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Pars Oil and Gas Company
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FOR CONSTRUCTION
DOCUMENT TITLE GENERAL REQUIREMENTS FOR CATHODIC PROTECTION
(ONSHORE FACILITIES)
8 7 6 5 4 3 2 1 0 REV.
13.Dec.10 25.Apr.10 09.Jun.09 20.Jan.09 28.Oct.08 30/08/2008 13/02/2008 13/06/2007 16/05/2007 DATE
Approved for construction Approved for construction Issued for Approval Issued for Approval Issued for Comment Approved for Design (AFD) Approved for Design (AFD) Approved for Design (AFD) Issued for Company Approval (ICA) DESCRIPTION
MG FP FP FP FP FM HLM RD RD PRPD.
A.S KM KM KM KM HM RD MS MS CHKD.
KM KM KM KM KM AGH RD RD RD APPD.
MF MF MF MF MF AKH MS MS MS AUTHD.
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TABULATION OF REVISED PAGES Page 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. REV.3 REV.4 REV.5 REV.6 REV.7 REV.8 X X X X X X X X X X X X X X X X Page REV.3 REV.4 REV.5 REV.6 REV.7 REV.8 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. X X X X X X X
X X X X
X X X X X X X X X X X X X X X X X X X
X X X
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Contents 1. 2. 3. 3.1 4. 4.1 4.2 5. 6. 7. 8. 9. 10. 10.1 11. 11.1 11.2 11.3 11.4 11.5 11.6 12. 12.1 DOCUMENT SCOPE ................................................................................ 6 INTRODUCTION....................................................................................... 7 PROJECT OVERVIEW ............................................................................. 7 Plant Description ................................................................................... 8 CODES AND STANDARDS ...................................................................... 9 General Requirements .......................................................................... 9 Codes and Standards ........................................................................... 9 REFERENCE DOCUMENTS .................................................................. 11 ABBREVIATIONS ................................................................................... 11 DEFINITIONS.......................................................................................... 13 PRECEDENCE ....................................................................................... 14 USE OF LANGUAGE .............................................................................. 14 CATHODIC PROTECTION GENERAL ................................................... 15 Overview ............................................................................................. 15 CATHODIC PROTECTION DESIGN CRITERIA..................................... 15 Design Life .......................................................................................... 15 Current Density ................................................................................... 16 Soil/Sea Water/Water Conditions........................................................ 18 Current Drain....................................................................................... 19 CP Protection Potential Ranges.......................................................... 19 Protection Current Demand and Anode Distribution ........................... 20 DESIGN CONSIDERATIONS ................................................................. 20 At Grade Storage Tank Bottoms ......................................................... 20
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12.2 12.3 12.4 12.5 12.6 12.7 12.8 13. 13.1 13.2 13.3 13.4 13.5 13.6 13.7 13.8 13.9 13.10 13.11 13.12 13.13 14. 14.1 14.2
Internal Tank Protection ...................................................................... 22 Reinforcement Steel and Electrical Earthing Material (Uninsulated Copper or Steel)................................................................................................... 23 Cathodic Protection Plant Piping......................................................... 24 Electrical Continuity and Isolation ....................................................... 24 Cased Crossings................................................................................. 25 Temporary Cathodic Protection System.............................................. 25 Interaction and Induced Effects........................................................... 25 MATERIALS ............................................................................................ 26 Transformer Rectifier Requirements ................................................... 26 Anode Materials .................................................................................. 26 Impressed Current Anodes ................................................................. 28 Zinc Anodes ........................................................................................ 29 Magnesium Anodes ............................................................................ 29 Anode Backfill ..................................................................................... 30 Reference Electrodes.......................................................................... 31 Cables ................................................................................................. 31 Distribution Boxes ............................................................................... 32 Isolation Joints .................................................................................... 32 Over Voltage Protective Devices......................................................... 33 Polarisation Cell Replacement ............................................................ 33 Test Stations ....................................................................................... 33 Cable Connections to Buried Piping and Tank Bottom ....................... 34 Sacrificial Anodes................................................................................ 35
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14.3 15. 16. 16.1 16.2 16.3 16.4 16.5 17. 18.
Electrical Isolation ............................................................................... 35 ELECTRICAL INTERFERENCE ............................................................. 35 DOCUMENTATION................................................................................. 36 Detail Design Report ........................................................................... 36 CP Layout Drawings and Detail Drawings .......................................... 36 Equipment Datasheets........................................................................ 37 Cable Schedule and Test Post Schedule............................................ 37 Material Take off List........................................................................... 37 PRE-COMMISSIONING .......................................................................... 37 COMMISSIONING .................................................................................. 38
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1.
DOCUMENT SCOPE
This specification defines the minimum requirements for design, supply, installation and commissioning of the Cathodic Protection Systems for the Onshore Facilities. The cathodic protection shall be applied to all external surfaces of metallic structures within the boundary limits of the Plant, which will be buried and/or in contact with the soil and shall include but not be limited to the following: External surfaces of above ground storage tanks in contact with soil External surfaces of buried metallic piping including metallic risers associated with firewater hydrants, monitors on non-metallic piping systems External surfaces of buried metallic vessels Miscellaneous parts such as steel piles, rebar of reinforced concrete and etc. which are in direct contact with the soil or electrolyte media. The onshore portion of the offshore pipelines coming, where they are in direct contact with soil ,sea water or electrolyte media. All equipment related to earthing system which are in direct contact with soil or electrolyte media Cathodic protection shall also be applied to the internals surfaces of the following items of equipment Internal surfaces of hydrocarbon tanks containing discrete water phase. Internal surfaces of above ground storage tanks containing conductive water such as fire water and potable water tanks Internal surfaces of hydrocarbon vessels containing a discrete water phase At the detailed engineering stage, the VENDOR shall compile a complete list of all structures to be protected in accordance with the final project data and drawings and shall submit the list for approval to the CONTRACTOR.
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2.
INTRODUCTION
The IDRO/OIEC/IOEC Consortium has been contracted by the National Iranian Oil Company (NIOC) to conduct the EPCC for South Pars Phases 17 & 18 Project. This Project includes Offshore Facilities, platform and undersea pipelines, and Onshore Facilities for the processing of the reservoir fluid. WorleyParsons Pty Ltd has in turn been contracted by the IDRO/OIEC Consortium to conduct the Basic Engineering and FEED for South Pars Phases 17 & 18 for the Onshore facilities. The South Pars Phases 17 & 18 Project offshore work-scope is being carried out by a separate Offshore Consultant. WorleyParsons will lead, identify and coordinate deliverables required to manage the physical interfaces between the Onshore and Offshore Design Consultants.
3.
PROJECT OVERVIEW
The Iranian South Pars field is the largest discovered offshore gas field in the world, located 100 km offshore in the Persian Gulf. Reservoir fluids are transported to shore via two sealines to the mainland (ASSALUYEH) at a distance of approximately 105 km for further treatment. South Pars Phases 17 & 18 are a further development of the South Pars gas field consisting of two 1000 MMSCFD phases. The facilities shall be developed on the basis of supplying treated lean gas to the domestic gas network and ethane gas to the nearby petrochemical complex at the required specifications while maximising liquid recovery as propane and butane and stabilised hydrocarbon condensate for export. A new interconnecting pipeline shall transport the lean gas produced to the domestic gas distribution network via fiscal metering facilities. The produced condensate shall be stored in dedicated storage facilities, periodically pumped through a condensate export pipeline to a SBM via fiscal metering facilities. The treated propane and butane shall be stored separately in refrigerated atmospheric double wall storage tanks, periodically pumped through a dedicated loading pipelines network to LPG carriers berthed at a jetty via fiscal metering facilities.
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3.1
Plant Description
The main functions of the Onshore processing facilities are: Reception facilities for the HP fluids and separation of the raw gas and condensate/water/MEG mixture. Condensate stabilisation producing stabilised condensate for storage and export. The light ends are recycled to the HP gas system. One condensate flashing unit, normally not operated, is provided as a back-up to the stabilisation facilities. Gas treatment facilities producing sales gas, gaseous ethane and NGLs consisting of: - H2S removal from gas / CO2 partial removal from gas. - Dehydration unit, using molecular sieves technology. - Mercury guard. - Ethane extraction unit, producing sales gas, gaseous ethane and NGL. Ethane treatment for CO2 removal and drying for further export. NGL fractionation facilities to produce sour liquid propane, butane and condensate. This condensate is routed to the condensate stabilisation system for treatment. Propane and butane treatment for mercaptans removal and drying for storage and export. Propane and butane separate atmospheric storage tanks, double wall, and full containment, refrigerated with reinforced concrete external walls. MEG regeneration and injection unit. Sulphur recovery producing liquid sulphur for solidification, granulation and export. Utilities, offsites as required for operation. Gas export compression.
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4.
All work shall be completed in accordance with engineering codes and standards listed in document: DB-1718-999-P332-0203: List of Applicable Codes & Industry Standards.
4.1
General Requirements
The cathodic protection design for the plant shall be based on the codes, standards, documents and drawings referred to in Sections 4.2 and 5 using the last revision before February 2005.
4.2
The cathodic protection system shall meet when applicable the requirements of the following Standards and Codes in their latest edition. API RP 1632 API RP 651 ASTM G 97 ASTM G57 BS 1377 Part 1 BS 1377 Part 3 BS 1377 Part 9 BS 7430 Cathodic Protection of Underground Petroleum Storage Tanks and Piping Systems. Cathodic Protection of Aboveground Petroleum Storage Tanks. Laboratory Evaluation of Magnesium Sacrificial Anode Test Specimens for Underground Applications. Field Measurement of Soil Resistivity Using Wenner Four-Electrode Method. Methods of test for soils for civil engineering purposes. General requirements and sample preparation. Methods of test for soils for civil engineering purposes. Chemical and electrochemical tests. Methods of test for soils for civil engineering purposes. In-situ tests. Code of practice for earthing.
BSI, BS 7361: Part 1 Cathodic Protection, part 1 code of practice for land and marine applications. IEC 60076 IEC 60076-11 Power Transformers. Power Transformers Part 11:Dry-Type Power Transformers
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IEC 60296 IEC 60529 IEC 60726 IEC 60947 . NACE RP 0169 NACE RP 0575 NACE RP 0675 NACE RP0388 NACE RP0177 NACE RP0193 NACE RP0196 NACE RP0285 NACE RP0387 NACE RP0388 NACE-RP-0286
Insulation Oils for Transformers and Switch Gear. Degree of protection provided by Enclosure. Dry-Type Power Transformers. Low voltage Switch Gear and Control Gear.
Control of External Corrosion on Underground or Submerged Metallic Piping Systems. Internal Cathodic Protection Systems in oil-Treating Vessels. Control of external corrosion on offshore steel pipelines. Impressed current protection of internal submerged surfaces of carbon steel water storage tanks Mitigation of Alternating Current and Lightning Effects on Metallic Structures and Corrosion Control Systems. External Cathodic Protection of on Grade Metallic Storage Tank Bottoms. Galvanic Anode Cathodic Protection of Internal Submerged Surfaces of Steel Water Storage Tanks. Corrosion Control of Underground Storage Tank Systems by Cathodic Protection. Metallurgical and Inspection Requirements for Cast Sacrificial Anodes for Offshore Applications. Impressed Current Cathodic Protection of Internal Submerged Surfaces of Steel Water Storage Tanks. The Electrical Isolation of Cathodically Protected Pipelines.
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5.
REFERENCE DOCUMENTS
This document is complemented by the following documents: RP-1718-999-1300-0001 RP-1718- 999-1630-0017 RP-1718-999-6600-0001 DB-1718-999-P332-0204 Piping Material Classes. Specification for Transformer-Rectifier Units for Cathodic Protection. Specification for Shop and Field Painting. Basic Engineering Design Data for Onshore Facilities.
To be issued during detail design Cathodic Protection Isolating Joints. RP-1718-999-2500-0001 RP-1718-999-1630-0007 RP-1718-999-1630-0029 SP-1718-999-1630-0008 RP-1718-999-1630-5012 Cylindrical Storage Tanks Small and Medium Size. Onshore Electrical Design Criteria. Electrical Cables Specification. Electrical Installation Specification. Specification for Electrical Junction Boxes
6.
ABBREVIATIONS
IDRO IOEC NIOC OIEC POGC AC AFC AFD Ag/AgCl Industrial Development and Renovation Organisation Iranian Offshore Engineering and Construction Company National Iranian Oil Company Oil Industries Engineering and Construction Company Pars Oil and Gas Company Alternating Current Approved for Construction Approved for Design Silver/Sliver chloride Reference Electrode
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ASA bbl CP EPCC FEED HMWPE HSE ICCP IR ISO MFD Mg MMO MMSCFD NaCl OVP PCR PDB PVC PVDF SBM SCADA SRB STBPD
Advanced Safety Audit Barrels Cathodic Protection Engineering, Procurement, Construction and Commissioning Front End Engineering Design High Molecular Weight Polyethylene Health, Safety & Environment Impressed Current Cathodic Protection Soil Voltage Drop International Organisation for Standardisation Material Flow Diagram Magnesium Mixed Metal Oxide Million standard cubic feet per day Sodium chloride Over Voltage Protection Polarisation Cell Replacement Positive Distribution Box Polyvinyl chloride Polyvinylidene Fluoride Single Buoy Mooring Supervisory Control and Data Acquisition Sulphate Reducing Bacteria Stock tank barrels per day
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TDS TR WP XLPE
Total Dissolved Solids Transformer Rectifier WorleyParsons Services Pty Ltd Cross Linked Polyethylene
7.
DEFINITIONS
Within this specification the following definitions shall apply: COMPANY: Shall mean NATIONAL IRANIAN OIL COMPANY (NIOC-POGC) CONTRACTOR: Shall mean the Consortium of IDRO, OIEC and IOEC (IOIC) in charge of EPCC realisation of SOUTH PARS Phases 17 & 18 in the CONTRACT with COMPANY, or his representative. CONSTRUCTION CONTRACTOR: Shall mean the party sub-contracted by CONTRACTOR for Construction WORK, or his representative. INSPECTION AGENCY: This term designates the inspection bodies as third party agencies which will be nominated by CONTRACTOR and approved by COMPANY to carry out the inspection and certification tasks independently based on the approved Inspection & Test Plans. SUB-CONTRACTOR: Shall mean the party sub-contracted by the CONTRACTOR for Engineering, Construction WORK. SITE: Shall mean the premises and places on, under, in, over or through which the WORK is to be executed or carried out including CONTRACTORs engineering office and the PLANT. SUPPLIER or VENDOR: Shall mean any person, firm or business which manufacture or supply material, equipment or services for the performance of any item of WORK. SUB-SUPPLIER or SUB-VENDOR: Shall mean any person, firm or business which is in CONTRACT with SUPPLIER/VENDOR to manufacture or supply material, equipment or services for the performance of any item of WORK. WORK: Shall mean all and any of the works and / or services and/or materials required to be provided by the CONTRACTOR or CONSTRUCTION CONTRACTOR.
QUALITY: Shall mean the degree to which a set of inherent characteristics fulfil requirements.
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QUALITY MANAGEMENT SYSTEM: Shall mean the management system that directs and controls an organisation with regard to quality. CONTINUED IMPROVEMENT: Shall mean a culture that encourages each team member to try to increase Project quality at every opportunity. PREVENTATIVE ACTION: Shall mean an action taken to eliminate the cause of a potential nonconformity or other potentially undesirable situation. CORRECTIVE ACTION: Shall mean an action taken to eliminate the cause of a detected non-conformity or other undesirable situation. VERIFICATION: Shall mean confirmation, by the provision of objective evidence, that specified requirements have been fulfilled. VALIDATION: Shall mean confirmation, by the provision of objective evidence, that the requirements for an intended use have been fulfilled.
8. PRECEDENCE
In case of conflict between requirements specified herein and the requirements of any other referenced document, the order of precedence shall be: This specification Particular specification Applicable technical codes industrial standards Data sheet Material requisition
9.
USE OF LANGUAGE
Throughout this specification, the words "will", "may", "shall" and "should when used, have meaning as follows: "Will" is used normally in conjunction with a request from CONTRACTOR;
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"May" is used where alternatives are equally acceptable; "Shall is used where a provision is mandatory; "Should" is used where a solution is preferred.
10.
10.1 Overview
The sacrificial anode/impressed current cathodic protection systems for the onshore facilities of the SOUTH PARS Phase 17/18 project will be generally applied to structures and surfaces which have been coated with a high quality coating. The items to be protected are indicated in Section 1 of this specification. All coating shall be in accordance with document RP-1718-999-6600-0001. All coatings used will have their suitability for use in conjunction with cathodic protection confirmed by documented cathodic disbondment testing and a demonstrated track record in the proposed environment whilst under cathodic protection. The cathodic protection system for the different areas shall be in accordance with the design criteria given in the following sections.
11.
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Note: The Sacrificial Anodes shall be designed for minimum 5 years life span and the relevant calculations shall be carried out during detail stage.
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Design Current Density Structure At grade tank bottoms Plant piping bare steel Coated plant pipeline: 3 Layer Polyethylene 3 Layer Polypropylene Fusion Bonded Epoxy Liquid applied Coatings Coal Tar Enamel Bitumen Tape Wrap system Water tank internal 20 (fresh water) 40 (seawater/produced water) Concrete rebar (where applicable) Electrical earthing 10 150 (galvanised steel) 500 (copper) Uncoated Steel, (mA/m2) 20 30
0.01
0.01
For structures and tanks operating at elevated temperatures the current density values shall be increased by 25% for each 10 deg. C rise in operating temperature above 30 deg. C.
The current densities given in Table 1 are indicative and valid for moderately corrosive soils. Should the soil survey indicate a very corrosive or non corrosive soil, then the above current densities should be adjusted accordingly during detail design.
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The expected coating breakdown in water tank internals will be typically in the range 5-10% and it is assumed that the coating will be regularly inspected and maintained in order to ensure that the exposed steel in these tanks is always less than 10% of the overall wetted tank area. Detail design of the CP system for the tanks shall take into consideration the specific operating conditions, coating system and estimate coating breakdown factors for each individual tank.
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Where tanks are constructed on ring beams the infill shall be selected washed sand and crushed rock. The resistivity of this material shall be taken in the range 250 to 500 ohm m for design purposes. Bituminous sand or asphaltic layers shall not be used and the tank floor will rest directly on the sand or crushed rock infill. In this manner the CP system will be able to more effectively protect the floor plates.
In cases where silver /silver chloride half-cells are used these shall be of the sealed low ion type. IR free potentials onshore shall be measured after disconnection of all bonds and sacrificial anodes (if practical) and instantaneously following the switching off all transformer rectifiers. Other methods of recording IR free potentials may also be used if approved by COMPANY e.g. waveform analyser or CP analyser.
[Deleted]
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For in-plant areas the complicated nature, which often exists in conjunction with the combination of materials used in some locations, can influence the potential levels. It may therefore be necessary to allow some flexibility in the protection potential criteria required. For example the 100mV polarisation decay test method (ref. NACE RP0169) may be used in congested areas, subject toCOMPANY approval, or in areas subject to cathodic shielding to determine that adequate protection has been achieved.
12.
DESIGN CONSIDERATIONS
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foundation. The calculation of current requirements, anode type, final siting of anodes, interconnection of tanks by bond cables and use of electrical isolation devices shall be addressed within the detailed design taking into account of the referenced codes and standards and due recognition of the service conditions likely to be encountered. Monitoring of the effectiveness of the CP systems shall be by potential measurement using permanent reference electrodes installed at time of construction beneath the tank floor. Electrodes shall be placed as close as possible to the tank floor to minimise the IR drop in the soil path. Numbers and distribution of reference electrodes for various tank diameters are given below:
Reference Electrode Location Central 1/3D at 120 Degree 2/3D at 90 degree Central 1/3D opposite 2/3D at 120 degree Central 1/3D opposite 2/3D opposite Central 1/2D opposite Central --
18<D30
1 2 3
10<D18
1 2 2
8<D10
1 2
1 None
Further monitoring facilities shall be provided at the tank periphery in the form of test cell access tubes penetrating the tank foundation. The access tubes shall be installed under the tank base and shall be in
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the form of slotted plastic tubes. These access points will be used in conjunction with portable monitoring equipment. This is particularly important where a secondary containment liner is used under the tank base as it allows a cross check of permanent electrodes with field measurements.
Internal corrosion protection of the tanks and vessels shall be achieved by lining (coating) of the tanks in conjunction with a cathodic protection system. Internal cathodic protection shall be provided for all submerged surfaces exposed to natural waters or contaminated waters (brines). The water resistivity shall determine the type of CP system to be installed. For water resistivities less than 10 ohm.m (i.e. water phase in the bottom of hydrocarbon tanks) zinc anodes shall be used. In general, aluminium anodes shall only be used in brines with resistivities of 1 ohm.m or less. Conventional zinc anodes as detailed in section 13.4 shall be used in the water phase of condensate tanks for temperatures <60C. Permanent monitoring within tanks shall be accomplished by provision of special connections on the side of the tank which allows insertion and retrieval of reference electrodes into the tank. The design of this connection shall be developed during detailed design. Proprietary Noranode zinc anodes, or approved equivalent, shall be used in vessels where the temperature is less than 80oC. Zinc anodes shall not be used in water systems providing water for human or animal consumption. The coating system shall be inspected and repaired at regular intervals. Coating breakdown shall not exceed 5 10% in the wetted areas. The anodes shall be located to ensure even current distribution over the whole water wetted area. Bolted or screwed connections shall be used to permit anode replacement at future inspections. The anodes shall be attached to plates or bosses that are pre-welded to the tank floor. Bolted and screwed connections, pads or mounting brackets shall be coated but shall not interfere with the electrical connection between the tank and the anode insert. Electrical continuity between the tank/vessel and the anode shall be checked and the resistance shall be less than 0.01 ohms.
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12.2.2
Internal Impressed Current Cathodic Protection for Aboveground Water Storage Tanks
For aboveground water storage tanks where the water resistivity is greater than 10 ohm.m, this may include the potable water and firewater storage tanks, sacrificial anodes will not be able to provide a practical CP system and an ICCP system shall be used. MMO anode wire strings shall be used for the impressed current system. The anode wires shall be suspended from the tank roof as an anode string through access hatches. The impressed current anodes shall be MMO coated titanium anode/copper wire strings. The quantity of anode wire strings and anode loop-to-tank and anode loop-to anode loop spacing will be dependent upon the tank diameter and water level. The anode wires shall be suspended from the hatch cover on a polypropylene rope wire with a cable connection to each anode. The cable shall be routed back to a junction box on the tank roof containing a suitably sized shunt. The anode strings shall be cabled back to a positive distribution box and this box shall be fed via a dedicated transformer rectifier unit. For tanks with internal and external impressed current the transformer rectifier unit for the internal CP and external CP systems shall be totally separate. Provision shall be made within the transformer rectifier unit for monitoring the DC current output and tankto-water potential via the SCADA system. Signal converters (4-20mA) shall be used for this purpose. Facilities shall be provided for each above ground water tank to enable internal monitoring of the structure-to-electrolyte potentials. Permanent monitoring within tanks with impressed current system installed shall be accomplished by permanent CU/CUSO4 reference electrodes in accordance with NACE RP0196 installed within each tank. In addition to these permanent devices, access ports around the roof periphery shall be provided to allow the insertion of portable reference electrodes for measuring tank shell potentials. All below and above cable runs shall be in accordance with SP-1718-999-1630-0008 Electrical Installation Specification.
12.3 Reinforcement Steel and Electrical Earthing Material (Uninsulated Copper or Steel)
Where ICCP is used the effect of CP on the corrosion rates of steel within concrete foundations and other structures shall be considered and allowances made for current losses. Generally in the case of in-plant, it is advantageous to use uncoated reinforcing steel so that interaction between individual sections is kept
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to a minimum. Depending upon the anode type and distribution used the reinforcing steel and electrical grounding shall be made deliberately continuous with the tank to ensure interaction and accelerated corrosion of either one is avoided. To minimise current drainage and cathodic shielding galvanised steel or stainless steel earthing rods shall be used rather than copper rods or copper earthing grids. Wherever possible, a proximity distance of at least 6 metres shall be maintained between earthing rods and protected steel structures and earthing rods and anodes. Under no circumstances shall earthing electrodes be installed between anodes and the structures they are intended to protect.
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At all locations where a buried line crosses existing metallic and buried foreign services, facilities shall be installed to allow testing to determine whether resistive bonding is required. Bonding facilities, if necessary, shall include resistors or diodes and current measuring shunts. Given the high integrity of the coating system to be applied on the pipelines, bonding to foreign pipelines should only be undertaken if all other mitigation measures are found to be ineffective. If such bonding is carried out consideration should be given to the possibility of over protection from existing CP systems that may be providing high current outputs to old or poorly coated pipeline systems.
12.8.2
Interaction at points where pipelines run parallel with other services such as high voltage overhead power transmission lines (>11kV) shall also be addressed. This interaction due to induced AC or short term interference effects (e.g. grounding fault) can lead to safety concerns with regards to personnel subject to electric shocks, accelerated corrosion of the pipeline and damage to the coating. As the pipeline coatings will be of high integrity it should be anticipated that induced AC may be problematic. AC interference effects should be investigated by survey to estimate the magnitude of the effects. If such surveys in conjunction with calculations demonstrate that there is a possibility of harmful
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voltages then mitigation measures should be provided. These mitigation measures may consist of one or a combination of the following: Dedicated pipeline earthing such as zinc ribbon Installation of solid state polarisation cells to allow AC current to flow (low impedance to AC) to earthing devices but to prevent flow from DC current (high resistance) from CP systems Installation of buried steel coupons in the affected section Installation of monobloc isolating joints at each end of the parallelism
13.
MATERIALS
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ITEM TO BE PROTECTED
ANODE MATERIAL
ANODE CONFIGURATION
BACKFILL Calcined petroleum coke or approved equivalent Washed sand Mg anodes only: Bentonite clay + Gypsum + Sodium sulphate
Plant piping
MMO
MMO
Loops or grid
Firewater Hydrants
Mg
Vertical
Internal tanks:
Water storage tanks resistivity 1 ohm.m) Water storage tanks 1ohm.m<resistivity < 10 ohm.m)
Al
Stand-off or flush
N/A
Zn
Stand-off or flush
N/A
Water storage tanks (resistivity 10 ohm.m) Hydrocarbon tanks (With discrete water phase)
MMO
N/A
Zn
N/A
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13.3.1
Wire Anodes
Wire anodes shall be of the MMO titanium type. Copper cored MMO titanium anodes shall be used where there are long anode runs and where current attenuation along the wire is of a concern. The wire anodes shall comply with the following:
Substrate Anode coating type Anode coating thickness Wire diameter Maximum anode current density (to be verified by MMO anode VENDOR)
Titanium or Titanium/copper MMO Rated for maximum current output for full design life 3mm (min) 3 A/m2 in soil 50 A/m2 in petroleum coke 50 A/m2 in fresh water
13.3.2
Tubular Anodes
Tubular anodes shall be MMO/Titanium type in a LIDA type arrangement and comply with the following: Substrate Anode coating type Anode coating thickness Titanium MMO Rated for maximum current output for full design life
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The maximum amount of other elements shall be 0.02 % each. Alloy Potential Alloy Capacity -1.050 Volts (vs Cu/CuSO4 ref cell) 780 Amp.hour / kg
Zinc anodes should not be used if the resistivity of the electrolyte is higher than 30 m unless the engineering evaluation or field test confirm that the design requirements can be met.
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Element Cu Al Si Fe Mn Ni Zn Mg
Magnesium anode shall be selected as grade B. Alloy Potential Alloy Capacity -1.75 Volts (vs Cu/CuSO4 ref cell) 1230 Amp.hour / kg
Magnesium should not be used if the resistivity of the electrolyte is higher than 150 .m unless the engineering evaluation or field test confirm that the design requirements can be met.
Calcined petroleum coke (only for tubular anodes) for use with impressed current anodes shall comply with the following requirements: Resistivity Fixed carbon Ash content Moisture content Volatile content Particle size 0.001 ohm.m 99.1% min 0.1% max 0.2% max 0.6% max 100% passing 1mm <10% retained 0.1mm
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13.6.2
Chemical Backfill
75% 20% 5%
Chemical backfill for use with sacrificial anodes shall comply with the following composition: Hydrated gypsum Bentonite Sodium sulphate
13.8 Cables
Impressed current anode cables shall be tin-coated, stranded single core copper with HMWPE/PVDF primary insulation and high molecular weight black polyethylene. All other cables shall be tin-coated, stranded single core copper with XLPE/PVC insulation. The minimum rating for all cables and wires shall be 600/1000 Volt grade. The minimum cable sizes shall be as follows: Positive and negative cathodic protection station cables: 35 mm2. Equi-potential bonding cables: 16 mm2. Monitoring cables:10 mm2. Impressed current anode cable tails: 10 mm2. Magnesium/Zinc anode cable tail: 10 mm2. Bonding cable: 10 mm2. Reference electrode cable tails: 6 mm2. Surge diverter (Over Voltage Protection) cable tails: 25 mm2. Negative cable shall be black and positive cables shall be red. Direct buried negative and positive cables shall be armoured.
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All above ground cables shall be suitably identified with stainless steel tags to show their origin and function. All below ground cables shall be suitably identified with concrete cable markers. Individual cable sizes shall be calculated at detailed design and a schedule included in the calculation package for each run.
L = 400
Where: L D = = = Internal coated length Nominal diameter of pipe Electrolyte resistivity
D (cm) r
cm cm Ohm.cm
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Pars Oil and Gas Company
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Page 33 of 46
Condensate and LPG pipelines. Lean gas export pipelines. Ethane export pipelines. Propane and butane circulation/vapour return lines. Between offshore pipe lines and on shore pipe lines in battery limits The isolation joints shall be positioned with particular attention to avoid short circuiting that might be caused by a support, walkway fittings, valves and actuators or any other metallic structures whether permanently or temporarily installed. All isolation joints shall be in accordance with project specification to be developed during detail design and shall have over voltage protective devices installed in accordance with section 13.11 below.
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electrode installed. In complex area where shielding of the cathodic protection system may occur, the test stations shall also have a coupon installed for local ON/OFF potential measurements. The coupon shall be of the same material as the pipe. Test stations shall be installed at the following locations: Every 100-150 meters of pipeline/piping run and at every change of pipe direction. The test station should generally be installed above the pipeline/piping. 2 per tank. At all isolation joints. At every foreign service crossing. At road crossings. At points of parallelism with high voltage AC. From each monitoring station two separate cables as a minimum shall be attached to the pipeline/piping. All cables shall be identified by colour coding or tags.
14.
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Pars Oil and Gas Company
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The electrical current rating of a cable shall not be exceeded for the temperature of use. Cable crosssection shall be selected to suit the condition of use.
15.
ELECTRICAL INTERFERENCE
Corrosion caused by electrical interference on buried metallic structures differs from other causes of corrosion damage in that the current, which causes the corrosion, has a source foreign to the affected structure. Usually the interfering current from a foreign source, not electrically continuous with the affected structure is drained from the soil by the affected structure. Detrimental effects of interference currents occur at locations where the currents are subsequently discharged from the affected pipeline to the earth. Types of DC interference are: Constant current sources such as from CP rectifiers, and Fluctuating current sources such as direct current electrified railway systems and transit systems, coal mine haulage systems and pumps, welding machines and direct current power systems. Types of AC interference are: Short term interference caused by faults in a.c. power systems and electrified railways Long term interference caused by inductive or conductive coupling between the pipeline and high voltage lines or electrified railways Telluric currents.
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It is the responsibility of the detail design Contractor to ensure that that no electrical interference will occur within the plant by employing suitable corrective actions. Further information on mitigation is detailed in ISO 15589-1 and shall be evaluated during detail design.
16.
DOCUMENTATION
Detail design contractor shall develop a detailed CP design based on this document and the referenced standards. The detail design shall be documented in a detail design report, CP layout drawings, CP detail drawings, equipment datasheets, cable schedule, test post schedule and a material take off list. All documentation shall be approved by Company.
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17.
PRE-COMMISSIONING
During detailed design a pre-commissioning test specification shall be generated which covers all aspects of tests during mechanical completion and pre-commissioning testing for tanks and buried piping. Such tests shall include: Procedure for testing backfill under tanks. Trial operation of anodes including individual anode loop resistance to earth immediately after completion of tank foundation and before tank plates are installed and then after the tank has been fabricated and power sources to confirm they can deliver their maximum capacity. Measurements and testing shall also be carried out to confirm satisfactory connection of all cables and circuits. Resistance to earth testing of all distributed groundbeds. Calibration of permanently installed reference electrodes.
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18.
COMMISSIONING
Onshore commissioning procedures shall be produced during detailed design for the approval of the COMPANY. The purpose of the commissioning procedure shall be used to show that the installed systems operate as specified and that the required design criteria have been met. The specification shall include as a minimum the following: Standard forms for recording commissioning results Procedure for disconnection of all sacrificial systems, depolarisation of the piping and measurement and recording of natural potentials Procedure for setting the cathodic protection systems in operation and measuring ON potentials Procedure for setting the cathodic protection parameters(potential and current) after 72 hours polarization period minimum. Procedure for measurement of IR free potentials Incoming/outgoing piping and pipelines with" foreign structure". Procedure for balancing CP systems The CONTRACTOR selected for detailed design shall provide the company with a program for the commissioning of the cathodic protection systems. The CONTRACTOR selected shall prepare a commissioning report, which shall include all commissioning results. The report shall include a discussion of the results obtained giving conclusions. The report shall also show the Natural ON and instant OFF potentials at all test stations in both tabular and graphical formats.
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pD 2 St (m2) = 4
Current Requirements
It ( A) = StCD
MMO Ribbon Length Requirements (min)
Rl (m) =
It Acd
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Ranode(Ohms) =
r 8D 2 D ln + ln 2 2p D d s
Where
-1
Where Ranode1 = resistance of 1st anode loop Ranode2 = resistance of 2nd anode loop RanodeN = resistance of Nth anode loop
IR =
R int Re xt
Where
R int =
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Water Tank Internals Impressed Current System Design Data MMO wire anode type MMO ribbon anode current output in water Circuit resistance Rectifier voltage IR loss in anode circuit Surface Areas 3mm dia (copper/titanium core) 50 A/m2 (max) to be confirmed by anode VENDOR 1 ohm (max) 24V (max) 10% (max)
St =
pD 2 + pDH (m2) 4
Where
Current Requirements
It = StCD (A)
MMO Ribbon Length Requirements (min)
Rl =
It (m) Acd
R=
r 8L ln - 1 (ohms) 2pL d
Where
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F = 1+
r [ln(0.66 N )] psR
N = number of anodes
s = anode-to-anode spacing
Rtotal = F
R (ohms) N
IR =
where
R int Re xt
Rint = Anode internal resistance (ohm) Rext = Anode resistance to earth (ohm)
R int =
Lc = anode length between conductors (m) A = anode cross sectional area (m2)
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Tank Internals Sacrificial Anodes Anode Resistance for Long Flush Mounted Anode
Ra =
r 2xS
Symbol
Description Anode resistance Fluid / Soil resistivity Arithemetic mean of anode length & width
Ra
r
S
Notes:
Ra =
0.315 r A
Unit Ohms Ohm.m cm2
Symbol
Description Anode resistance Fluid / Soil resistivity Exposed anode surface area
Ra
r
A
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Anode Weight
W =
Iav x t x 8766 Z xU
Symbol
Description Total anode weight for design life Average design current over design life Time Anode alloy capacity Anode utilisation factor
W Iav t Z U
NOTE 1 Anode utilisation factors as given in DNV RP B401: Long slender stand-off Long flush mounted Short flush mounted 0.90 0.85 0.80
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pD 2 St (m2) = 4
Current Requirements
It ( A) = StCD
MMO Ribbon Length Requirements (min)
Rl (m) =
It Acd
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Ra =
Where
F = 1+
r [ln(0.66 N )] psRa
R (ohms) N
Ratotal = F
Total Resistance in system shall also take into account resistance in anode cables, positive cables to junction boxes and negative cables. Potential shift on pipe The potential shift on the pipe shall be calculated directly opposite the anode and between the anodes.
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