17 Samss 008

Materials System Specification
17-SAMSS-008 25 March 2017

Junction Boxes for Cathodic Protection
Document Responsibility: Cathodic Protection Standards Committee
Contents
1 Scope ................................................................ 3
2 Conflicts and Deviations .................................... 3
3 References ........................................................ 3
4 Definitions and Abbreviations ............................ 4
5 Qualification Requirements................................ 8
6 Site Conditions .................................................. 9
7 Design ............................................................. 10
8 Testing ............................................................. 12
9 Packing and Shipping ...................................... 13
Revision Summary................................................. 13
Previous Issue: 10 July 2013 Next Planned Update: 25 March 2020

Page 1 of 13
Contact: Nawaf A. Al-Dawoud (dawona0d) on phone +966-13-8809455
©Saudi Aramco 2017. All rights reserved.

Document Responsibility: Cathodic Protection Standards Committee 17-SAMSS-008
Issue Date: 25 March 2017
Next Planned Update: 25 March 2020 Junction Boxes for Cathodic Protection
Detailed Table of Contents

1 Scope ............................................................................................................. 3
2 Conflicts and Deviations ................................................................................. 3
3 References ..................................................................................................... 3
3.1 SAUDI ARAMCO DOCUMENTS ................................................................... 3
3.2 INDUSTRY CODES AND STANDARDS .......................................................... 4
4 Definitions and Abbreviations ......................................................................... 4
5 Qualification Requirements ............................................................................ 8
5.1 SME APPROVAL....................................................................................... 8
5.2 QUOTATION INFORMATION REQUIREMENTS ............................................... 9
5.3 PURCHASE ORDER INFORMATION REQUIREMENTS ..................................... 9
6 Site Conditions ............................................................................................... 9
6.1 TEMPERATURE AND HUMIDITY .................................................................. 9
6.2 ONSHORE ENVIRONMENT ......................................................................... 9
6.3 OFFSHORE ENVIRONMENT ..................................................................... 10
7 Design .......................................................................................................... 10
7.1 GENERAL REQUIREMENTS ..................................................................... 10
7.2 EDGE SHARPNESS ON ENCLOSURES ....................................................... 12
7.3 OBSERVATION W INDOWS ....................................................................... 12
8 Testing ......................................................................................................... 12
8.1 FACTORY ACCEPTANCE REQUIREMENTS ................................................. 12
8.2 POLYMERIC BELOW GRADE JUNCTION BOX ............................................. 12
8.3 CERTIFICATION ..................................................................................... 12
9 Packing and Shipping .................................................................................. 13
Revision Summary .............................................................................................. 13
Saudi Aramco: Company General Use

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1 Scope
This specification defines the requirements for above and below grade junction boxes to
be used with cathodic protection systems.
This scope defines only installations in non-classified areas as recommended to be

installed. If installation is needed at classified areas, please refer to the appropriate
electrical and loss prevention codes.
2 Conflicts and Deviations
2.1 Any conflicts between this specification and other applicable Saudi Aramco
Materials System Specifications (SAMSSs), Engineering Standards (SAESs),
Standard Drawings (SASDs), or industry standards, codes, and forms shall be
resolved in writing by the Company or Buyer Representative through the
Manager of the Consulting Services Department of Saudi Aramco, Dhahran.
2.2 Direct all requests to deviate from this specification in writing to the Company or
Buyer Representative, who shall follow internal company procedure SAEP-302
and forward such requests to the Manager of the Consulting Services Department
of Saudi Aramco, Dhahran.
3 References
The design, product fabrication, and selection of material covered by this specification
shall comply with the latest edition of the references listed below unless otherwise
noted.
3.1 Saudi Aramco Documents
Saudi Aramco Engineering Procedure

SAEP-302 Instructions for Obtaining a Waiver of a Mandatory
Saudi Aramco Engineering Requirement
Saudi Aramco Engineering Standard

SAES-P-104 Wiring Methods and Materials
Saudi Aramco Standard Drawings

AA-036108 Cathodic Protection, Offshore Negative Terminal
Junction Box
AD-036132 Termination Detail and Cable Identification
AA-036145 Cathodic Protection, Junction Box - Cable Splice
AA-036157 Cathodic Protection, 3-Pin Test Station
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AB-036274 Cathodic Protection, Junction Box-5 Terminal

AB-036275 Cathodic Protection, Junction Box-12 Terminal
AA-036276 Cathodic Protection, Multi-Purpose Junction Box
AA-036277 Cathodic Protection, Bond Box-5 Terminal
AA-036347 Cathodic Protection, Junction Box-20 Terminal
AA-036384 Cathodic Protection, Offshore Anode Junction Box
AB-036540 Cathodic Protection, Junction Box - Mounting
Support Details
AB-036907 Cathodic Protection, Kilometer Marker, and CP
Test Stations for Buried Pipelines
3.2 Industry Codes and Standards
American National Standards Institute

ANSI B1.20.1 Pipe Threads General Purpose
ANSI C80.1 Rigid Steel Conduit - Zinc Coated
National Electrical Manufacturers' Association

NEMA ICS 6 Enclosures for Industrial Controls and Systems
NEMA 250 Enclosures for Electrical Equipment
4 Definitions and Abbreviations
The following list of definitions and abbreviations has been developed specifically for
application with ALL Saudi Aramco cathodic protection standards and specifications.
AA: The ANSI cooling class for a dry-type self-cooled transformer or reactor that is
cooled by the natural circulation of air. Syn.: AN (IEC), See definition 3.1 in IEEE Std.
C57.12.
Anode: An impressed current or a galvanic anode for cathodic protection applications.
Anode Cable: A cable directly connected to an impressed current or galvanic anode.
ANSI: American National Standards Institute
ANV: The ANSI cooling class for a dry-type non-ventilated self-cooled transformer,
which is so constructed as to provide no intentional circulation of external air through

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the transformer, and that operates at zero gauge pressure. Syn.: ANAN (IEC).
See definition 3.15 in IEEE Std. C57.12.
ASTM: American Society for Testing and Materials
AWS: American Welding Society
Armored Cable: Armored cable for cathodic protection is a single core insulated cable
manufactured with a double layer spiral wound insulated galvanized steel sheath to
provide mechanical protection, and typically used for subsea applications.
ASME: American Society of Mechanical Engineers (USA)
Bond Cable: A cable installed between two metallic structures to provide electrical
continuity between the structures for the purpose of cathodic protection.
Buyer: Saudi Aramco Purchasing Department Representative.
Buyer's Representative: The person or persons designated by the Purchasing
Department to monitor/enforce the contract. Normally, this is the on-site inspector.
Calcined Petroleum Coke Breeze: A carbonaceous backfill used as a conductive
backfill media for impressed current anodes in soil.
CP: Cathodic Protection
CP Assessment Probe: A multi-electrode probe custom fabricated for Saudi Aramco
that is designed to facilitate representative measurements of instant off, total
polarization, current density, and resistivity.
CP Coupon: A cathodic protection coupon used to measure representative potentials
or current densities on a pipeline or other buried or immersed metallic structure.
CP System Operating Circuit Resistance: The total resistance seen at the output of a
CP power supply or the total working resistance in a galvanic anode system.
CP System Rated Circuit Resistance: The rated output voltage of a cathodic
protection power supply divided by the rated output current. For photovoltaic power
supplies, the rated output current is the design commissioning current.
CSD: The Saudi Aramco Consulting Services Department.
Deep Anode Bed: Anode or anodes connected to a common CP power supply and
installed in a vertical hole with a depth exceeding 15 m (50 ft).
Cross Country Pipeline: A pipeline between; two plant areas, another cross country
pipeline and a plant area, or between two cross country pipelines.
Design Agency: The organization responsible for the design of the pipeline and
associated CP system. The Design Agency may be the Design Contractor, the Lump
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Sum Turn Key Contractor or an in house design organization of Saudi Aramco.

Flowline: A pipeline connected to a well.
Foundry (for anodes): An anode foundry is a facility that produces metal castings
from either ferrous or non-ferrous metals or alloys.
Galvanic Anodes: Anodes fabricated from materials such as aluminum, magnesium or
zinc that are connected directly to the buried structure to provide cathodic protection
current without the requirement for an external cathodic protection power supply.
Galvanic anodes are also referred to as sacrificial anodes.
GOSP: Gas and Oil Separation Plant
Hazardous Areas: An area where fire or explosion hazards may exist due to
flammable gases or vapors, flammable liquids, combustible dust, or ignitable fibers or
filings (see NEC Article 500).
HMWPE: High molecular weight poly ethylene.
ICCP: Impressed Current Cathodic Protection
Impressed Current Anodes: Anodes typically fabricated from High Silicon Cast Iron
(HSCI) or Mixed Metal Oxide (MMO) that are connected through a DC power supply
to the buried or immersed structure to provide cathodic protection current.
Lead Wire (for anodes): A cable directly connected to an anode.
Manufacturer: The Company that assembles the components for the finished product
and provides the finished product either through a Vendor or directly to Saudi Aramco.
Megger: A meter designed to measure ground resistivity, or can be connected to
measure resistance in a format that excludes the resistance of the test wires.
Mill (for anodes): An anode mill is a facility that produces anodes such as MMO or
Platinized Niobium (without lead wires) for cathodic protection applications (or any
other anode type that does not involve casting).
MSAER: Mandatory Saudi Aramco Engineering Requirements
NEC: National Electric Code
NEMA: National Electrical Manufacturers Association (USA). Example NEMA 4 X.
Negative Cable: A cable that is electrically connected (directly or indirectly) to the
negative output terminal of a cathodic protection power supply or to a galvanic anode.
This includes bond cables to a cathodically protected structure.
Non-incendive Equipment: Equipment having electrical/electronic circuitry that is
incapable, under normal operating conditions, of causing ignition of a specified
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flammable gas-air, vapor-air, or dust-air mixture due to arcing or thermal means.

(See NEC Article 100)
Off-Plot: Off-plot refers to any area outside of the plot limits.
ONAN: The ANSI cooling class for a transformer or reactor having its core and coils
immersed in mineral oil or synthetic insulating liquid with a fire point less than or equal
to 300C, the cooling being effected by the natural circulation of air over the cooling
surface. (ONAN was previously termed OA). See definition 3.303 in IEEE Std. C57.12.
On-Plot: On-plot refers to any area inside the plot limit.
Perimeter Fence: The fence which completely surrounds an area designated by Saudi
Aramco for a distinct function.
Photovoltaic Module: A number of solar cells wired and sealed into an
environmentally protected assembly.
Pipeline: The term “pipeline” is used generically to refer to any type of pipeline.
Plant Area: The area within the plot limits of a process or storage facility.
Plot Limit: The plot limit is the boundary around a plant or process facility. The plot
limit may be physical such as a fence, a wall, the edge of a road or pipe rack, chains and
posts or a boundary indicated on an approved plot plan.
Positive Cable: A cable that is electrically connected (directly or indirectly) to the
positive output terminal of an impressed current cathodic protection power supply,
including impressed current anode cables.
Process Pipeline: A pipeline typically associated with a plant process and typically
above ground within a plant facility.
Production Pipeline: A pipeline transporting oil, gas or water to or from a well.
These include flowlines, test lines, water injection lines, and trunklines.
Pyramid Anode: An offshore anode assembly custom manufactured for Saudi Aramco
that is fabricated with mixed metal oxide anode components and placed on the sea bed.
The pyramid anode derives its name from the pyramid shaped concrete base.
Reference Electrode: An industry standardized electrode used as a common reference
potential for cathodic protection measurements. A copper/copper sulfate (Cu/CuSO4)
reference electrode is typically used for soil applications. A silver/silver chloride
(Ag/AgCl/0.6M Cl) reference electrode is typically used for aqueous applications.
Responsible Standardization Agent (RSA): for CP material, this would usually be
the Supervisor of the CSD Cathodic Protection Team or the Saudi Aramco CSD
cathodic protection Subject Matter Expert.

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SAES: Saudi Aramco Engineering Standard

SAMSS: Saudi Aramco Materials System Specification
Soil Transition Point: The surface location where a pipeline enters or exits the soil,
i.e., above grade to below grade transition, or below grade to above grade transition.
Subject Matter Expert (SME): The SME is the assigned Consulting Services
Department cathodic protection specialist.
Surface Anode Bed: Anode or anodes connected to a common CP power supply,
installed either vertically or horizontally at a depth of less than 15 m (50 ft).
Tension Spring Anode: An offshore anode assembly custom manufactured for Saudi
Aramco that is fabricated with mixed metal oxide anode components and suspended on
a wire rope/tension spring assembly beneath an offshore platform.
Test Line: A pipeline that is used for testing an individual well or group of wells.
Thermite Weld: An exothermic process for use in making electrical connections
between two pieces of copper or between copper and steel.
Transformer/Rectifier (T/R): A CP power supply that transforms and converts AC to
DC power, often referred to in the cathodic protection industry as a rectifier.
Transmission Pipeline: A cross country pipeline transporting product between GOSPs
WIPs or other process facilities.
Trunkline: A pipeline designed to distribute or gather product from two or more wells,
typically connecting flowlines or injection lines to the associated GOSP or WIP.
Type Approval Test: A test conducted by the manufacturer to demonstrate that the
equipment satisfies all standard requirements.
Utility line: A pipeline that delivers a service product (typically water, gas or air).
Vendor: A company that receives a purchase order to supply the finished product,
material or equipment. The Vendor may also be the Manufacturer.
WIP: Water Injection Plant
5 Qualification Requirements
5.1 SME Approval
Cathodic protection junction boxes shall be inspected by the Saudi Aramco

SME for workmanship and compliance with the applicable standard drawing
and this material specification. Refer to Section 8 of this specification for
additional details. The manufacturer shall maintain at all times qualified
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personnel and at least one of these personnel shall have NACE International CP
Level 2 Certification.
5.2 Quotation Information Requirements
The following information shall be provided with the quotation if the junction
boxes used for the quotation contain any material or dimensional deviations
from the applicable standard drawing listed in Section 3.1 of this specification:
a) Construction drawings of the junction box
b) Detailed list of materials
c) Copy of SME “Type Approval”
Commentary Note:
The above information is necessary only if there are deviations from the
applicable standard drawing. The information will be used to complete the
technical evaluation of the quotation.
5.3 Purchase Order Information Requirements
The following information shall be specified in the Purchase Order:

a) Type of junction box, i.e., “Bond Box - 5 Terminal for offshore
environment”
b) Applicable Standard Drawing
c) Hazardous area classification (if applicable)
6 Site Conditions
6.1 Temperature and Humidity

Relative Humidity: Minimum 0%
Maximum 100% (Condensing)
Temperature: Minimum 0°C (32°F)
Maximum 55°C (131°F)
Ultraviolet Radiation Hourly mean (Dec) 14 W/m²
Hourly mean (July) 28 W/m²
6.2 Onshore Environment
The normal air-borne dust concentration is 1 mg/M³. During sand storm

conditions, dust concentrations may reach 500 mg/M³ and winds may gust to
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112 km/hr. 95% of all dust particles are less than 20 micrometers, and 50% of
all particles are less than 1.5 micrometers in size. The dust may contain sodium,
calcium, magnesium, silicon, and aluminum compounds. During high humidity
conditions, these compounds function as electrolytes and can result in severe
corrosion. Other pollutants which may be present are: H2S (1 to 5 ppm),
CO (50 to 100 ppm), NOx (1 to 5 ppm), SO2 (1 to 5 ppm), and hydrocarbons
(10 to 50 ppm).
Commentary Note:
Areas within one kilometers from the Red Sea and within 30 meters from Arabian
Gulf considered to be offshore.
6.3 Offshore Environment
Offshore equipment is subjected to a severely corrosive environment due to

cyclic wet/dry conditions from wind-blown sea water spray and the
accumulation of associated mineral salts on exposed surfaces. Other pollutants
which may be present are: H2S (1 to 5 ppm), CO (50 to 100 ppm),
NOx (1 to 5 ppm), SO2 (1 to 5 ppm), and hydrocarbons (10 to 50 ppm).
7 Design
7.1 General Requirements
All cathodic protection junction box enclosures for non-classified areas shall have:
a) A continuous full length hinge located on the left hand side when facing the
front of the enclosure
b) Two quick release toggle latches located on the right hand side of the
enclosure
c) A gasket shall be secured with adhesive or by mechanical means.
The gasket and its securing means shall not be damaged when the gasketed
joint is opened, see details in SAES-P-104 Section 4.1 and NEMA 250
Section 3.14. Junction boxes require breathers as detailed in respective
Saudi Aramco electrical standards.
d) Hinges and latches fabricated from material that is galvanically compatible
with the enclosure metal and of equal or better corrosion resistance.
Non-metallic components may be used for hinges and latches.
Exception:
Grade 304L stainless steel latches may be used on grade 316 or 316L
stainless enclosures.

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7.1.1 Onshore cathodic protection junction box enclosures placed in

non-classified areas shall be NEMA 4X compliant and shall be
constructed of:
● Type 5052 aluminum alloy, or
● Type 1050 aluminum (or comparable metallurgy) with a light
colored (white or light green) baked powder (polyester or phenolic)
coating with a minimum dry film thickness of 90um (3.5mils).
● 304 (or higher) stainless steel, or
● UV stabilized polymeric material.
The thickness of metal sheeting used for the enclosure construction shall
comply with Table 7-1 or Table 7-2 of NEMA ICS-6. Welding shall be
done by Gas Tungsten Arc Welding or Gas Metal Arc Welding.
Aluminum enclosures shall be welded with aluminum 5356 filler metal.
Polymeric cathodic protection junction box enclosures shall be fabricated

from a UV stabilized material suitable for the exposure detailed in
Section 6.1 of this material specification.
Area where cable theft and vandalism or other operating conditions

prohibit the use of above ground junction boxes, polymeric sealed
underground junction box in compliance with NEMA 4X shall be used.
Commentary Note:
Concrete Test stations and Junction Boxes can also be used in areas
where it is expected to be beneficial such as vandalism prone areas,
locations of OHPLs. Specific approval for use of concrete junction and
test stations shall be obtained in writing from the Proponent and CSD
SME prior to actual recommendation of Concrete type junction boxes and
test stations.
7.1.2 Offshore cathodic protection junction box enclosures for non-classified

areas shall be NEMA 4X compliant and shall be constructed of:
● 316L stainless steel, or
316, 316L Stainless Steel or non-metallic breathers and drains shall be

installed for all offshore cathodic protection junction boxes.
7.1.3 One pin and three pin test stations shall be manufactured from one of the
following material:
● Malleable or ductile cast iron coated with 1 mil electroplated zinc, or
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● Alloys such as Feraloy® or Grayloy® coated with 1 mil electroplated

zinc, or
● Copper free aluminum, or
7.2 Edge Sharpness on Enclosures
Enclosures’ edges shall be designed in accordance to NEMA 250 requirements.

Tag plates and nameplate to be supplied with SS316L with screw sets for
severely corrosive areas as detailed in SAES-P-104. Use bottom entry of
¾ conduits with hubs or cable glands where applicable for corrosive areas as
detailed in SAES-P-104.
7.3 Observation Windows
Provided with CSD SME approval, enclosures’ observation window could be

used where needed and shall be fabricated in accordance with NEMA 250 and
the appropriate NEMA and IEC standard requirements.
8 Testing
8.1 Factory Acceptance Requirements
All cathodic protection junction boxes shall receive a “Type Approval” on every
type (Polymeric, metallic, etc.) inspection completed by the Saudi Aramco SME
before an approved Manufacturer ships their first purchase order. After “Type
Approval” is received, materials and components used for construction of the
junction boxes shall not be changed or modified without written authorization
by the SME.
8.2 Polymeric Below Grade Junction Box
Below grade polymeric junction and bond boxes shall be tested with pressurized
immersion and be energized at 200 VDC for 60 days to assess reliability.
8.3 Certification
Cathodic protection junction box enclosures imported into Saudi Arabia shall
be certified, labeled or listed by an approved and recognized testing organization
to indicate and to permit tracing for full compliance with NEMA ICS 6 and
NEMA 250 for the applicable NEMA rating and the appropriate NEMA and
IEC standard.
Cathodic protection junction box enclosures manufactured in Saudi Arabia for

non-classified areas shall comply with Saudi Aramco standard drawings and the
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appropriate NEMA standard. However, they are exempted from requiring the
above certification labeling or listing provided the required testing has been
completed with documentation to confirm performance and quality.
9 Packing and Shipping
The export packing, marking and shipping shall be as specified in the Purchase Order.
Material storage, handling and preservation of the CP Junction Boxes shall be in
accordance with applicable company procedure. For traceability requirements of CP
junction box include information such as the manufacturer’s name, date of
manufacturing, order no, etc.
Revision Summary
16 April 2012 Revised the “Next Planned Update.” Reaffirmed the content of the document, and reissued
with minor revisions as follows:
- Revised enclosure material to include Type 1050 Aluminum with powder coating.
- Revised enclosure requirements to align with NEC and allow non-explosion proof enclosures
in Class 1 Div. 2 areas provided there are no current interrupting equipment in the enclosure.
- Replaced “RSA” with “SME” to be in line with the new RVL procedures.
- Removed the reference to “vendor”
- Combined paragraph 6.1.1 and 6.1.2.
10 July 2013 Editorial revision to modify the scope of the specification.
25 March 2017 Revised the “Next Planned Update.” Reaffirmed the content of the document, and reissued
with minor revisions as follows:
- Included the underground buried junction box and associated qualification tests.
- Revised the scope to include the below grade junction boxes and exclude the classified area
junction box.
- Edition and modification to some requirements.
- Included concrete as a possible material for CP junction box.
- Added enclosure edge sharpness requirements.
- Included definitions and abbreviations section.
- Deleted the near shore requirement and re-defined the offshore environments to meet
coating standards.
- Included test requirement of below grade polymeric junction box.
- Included enclosure observation windows requirement.

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Materials System Specification

17-SAMSS-008 25 March 2017

Previous Issue: 10 July 2013 Next Planned Update: 25 March 2020

©Saudi Aramco 2017. All rights reserved.

Detailed Table of Contents

Saudi Aramco: Company General Use

This scope defines only installations in non-classified areas as recommended to be

2 Conflicts and Deviations

3.1 Saudi Aramco Documents

Saudi Aramco Engineering Procedure

Saudi Aramco Engineering Standard

Saudi Aramco Standard Drawings

AB-036274 Cathodic Protection, Junction Box-5 Terminal

3.2 Industry Codes and Standards

American National Standards Institute

National Electrical Manufacturers' Association

4 Definitions and Abbreviations

Saudi Aramco: Company General Use

Sum Turn Key Contractor or an in house design organization of Saudi Aramco.

flammable gas-air, vapor-air, or dust-air mixture due to arcing or thermal means.

Saudi Aramco: Company General Use

SAES: Saudi Aramco Engineering Standard

5.1 SME Approval

Cathodic protection junction boxes shall be inspected by the Saudi Aramco

5.2 Quotation Information Requirements

5.3 Purchase Order Information Requirements

The following information shall be specified in the Purchase Order:

6.1 Temperature and Humidity

6.2 Onshore Environment

The normal air-borne dust concentration is 1 mg/M³. During sand storm

6.3 Offshore Environment

Offshore equipment is subjected to a severely corrosive environment due to

7.1 General Requirements

Saudi Aramco: Company General Use

7.1.1 Onshore cathodic protection junction box enclosures placed in

Polymeric cathodic protection junction box enclosures shall be fabricated

Area where cable theft and vandalism or other operating conditions

7.1.2 Offshore cathodic protection junction box enclosures for non-classified

316, 316L Stainless Steel or non-metallic breathers and drains shall be

● Alloys such as Feraloy® or Grayloy® coated with 1 mil electroplated

7.2 Edge Sharpness on Enclosures

Enclosures’ edges shall be designed in accordance to NEMA 250 requirements.

7.3 Observation Windows

Provided with CSD SME approval, enclosures’ observation window could be

8.1 Factory Acceptance Requirements

8.2 Polymeric Below Grade Junction Box

Cathodic protection junction box enclosures manufactured in Saudi Arabia for

9 Packing and Shipping

Saudi Aramco: Company General Use

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