodes are located inside test posts.
Due to vandalism, theft and / or damage which occur during normal operation of a TP, it is
not possible to detail all of the TPs available. Only the most common test posts acceptable to
SASOL shall be detailed below.
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17.2 LOCATION OF TEST POSTS / STATIONS
17.2.1
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
Test posts / stations for potential monitoring and for the operation of the CP system shall be
installed at the following locations:
At all galvanic sacrificial anode locations, unless otherwise specified by SASOL;
At all pipeline crossings (SASOL and foreign) which are cathodically protected and
major pipeline (> 200 mm OD) crossings which are not cathodically protected;
At all cased, directional drilled and / or pipe jacked crossings;
On either side of all electrified railway lines;
On either side of all DC traction affected non electrified railway lines;
On either side of all national, provincial and major roads. On one side of all frequently
used (> 50 vehicles per day) roads and / or heavy haul sand / dirt roads;
At intermediate locations on long piping runs (maximum separation 1 km). Care shall
be exercised in order to ensure that they are suitably located in order to facilitate
monitoring;
In severe DC traction stray current environments, all TPs shall included IR free
monitoring facilities and permanent IR free reference electrodes every 1 km
(maximum separation between any two TPs);
At AC mitigation earthing stations;
At all under ground pipeline isolators in order to permit testing of live and dead sides
and current measuring facilities during temporary cross bonding;
On both sides of a major water crossing. A major crossing shall constitute any river
where water flows for at least 6 month of the year on a continuous basis and the river
crossing exceeds 3 m in length;
On both sides of a waterway (navigable crossing);
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m. On both sides of a major vlei, marsh and / or wetland (pipeline traverses nominally >
500 m through the obstacle during the wet season). If the crossing is shorter, one TP
may be permitted upon approval from SASOL;
n.
17.2.2
a.
b.
c.
d.
17.2.3
17.3
In plant areas in order to monitor the efficacy of the CP system. Care shall be
exercised relating to hazardous area classification, and avoiding obstruction relating to
normal plant operations.
The test point shall be selected based on a number of considerations, such as:
Risk of vandalism, theft and / or general damage;
Access relating to operation, maintenance and monitoring;
Possible damage by agricultural vehicles, plant vehicles, etc.;
Plant hazardous area classification.
The mechanical construction of the TP is of great importance, as it may be subject to
vandalism, or to wear and tear caused by contact with farm animals, plant operators, etc.
The TP shall be constructed from a minimum 30 MPa reinforced concrete. The reinforcing
shall be normal mild steel in non corrosive environments and hot-dipped galvanised steel in
corrosive environments. Prospective manufacturers shall submit drawings together with
relevant details with their RFQ document.
TYPICAL CP TEST POSTS
Three types of test posts shall be discussed, that is, the potential / reference monitoring test
post (TP-R), recordable / lockable test post and the process plant potential test post.
The TP-R is used to monitor the pipe potential, whereas the other two may be used for
monitoring and / or operating CP systems.
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17.3.1 Potential / Reference Monitoring Test Post (TP-R)
a. The TP-R shall nominally be constructed as follows:
DESCRIPTION DIMENSION (mm)
Overall Length 1 400
Overall Width 155
Overall Depth 135
Monitoring Points As supplied by Manufacturers
b.
c.
d.
e.
17.3.2
a.
Approximately the bottom 0,5 m shall be concreted into the ground. The TP-R shall
be installed over the pipeline as detailed in Standard Drawing STDD-6005CW.
A single / multiple cable(s) from the pipe and / or reference cable(s) from IR free
PREs may terminate inside the top section of the TP. This aspect shall be covered
during the design of the CP system.
The TPs shall be painted with a concrete bonding liquid and then with road marking
paint. The colour shall be determined by SASOL, as several colours are currently
being used by SASOL and other foreign services. A circle shall be painted with road
marking paint around the aluminium number plate for easy identification.
The chainage and TP-R number must be engraved in letters approximately 6 mm high,
on an aluminium plate 50 mm x 50 mm x 2 mm thick. The plate shall be screwed to
the test post and the heads damaged upon installation, in order to prevent the
removal of the plate. The test post and cable shall not be damaged during the
installation of the identification plate.
Lockable Recording Test Post (R-TP)
The R-TP is used to monitor the pipe potential, as well as for the installation of
permanent IR free reference electrode installations and magnesium anode
installations.
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The R-TP shall nominally be constructed as follows:
DESCRIPTION DIMENSION (mm)
Overall Length 1 400
Overall Width 210
Overall Depth 210
Enlarge Head Length 350
Enlarge Head Width 250
Enlarge Head Depth 170

b.
c.
d.
17.3.3
Approximately the bottom 0,5 m shall be concreted into the ground. The R-TP shall be
installed over the pipeline as detailed in Standard Drawing STDD-6005CE. The
enlarged head shall contain a hot-dipped galvanised vandal resistant enclosure suitable
for IR free PC cards and / or data loggers.
The R-TP shall be painted with concrete bonding liquid and then road marking paint.
The colour shall be determined by SASOL, as several colours are currently being used
by SASOL and other foreign services.
The chainage must be engraved in letters approximately 6 mm high, on an aluminium
plate 100 mm x 50 mm x 2 mm thick. The plate shall be screwed to the test post and
the heads damaged upon installation, in order to prevent the removal of the plate.
The test post and cable shall not be damaged during the installation of the
identification plate.
Process plant Test Post (P-TP)
The P-TP, ostensibly consists of a hot dipped galvanised stand and a suitably sized, ex rated
box / enclosure, which will permit the installation of the required cabling and / or bonding
and / or testing facilities, such as an IR free PC card.
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The P-TP is used to monitor the pipe potential, as well as for the installation of permanent
IR free reference electrode installations and magnesium anode installations. The P-TP is
numbered using engraved polymer which shall be fixed with pop-rivets to the hot dipped
galvanised stand.
18
18.1
18.1.1
18.1.2
a.
b.
c.
18.1.3
18.1.4
a.
SOLID STATE DC DECOUPLING DEVICES
INTRODUCTION
CP is most effectively, efficiently and uniformly applied when the primary structure
requiring CP is electrically isolated from those structures not requiring CP. Electrical
isolation implies that all metallic / electrical contacts with foreign metallic structures are
completely eliminated.
Electrical isolation provides three major benefits:
Restriction of the required protective current to the surface of the primary structure to
produce a uniform polarised level of protection;
Minimising stray current influence (AC and / or DC);
Prevention of unwanted galvanic current flowing between metallic structures.
The use of SS-DCDs are the most superior form of ensuring electrical isolation. This
equipment must not only ensure that it meets the safety standards enforced relating to
effective earthing of a structure, but it must also ensure adequate electrical isolation for the
CP system.
The SS-DCD shall protect personnel and equipment during all types of electrical
disturbances by providing an effective earth path which will instantaneously conduct:
AC fault currents;
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b. Lightning;
c.
d.
18.1.5
a.
b.
c.
d.
18.2
18.2.1
18.2.2
Induced AC;
Power switching surge currents.
Applications include but are not limited to:
AC fault current protection across insulation joints (IF / IJ) and other devices;
Mitigation of induced AC on pipelines and other structures;
Lightning protection for equipment including TRUs, pipelines, cathodically protected
tanks and other structures;
Decoupling between primary structures and general earthing systems.
ELECTRICAL CONSTRUCTION
Essentially two Solid State DC Decoupling (SS-DCD) devices are available. A diode type
device is generally used where low blocking DC voltages are encountered and a thyristor
type device which is used where high blocking DC voltages are encountered. For all SASOL
transmission and distribution pipeline applications the thyristor units shall be used, as the
pre-set DC blocking voltage can be set to any value i.e. used in any application, moved to a
new location and the voltage value re-set.
This cannot be carried out if a diode type unit is used. The blocking voltage is also limited to
6 V on a diode type unit and may only be used in process areas.
The magnitude of the steady state AC fault current and transient surges, shall be determined
from site tests and other pertinent information. The SS-DCD shall be designed such that all
of the electrical components are suitably sized and rated, in order to ensure its uninterrupted
operation. The typical electrical wiring diagram is shown in Figure 5.
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FIGURE 5: ELECTRICAL WIRING DIAGRAM

18.2.3
a.
b.
c.
d.
The following shall be included in the design and quoted as a minimum for each SS-DCD
prior to them being reviewed by SASOL:
AC fault current exposure - Rated from 5 kA 1 cycle @ 50 Hz RMS;
Surge / lightning protection - Peak surge current @ 8 / 20 sec. e.g. 100 kA / 70 kA;
Voltage threshold - Blocking DC voltages: 2,5 V to 20 V RMS;
Included steady state AC - steady state AC: 0 A to 100 A @ 50 Hz RMS;
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e. Enclosure type rating - example includes: Ex type enclosure, IP66, etc.
18.2.4
18.2.5
18.3
18.4
18.4.1
18.4.2
The SS-DCD shall be non-electrolytic, fail-safe and maintenance free.
Fail-safe shall imply that the failure of any SS-DCD component shall result in an open
circuit system and not a short circuit system. That is, the pipeline or structure shall never be
directly connected to the earthing system.
ENCLOSURE CONSTRUCTION
The SS-DCDs shall be enclosed in a suitably rated enclosure as required by SANS 10108 /
SABS 0108, SANS 10089-2 / SABS 089-2 and SANS 10086-1 / SABS 086-1. The enclosure
shall also be rated according to the environmental conditions prevailing. This includes but is
not limited to vandal resistant concrete reinforced structures where required on transmission
and distribution pipelines and ex type rated enclosures in Zone One / Two process plant
areas.
INSPECTION AND TESTING
The testing of the SS-DCD shall be carried out at the contractors works or at the third party
Inspectors laboratory / works. A sample of the SS-DCD to be supplied shall be selected in
accordance with BS 6001, Part 1 for testing purposes.
All of the SS-DCD device components shall pass the tests and the testing shall be carried out
in the presence of SASOL or at the discretion of SASOL. The contractor will issue a test
certificate upon completion of the tests and it shall be signed by SASOL. All of the testing
shall be carried out at the contractors expense.
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18.4.3 The SS-DCD shall be tested at 125 % of the fault current rating and for at least 3 cycles of a
standard 50 Hz cycle. The pre-set DC blocking voltage shall be tested and confirmed. At
least 125% of the steady state AC shall be passed through the unit for a minimum 15 minute
period. No item and / or component of the SS-DCD shall fail. Failure of a single item /
component shall imply complete failure of the SS-DCD.
18.4.4
18.5
a.
b.
18.6
18.7
SASOL may also call for other pertinent tests in order to prove compliance. The construction
contractor shall supply a COC upon completion of the installation.
DOCUMENTATION
The SS-DCD shall be supplied with the following items:
A removable clear-polyester laminated circuit diagram, which shall be located inside
the enclosure;
Operation and Maintenance Manual (OMM). Two hard copies and one electronic
(PDF format) copy of the OMM for each type of SS-DCD shall be supplied to
SASOL.
GUARANTEE
The equipment shall carry an unconditional three year guarantee from commissioning.
The only exceptions shall be for damages arising from vandalism, mechanical damage,
external fire or flooding.
SS-DCDs shall be supplied only by contractors pre-qualified by SASOL.
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19 INSULATING FLANGE MATERIALS
19.1
19.1.1
19.1.2
19.2
19.2.1
Pipeline electrical insulating flange (IF) materials shall be selected with consideration given
to quality and standard material availability. The chosen material shall be able to withstand
the maximum line temperature, pressure and predicted line movement. All IF materials shall
be crossed-referenced to the manufacturers specifications to ensure compatibility between
materials, service and the environment.
The materials required per IF, shall be supplied as one complete set. The latter shall consist
of an insulating non-metallic central gasket, non-metallic bolt sleeves and non-metallic
washers and steel thrust washers, as well as the associated high tensile steel studs, nut and
bolts.
MATERIAL SPECIFICATIONS
The non-metallic central gasket and non-metallic washers shall conform to the following
materials specification:
VALUE
MATERIAL PROPERTY
ASTM TEST
METHOD SI IMPERIAL
Dielectric Strength (Min) D149 21 kV / mm 540 V / mil
Compressive Strength (Min) D625 340 MPa 49,000 psi
Water Absorption (Max) D229 0,1 % 0,1 %
Operating Temperature (Min) N / A -17 C 0 F
Operating Temperature (Max) N / A +93 C 200 F
Hardness, Rockwell M (Min) D785 115 115
Shear Strength (Min) D732 150 MPa 22,000 psi
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19.2.2 Steel thrust washers shall be machined with diameter and thickness to SANS 1149 / SABS
1149 Table 3 or to ASTM A325-61T. Thrust washers shall have machined, parallel faces.
19.2.3
19.2.4
19.2.5
19.2.6
19.2.7
Insulating sleeves shall be a minimum 0,8 mm thick glass fibre-reinforced polyester sleeve
for each bolt. Total length of each sleeve is to be 2,3 mm longer than the length between
outside faces of the steel washers. The insulating sleeves shall fit completely inside the
insulating washers and extend partially inside the steel washers.
Insulating washers shall be manufactured from 3,2 mm thick fabric reinforced phenolic resin
with the outer diameter (OD) being the same as that of machined steel washer - two for each
stud bolt. The inner diameter of the insulating washer shall be a sliding fit over the OD of
insulating sleeves.
Stud bolts and studs shall be Grade 8.8 and nuts grade 8 to SANS 1700-7 / SABS 1700-7
and SANS 1700-14 / SABS 1700-14. Stud bolt diameters shall be selected to the next
smaller size for installation in standard drilled flanges. Stud bodies shall be machined down
to the next standard smaller size and a smaller nut is also to be used.
A SS-DCD shall be installed across the flange faces complete with hot-dip galvanising mild
steel mounting brackets to suit the flange bolt. The decoupling device shall be located in a
suitably hazardous area classification rated enclosure as stipulated in SANS 60079-10 /
SABS IEC 60079-10 and SANS 10108 / SABS 0108.
The entire insulating flange shall be wrapped circumferentially with a 15 mm to 20 mm thick
white plastic backed Polymer modified Bituminous tape, or similar approved. The latter shall
have a minimum overlap of 25 mm. In the case of surface irregularities, i.e. stepped flanges,
etc., a SASOL reviewed Petrolatum mastic material shall be used to provide a smooth
contour for subsequent tape application.
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19.3 IDENTIFICATION / LABELS, OPERATING INSULATING FLANGE, NO
ATTACHMENTS TO PIPEWORK PERMITTED
19.3.1
19.3.2
19.3.3
19.4
19.4.1
a.
b.
c.
d.
e.
f.
g.
h.
A 25 mm wide plastic backed electrical tape to SANS 122 / SABS 122 colour red shall be
applied in the centre on the horizontal surface.
A 2 mm thick aluminium plate, 80 mm x 80 mm shall be engraved as detailed above. The
characters shall be 20 mm high and filled with black indelible ink.
The aluminium plate shall be fixed to the insulating flange with stainless steel strapping.
MONOLITHIC INSULATING JOINTS
Where IFs cannot be employed, then IJs shall be used. Due to the large variety of IJs
available, e.g. gas, liquid Hydrocarbon, water, etc., the following shall be used as a
guideline, in conjunction with Standard Drawing STDD-6005CY:
All welds in contact with the pipe shall undergo 100 % radiographic inspection;
The closure welds (not in contact) shall be inspected by ultrasonic inspection;
All IJs shall be supplied in accordance with Class ANSI 300;
Pipe pups shall be manufactured in the required API grades;
Forged rings shall comply with ASTM 694 St 52;
Insulating rings shall be manufactured from glass / epoxy laminated material to ASTM
D709 G10 / G11 or Polycarbonate reinforced with glass fibre for oxygen use;
Gaskets shall be manufactured from Nitrile rubber to ASTM D2000 or FPM -
fluoridated rubber for oxygen use;
All ends shall be bevelled to API standards;
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i. The external surface shall be shot blasted and coated with a high build epoxy dry film
thickness (DFT) of 150 m;
j.
19.4.2
19.5
19.5.1
The internal surface shall be blasted to SA 2, ISO 8501-1. The internal surface shall be
left bare and then capped and sealed with internal silicon gel bags, or coated with a
high build amide cured epoxy DFT 150 m depending upon its application.
Reviewal from SASOL shall be obtained prior to specifying and / or supplying an IJ, due to
the lead times and costs associated with their supply.
INTERNAL PIPE LINING FOR COOLING WATER SERVICE
This section defines the materials, surface preparation, application and inspection of internal
lining for piping NPS 24 and larger in cooling water services only.
This work is intended to be performed at the job site. All welding, which could be damaging
to the lining, shall be completed before any lining work is done.
The lining of pipes, weld fittings and weld joints shall be carried out in accordance with a
detailed written procedure, reviewed by SASOL.
Extent of Lining
The lining shall be applied from the insulating coupling for a distance as indicated in
Table 19.5.1:
TABLE 19.5.1: EXTENT OF LINING
NOMINAL PIPE
SIZE (inches)
LENGTH OF
INTERNAL LINING
(m)
24 1,5
28 2
30 2
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NOMINAL PIPE
SIZE (inches)
LENGTH OF
INTERNAL LINING
(m)
36 3
42 4
48 5
54 6
66 9
72 10
84 14
The length of lining shall be measured from the edge of the insulating coupling along the
pipe on the cathodically protected (under ground) portion.
In the case of a T connection where an insulating coupling is above grade on the centre leg
of the T, the lining shall extend for the tabulated length from the insulating joint into each
of the two under ground pipe legs, as detailed in Figure 6.
FIGURE 6: T CONNECTION LINING

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In the case of a T connection where the insulating couplings are above grade in each of the
two legs of the T, the lining shall extend for the tabulated length from each insulating
coupling into the under ground pipe leg, as per Figure 7. The minimum distance between
insulating joints in this case shall be the tabulated length of lining as indicated in Table
19.5.1.
FIGURE 7: T CONNECTION LINING

Short lengths, such as under-road crossings, shall be totally coated from insulating joint /
flange to insulating joint / flange.
19.5.2 Lining Material
The lining material shall be a self-priming high build polyamide or amine epoxy system.
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19.5.3 Surface Preparation
The interior surface preparation of all pipe sections scheduled for internal lining shall
conform to visual Standard Sa2 in accordance with ISO 8501-1 / SIS 05 59 00.
Abrasives for blast cleaning shall be clean and dry and shall be selected to provide the
correct surface profile for the subsequent lining materials.
19.5.4
19.5.5
Application
The lining materials shall be applied on the same day during which cleaning is done and
before rust bloom or re-contamination occurs. All lining work shall be applied in strict
accordance with the manufacturers instruction and as reviewed by SASOL.
The lining system shall be applied in multiple coats to produce a minimum dry film
thickness of 250 m.
Where the distance of the lining extends beyond a weld joint, the pipe and / or pipe fittings
may be lined before erection provided the lining is held back a minimum of 150 mm for
welding purposes. Written procedures shall be submitted for reviewal by SASOL for repair
and making good of the weld lanes.
Inspection
Materials supplied and / or used in connection with this lining work are subject to inspection
and reviewal from SASOL.
Dry film thickness measurements shall be taken with a SASOL reviewed and calibrated dry
film gauge. Details shall be submitted to SASOL for reviewal prior to using the instrument.
The pictorial visual standards ISO 8501-1 / SIS 05 59 00 shall be used as inspection
standards for acceptable surface preparation. Any surfaces found to be incorrectly prepared
shall be corrected.
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The finished surface shall be free from pinholes, voids, holidays, runs, sags or other surface
imperfections. The method of testing shall be reviewed by SASOL.
20
20.1
20.1.1
a.
b.
c.
20.1.2
HIGH POTENTIAL SACRIFICIAL MAGNESIUM ANODES (SOIL USE)
The performance characteristics of the 1,75 V high potential magnesium alloy, is detailed
below. The high potential alloy is specially formulated from pure virgin magnesium and
other elements to produce the higher voltage. The advantages of the high potential anode
versus its 1,55 V counterpart, is as follows:
The higher driving potential permits fewer anodes in this specific application;
The capacity of a high potential anode is some 4 % greater than that of the other
anodes, improving the overall life of the anode;
The material will be produced from virgin magnesium and shall contains no scrap,
thus ensuring points (a) and (b) above.
The anodes shall be manufactured in accordance with ISO 9002. The contractor shall submit
written confirmation from the relevant standards authority, confirming complete registration
in this regard.
ELEMENT PERCENTAGE (%)
Aluminium (Al) 0,001 Maximum
Zinc (Zn) N / A
Silicon (Si) N / A
Manganese (Mn) 0,50 to 1,30
Nickel (Ni) 0,001 Maximum
Iron (Fe) 0,03 Maximum
Copper (Cu) 0,02 Maximum
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ELEMENT PERCENTAGE (%)
Other N / A
Total of all Other Impurities N / A
Magnesium Balance
20.2
20.2.1
20.2.2
20.3
20.3.1
20.3.2
20.3.3
MAGNESIUM ANODE CHEMICAL COMPOSITION
The high potential magnesium anode shall conform to the following chemical composition:
The anode capacity shall be a minimum of 1200 A.hr/kg
HIGH POTENTIAL MAGNESIUM ANODE PHYSICAL PROPERTIES
The high potential magnesium alloy anode shall have a net minimum weight of 10 kg and a
minimum length of 533 mm and nominal diameter of 114 mm, when unpacked. The
unpacked and packed dimensions are detailed in Standard Drawing STDD-6005CZ.
The anode shall be free of blow holes, cold laps, porosity seams and any other imperfection
which may impair its performance. Extruded anodes shall be used and cast anodes may be
used if reviewed by SASOL.
A 5 mm diameter pre-galvanised steel threaded stud or rod shall be centrally located within
the anode. The latter shall extend for at least 95% of the anode length and shall be extruded
or cast into it. The pre-galvanised threaded steel stud or rod shall be suitable for the electrical
connection of the anode to anode cable, which shall terminate in a recess at the one end. The
connection shall be suitable for 20 years under submerged conditions.
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20.4 ANODE CABLE AND CABLE CONNECTION
20.4.1
20.4.2
20.4.3
20.4.4
20.4.5
20.4.6
20.4.7
20.4.8
The anode cable shall be as specified in Section 14 of this Specification and the length shall
be 6 m or as specified in the RFQ document and detailed in Drawing STDD-6005CU.
In all instances a suitable hole will be drilled into the end of the thread or rod and the cable
shall be brazed / soldered into the hole.
The insulation of the cable shall be removed for a length such that at least 25 mm of the
copper is inserted into the drilled galvanised steel rod hole.
The cable shall then be brazed / soldered into the hole. At least 25 mm of insulation shall
extend into the anode recess.
Mechanical connections between the anode cable and the pre-galvanised steel rod or thread
shall not be permitted under any circumstances.
The anode recess shall be completely flooded with hydrochloric acid (10% solution) resistant
epoxy. All proposed epoxies shall be submitted to SASOL for reviewal, prior to their use.
The epoxy shall completely fill the recess without spilling over onto the external surface of
the anode.
No bare copper cable shall extend outside the epoxy; the insulation shall extend at least
25 mm into the epoxy as stipulated above.
The maximum cable to anode resistance shall be 10 m. The cable shall be pulled or tugged
initially as a test after making the cable to anode connection.
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20.5 ELECTROCHEMICAL PROPERTIES
20.5.1
20.5.2
20.6
20.6.1
20.6.2
20.6.3
20.7
20.7.1
The solution potential of the anode when fully submerged in the test chamber, shall be more
negative than -1,65 V with respect to a saturated copper / copper sulphate reference
electrode.
The anode shall maintain this potential at a 100 mA output and shall possess a capacity of
1200 A.hrs/kg.
TESTING AND REVIEWAL
A complete set of both chemical and metallurgical tests shall be conducted on a number of
randomly selected anodes, as determined in accordance with BS 6001, Part 1, prior to
installation of the anodes. Anodes may only be installed subsequent to testing and reviewal
from SASOL.
Complete chemical and metallurgical compliance shall be ensured prior to their installation
and a detailed report shall be submitted to SASOL for reviewal. Testing shall be carried out
at the contractors expense.
The natural anode potential and current drawn shall be measured prior to permanently
connecting the anode to the pipe / structure. This data shall be submitted with the
commissioning report.
TYPICAL INSTALLATION DETAILS
All anodes shall be installed at a minimum depth of 2,5 m or pipe invert depth, which ever is
the deeper. The anodes shall be located a minimum of 3,5 m from the pipe or as determined
by the CP Design. The anode / pipe separation distance shall be stipulated in the bill of
quantities of the RFQ document.
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20.7.2 The distribution of the anodes shall also be stipulated in the in the bill of quantities of the
RFQ document.
20.7.3
20.7.4
20.7.5
21
21.1
The anodes shall be located in a cotton bag which shall ensure that a minimum of 35 mm of
crushed natural granular gypsum / bentonite / anhydrous sodium sulphate in the ratio by
volume of 75% / 20% / 5% respectively, surrounds the entire anode surface.
The anodes shall be completely submerged for 2 hours prior to installation and the entire
anode excavation (hole) into which they are to be placed shall be thoroughly soaked prior to
backfilling. Care shall be exercised when backfilling in order to prevent damage to the anode
cable.
The cable connection, installation and backfilling / reinstatement shall be witnessed by
SASOL.
AC MITIGATION EARTH ELECTRODE
ZINC TUBE MATERIAL SPECIFICATION
The zinc tube required for AC mitigation shall comply in full with the following details.
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21.2 ZINC TUBE DIMENSIONS
The zinc tube dimensions shall be as follows:
DESCRIPTION DIMENSION
Length 1500 mm 5%
Diameter 80 mm 5%
Wall Thickness 5 mm 5%
21.3 ZINC TUBE CHEMICAL COMPOSITION
The chemical composition of the zinc shall comply with those of high purity zinc materials
in accordance with ASTM B418 Type I and as indicated below:
ELEMENT
TYPE I
ELEMENT PERCENT (%)
Aluminium (Al) 0,1 to 0,5
Cadmium (Cd) 0,025 to 0,07
Iron (Fe) 0,005 Maximum
Lead (Pb) 0,005 Maximum
Copper (Cu) 0,005 Maximum
Others - total 0,1 Maximum
Zinc Remainder
21.4 HARDNESS MEASUREMENTS
The zinc tube average hardness shall be 39 6,5 Hv
10
using a Vickers hardness tester.
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21.5 METALLOGRAPHY
A transverse and longitudinal section (as indicated by figures 8 and 9) shall be removed from
the supplied tube, mounted in cold mounting resin and prepared for metallographic. The
samples shall be etched in a solution of chromic acid to which sodium sulphate shall be
added, to reveal the microstructure of the tube. No significant differences shall be observed
between the transverse and longitudinal sections. The grain size shall be estimated using the
comparison method described in ASTM E112. The ASTM grain size in both the
longitudinal and transverse sections shall be less than one. The microstructure of the tube
shall consist of equi-axed grains.
FIGURE 8: REQUIRED MICROGRAPH OF A LONGITUDINAL SECTION
THROUGH THE ZINC TUBE

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Page 127 of 127
FIGURE 9: REQUIRED MICROGRAPH OF A TRANSVERSE SECTION THROUGH
THE ZINC TUBE

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