Cp Installation Manual
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Document Review Status Triune Energy Services Pvt. Ltd.
Job No. 9637
Name / Sign / Dept. / Date
Ram Narayan Singh
Digitally signed by Ram Narayan Singh DN: cn=Ram Narayan Singh, o=TESPL, ou=Electrical, [email protected], c=IN Date: 2016.06.08 17:20:30 +05'30'
(1) NO COMMENTS, CAN PROCEED (2) PROCEED AS PER COMMENTS, REVISED DOCUMENT REQUIRED
(3) NOT MEETING REQUIREMENTS, RESUBMIT (4) RETAINED FOR RECORDS, CAN PROCEED APPROVAL BY COMPANY DOES NOT ABSOLVE THE CONTRACTOR / SUPPLIER OF HIS RESPONSIBILITY / LIABILITY AS PER CONTRACT
A
06.05.2016
ISSUED FOR INFORMATION
M.L.
Rev. No.
Date
Description
Prepared
Contractor
T.T.
M.H.
Checked Approved
‐‐‐‐‐‐‐‐‐‐‐‐
Document Title CATHODIC PROTECTION SYSTEM (INSTALLATION MANUAL)
Executive desk: Q1‐05, Office ;094/C Sharjah Airport International ERG Free zone Sharjah , UAE Tel: +971 6557 0720 Co. Org. Cod
Document No.
CAL
EMM
STE
P01
Doc Type
Disc. Code
Unit Code
Prj. Type
324
15
Prj.
Prj.
No
Year
010
Rev Scale A
DCC SeqNo Page
Ergil Group Middle East Zubair Plant Project, Iraq Installation Manul
CONTENTS
1 1.1 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 3 4 5 5.1
INTRODUCTION ....................................................................................................... 3 GENERAL ................................................................................................................. 3 INSTALLATION ........................................................................................................ 3 GENERAL ................................................................................................................. 3 MMO RIBBON & CONDUCTOR BAR ....................................................................... 3 SPOT WELDING PROCEDURE ............................................................................... 4 POWERFEED CONNECTORS ................................................................................. 6 POTENTIAL MONITORING FACILITIES .................................................................. 7 NEGATIVE TANK CONNECTION ............................................................................. 7 POSITIVE AND NEGATIVE HEADER CABLES ........................................................ 8 JUNCTION BOXES ................................................................................................... 9 TRANSFORMER RECTIFIER UNIT .......................................................................... 9 INTERNAL GALVANIC ANODE .............................................................................. 10 PRE-COMMISSIONING TESTS .............................................................................. 11 COMMISSIONING .................................................................................................. 12 MAINTENANCE SCHEDULE ................................................................................. 13 CRITERION FOR ACHIEVING CATHODIC PROTECTION .................................... 14
Document Title Document No CPCL Project No
Installation Manual 23881-CP-07-IM P23881-CP
Date Revision Page
28/04/2016 0 2 of 14
Ergil Group Middle East Zubair Plant Project, Iraq Installation Manual
1
INTRODUCTION 1.1
GENERAL This document is the installation manual relating to the permanent cathodic protection systems installed to protect the tanks at the Zubair Plant, Iraq.
2 2.1
INSTALLATION GENERAL All installation works associated with the Cathodic Protection system shall be conducted in accordance with this specification and the appropriate design drawings. Any conflict between this specification and the drawings and / or other project specifications and drawings shall be brought to the attention of the CPCL Engineer in writing for clarification as soon as it is discovered.
2.2
MMO RIBBON & CONDUCTOR BAR For the successful operation of the Cathodic Protection system it is imperative that the MMO Ribbon is installed at a depth of 350 mm minimum below the tank bottom where possible. It must be noted that the MMO Ribbon anodes and conductor bar assembly should be placed above the leak containment membrane.
The membrane should be at least 50 mm below the proposed location of MMO ribbon grid. In addition, it is essential that the membrane shall cover the entire inner face of the concrete ringbeam foundations to isolate the reinforcing rebar from the anode network. The Tank Construction Contractor shall confirm the membrane is a uniform depth below the proposed bottom of the tank.
A layer of chloride free, clean washed sand shall be installed directly above the membrane which shall be compacted as normal and the anode shall be installed in this layer. The pattern of the anodes and conductor bar is shown in the design drawings. The Tank Construction Contractor shall confirm the sand layer is uniform and at least 50 mm above the membrane level.
Document Title Document No CPCL Project No
Installation Manual 23881-CP-07-IM P23881-CP
Date Revision Page
28/04/2016 0 3 of 14
Ergil Group Middle East Zubair Plant Project, Iraq Installation Manual
The anodes shall be rolled out onto the sand base layer in the pattern as shown in the relevant design drawing. Where appropriate the anodes shall be temporarily weighed down to avoid movement, however great care shall be taken to ensure that the coating of the anodes is not scratched or damaged in any way.
As the anode ribbons are being laid out the conductor bars shall be placed over them in the pattern shown in the relevant design drawing. At each and every crossover of the anode ribbon with the conductor bar, the anode shall be resistance welded, (spot welded) to the conductor bar. Prior to conducting the spot welding for each tank a sample spot weld shall be made and inspected by Cathodic Protection Co Ltd Engineer or other suitably authorised person. Refer to section below on spot welding procedure.
At each and every crossing of the perpendicular and parallel conductor bars, they shall be resistance welded to each other. The welding equipment shall be operated in accordance with the manufacturers Operation Manual. Where necessary, anodes and conductor bars shall be extended using the same procedure. 2.3
SPOT WELDING PROCEDURE The personnel used for welding must fulfill project certification requirements. A recommended welding procedure that is compliant with the Project Specification API 650 Standard is required. API 650, Section 7-Welding Procedure and Welder Qualifications terms relate to all welding shall be interpreted as defined in Section IX of the ASME Code.
The scope of the work for this procedure is responsibility of the installing contractor.
Document Title Document No CPCL Project No
Installation Manual 23881-CP-07-IM P23881-CP
Date Revision Page
28/04/2016 0 4 of 14
Ergil Group Middle East Zubair Plant Project, Iraq Installation Manual
ASME IX.par.QW-285 spot welding procedure
ASME IX.par.QW-196 testing
ASME IX .par. QW – 462.8
Document Title Document No CPCL Project No
Installation Manual 23881-CP-07-IM P23881-CP
Date Revision Page
28/04/2016 0 5 of 14
Ergil Group Middle East Zubair Plant Project, Iraq Installation Manual
ASME IX.par.QW -462.9
2.4
POWERFEED CONNECTORS The powerfeed connections locations shall be identified as per the design drawings.
Power feed connectors shall be field connected to the 1c 25 mm² PVDF/HMWPE stranded cable using a line tap and splice kit with the instruction supplied with the splice kit. Once installed in the correct location the conductor bar tail from the powerfeed cable encapsulation shall be connected to the conductor bar using where appropriate resistance welding (spot welding).
Document Title Document No CPCL Project No
Installation Manual 23881-CP-07-IM P23881-CP
Date Revision Page
28/04/2016 0 6 of 14
Ergil Group Middle East Zubair Plant Project, Iraq Installation Manual
Upon completion of the powerfeed assembly, the powerfeed cable shall be routed to the chosen exit point from the foundations and routed out of the foundations via a suitable conduit, (cast into the concrete ringbeam), as shown in the design drawings. A 25 mm ‘sand bridge’ shall be made at each powerfeed cable / anode crossing location to ensure that they are not in direct contact. Once the cables have been routed out of the foundations, the entire anode, conductor bar and cable assembly shall be covered with another layer of chloride free, clean washed sand, which shall be smoothed flat and compacted. The installation contractor shall confirm the sand layer is uniform and at least 50 mm above the MMO Ribbon layer.
The powerfeed cables shall be routed from the tank to the location of the positive / negative junction box installed adjacent to the tank, outside of the bunded area. At all times the cables shall be laid in a single length without further splicing, free from kinks and excessive bends. 2.5
POTENTIAL MONITORING FACILITIES When at least a 150 mm layer of backfill over the MMO ribbon has been completed the slotted monitoring pipe shall be installed as shown in the relevant design drawing, ensuring that the pipe is straight and flat to allow a reference electrode to pass without hindrance.
Inside the pipe a loop of 8 mm polypropylene rope to pull the reference electrode through should be installed and connected to the end cap by the eyebolts.
Also the permanent reference electrodes should be buried and surrounded by 100 mm of soft clean washed sand. Note each reference electrode has different length of cable tail and must be installed in the correct location to allow termination in the test box. Cable tails to should be routed appropriately back the test box without damage to insulation. 2.6
NEGATIVE TANK CONNECTION Negative tank connections shall be supplied and welded to each tank at two locations by the main contractor in accordance with the appropriate project welding specification. These shall be near to the positive / negative junction box for ease of laying cables and at 180o from the first. The connection shall be a prefabricated assembly designed for welding to the side of the tank as shown in the relevant design drawing.
Document Title Document No CPCL Project No
Installation Manual 23881-CP-07-IM P23881-CP
Date Revision Page
28/04/2016 0 7 of 14
Ergil Group Middle East Zubair Plant Project, Iraq Installation Manual
After completion of each connection the following tests shall be done:
The electrical resistance of the connection shall be recorded by placing one resistance probe on the bare metal of the connection and the other on the cable lug. The measured resistance shall be recorded and if the recorded resistance value is greater than 0.01 Ohm the connection shall be recorded as having failed. In the event of a failure the cable connection shall be re-made.
Test the mechanical strength of the connection hit the connection with a sharp blow with a 2.2 kg copper headed hammer or exert a pull of 240 kg on the connection cable.
Where the connection has a satisfactory resistance the cable shall be inspected by Cathodic Protection Engineer or other suitably authorised person. In the event of failure of the connection or cable strands the connection shall be re-made.
Upon successful testing of the connection it shall be encapsulated taking care to avoid any damage to either the cable connection and/or the cable. 2.7
POSITIVE AND NEGATIVE HEADER CABLES All positive and negative header cables shall be laid in a single length without splicing where possible, free from kinks and excessive bends.
A minimum depth of 600 mm shall be
maintained at all times. The cable shall be laid in the centre of a 100 mm thick soft sand bed and care shall be taken to avoid any damage to the cable insulation.
A stress relief loop shall be left in cable prior to entering equipment to prevent damage to the cable in the event that the junction box is accidentally displaced and the cables are pulled.
During construction and prior to installation of the test facilities to prevent accidental damage to or theft of the cable, the cable shall be looped and buried at a depth of 500 mm and a wooden board placed over the cable to prevent damage when the cable is retrieved.
The location of the buried cable shall be suitably marked on the surface to ease location of the cable when it is required.
Document Title Document No CPCL Project No
Installation Manual 23881-CP-07-IM P23881-CP
Date Revision Page
28/04/2016 0 8 of 14
Ergil Group Middle East Zubair Plant Project, Iraq Installation Manual
2.8
JUNCTION BOXES The positive / negative junction boxes shall be installed on a concrete plinth in a location shown in the marked up design drawings. The concrete plinth shall be provided with cable conduits and support bolts. The DC cables shall be installed in the junction boxes but not terminated. Termination shall be done by an experienced CP Engineer at the time of commissioning. The DC cables shall be routed to / from the Transformer Rectifier Unit as per the details of the design drawings.
The junction boxes shall be located in electrically rated locations according to their electrical classification rating. The final location of the junction boxes shall be decided on site by the CP Engineer in consultation with the Project Engineers. They shall, where practicable, be installed in such a fashion that easy access to the junction boxes is maintained.
Under no
circumstances shall a junction box unit be installed in a location where it could be damaged, stolen and / or cause an obstruction or interference to the legitimate activities of the operator.
2.9
TRANSFORMER RECTIFIER UNIT The Transformer Rectifier Unit shall be installed in non-hazardous location near to the tank, outside of the bunded area on a concrete plinth in a location shown in the marked up design drawings. The concrete plinth shall be provided with cable conduits and support bolts. The Transformer Rectifier shall be mounted on the plinth and provided with AC power by the main contractor.
The DC output cables shall be installed in the Transformer Rectifier but not terminated. Termination shall be done by an experience CP Engineer at the time of commissioning. The DC output cables shall be routed to / from the Transformer Rectifier to the positive / negative junction box, as per the details of the design drawings.
The unction boxes shall be located in electrically rated locations according to their electrical classification rating. The final location of the Transformer Rectifier units shall be decided on site by the CP engineer in consultation with the main contractor and client. The Transformer Rectifier units shall, where practicable, be installed in such a fashion that easy access to the Transformer Rectifier unit is maintained. Document Title Document No CPCL Project No
Installation Manual 23881-CP-07-IM P23881-CP
Date Revision Page
28/04/2016 0 9 of 14
Ergil Group Middle East Zubair Plant Project, Iraq Installation Manual
Under no circumstances shall a Transformer Rectifier unit be installed in a location where it could be damaged, stolen and / or cause an obstruction or interference to the legitimate activities of the operator.
2.10 INTERNAL GALVANIC ANODE This procedure assumes that the tanks are fully constructed apart from coating patch repairs on the tank internals: Prior to anode installation, anode stand-off brackets shall be installed between the anode insert and the tank as shown on the installation drawing. These should have been welded in location during fabrication of the tanks. In order to maximize galvanic anode water immersion and in turn maximize cathodic protection of the tank bottom, installation of anode on support brackets shall be as close to the tank bottom as possible. Anode to floor distance shall be at least 100 mm but not more than 150 mm, unless field owner engineers determines this spacing is not achievable. There shall be a redundant welded metallic path established from the anode core bar or rod to the tank bottom. In order to prevent tank interior coating damage from the act of welding anode core rod to the pre-installed support bracket, floor coating shall be protected utilizing protective blankets". For each anode installation the following method shall apply:
Secure the anode in place by installation of ‘U’ bolts across steel anode inserts to the relevant mounting holes on each of the stand-off brackets.
Re-coat the freshly welded sections and the stand-off bracket with project approved re-coating material Do not coat the anode as this will render the anode useless in water
Visually inspect all anode insert to stand-off bracket connection
Visually inspect all stand-off brackets to tank welds
Record the anode locations
Document Title Document No CPCL Project No
Installation Manual 23881-CP-07-IM P23881-CP
Date Revision Page
28/04/2016 0 10 of 14
Ergil Group Middle East Zubair Plant Project, Iraq Installation Manual
3
PRE-COMMISSIONING TESTS The following sections outline the pre-commissioning tests and procedures that shall be used to determine that the CP system and materials as installed shall operate correctly and provide the tanks with a satisfactory level of protection. Any conflict between this specification and the drawings and / or other project specifications and drawings shall be brought to the attention of the Main Client Engineer in writing for clarification as soon as it is discovered.
The tests shall include as a minimum: A visit to each piece of CP equipment installed to ensure that it is correctly installed. Trial operation of power sources to their maximum capacity. Measurements and testing should be carried out to confirm satisfactory connection of all cables and circuits. Resistance to earth testing of groundbeds. Calibration of permanent electrodes.
All the results shall be properly documented and signed off by all the relevant parties. This documentation will form part of the final handover documentation.
Document Title Document No CPCL Project No
Installation Manual 23881-CP-07-IM P23881-CP
Date Revision Page
28/04/2016 0 11 of 14
Ergil Group Middle East Zubair Plant Project, Iraq Installation Manual
4
COMMISSIONING The purpose of the commissioning procedure should be used to show that the installed systems operate as specified and that the required design criteria have been met.
The test shall include as a minimum the following:
Standard forms for recording commissioning results.
Recording of natural potentials
Activating the cathodic protection systems
Measurement of potentials (“ON” and IR free / “instant OFF”)
A commissioning report will be prepared by CP Engineer, 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.
Document Title Document No CPCL Project No
Installation Manual 23881-CP-07-IM P23881-CP
Date Revision Page
28/04/2016 0 12 of 14
Ergil Group Middle East Zubair Plant Project, Iraq Installation Manual
5
MAINTENANCE SCHEDULE Inspection Type
Works to be Conducted
Monthly
Transformer Rectifiers:
Three Monthly
Record the output voltage and current.
Record structure-to-electrolyte potential for permanent reference electrode
As above plus: Transformer Rectifiers:
Calculate the circuit resistance from the output voltage and current.
Record general appearance, condition and efficiency of the TR unit.
Adjust output as required to achieve protection
Structures:
Annually:
Record structure-to-electrolyte potentials at each test facility.
As above plus: Transformer Rectifiers:
Document Title Document No CPCL Project No
Installation Manual 23881-CP-07-IM P23881-CP
Recalibrate to zero all output meters.
Date Revision Page
28/04/2016 0 13 of 14
Ergil Group Middle East Zubair Plant Project, Iraq Installation Manual
5.1 CRITERION FOR ACHIEVING CATHODIC PROTECTION The protection criteria for items in contact with soil are in line with document industry standard and in summary:
Steel in Soil -0.850 Volts verses vs. Cu/CuSO4 reference electrode.
As an alternative a minimum of 100 mV of cathodic polarisation between the structure and a stable electrode contacting the electrolyte.
All above potentials are IR free or “OFF” potentials.
Document Title Document No CPCL Project No
Installation Manual 23881-CP-07-IM P23881-CP
Date Revision Page
28/04/2016 0 14 of 14
Job No. 9637
Name / Sign / Dept. / Date
Ram Narayan Singh
Digitally signed by Ram Narayan Singh DN: cn=Ram Narayan Singh, o=TESPL, ou=Electrical, [email protected], c=IN Date: 2016.06.08 17:20:30 +05'30'
(1) NO COMMENTS, CAN PROCEED (2) PROCEED AS PER COMMENTS, REVISED DOCUMENT REQUIRED
(3) NOT MEETING REQUIREMENTS, RESUBMIT (4) RETAINED FOR RECORDS, CAN PROCEED APPROVAL BY COMPANY DOES NOT ABSOLVE THE CONTRACTOR / SUPPLIER OF HIS RESPONSIBILITY / LIABILITY AS PER CONTRACT
A
06.05.2016
ISSUED FOR INFORMATION
M.L.
Rev. No.
Date
Description
Prepared
Contractor
T.T.
M.H.
Checked Approved
‐‐‐‐‐‐‐‐‐‐‐‐
Document Title CATHODIC PROTECTION SYSTEM (INSTALLATION MANUAL)
Executive desk: Q1‐05, Office ;094/C Sharjah Airport International ERG Free zone Sharjah , UAE Tel: +971 6557 0720 Co. Org. Cod
Document No.
CAL
EMM
STE
P01
Doc Type
Disc. Code
Unit Code
Prj. Type
324
15
Prj.
Prj.
No
Year
010
Rev Scale A
DCC SeqNo Page
Ergil Group Middle East Zubair Plant Project, Iraq Installation Manul
CONTENTS
1 1.1 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 3 4 5 5.1
INTRODUCTION ....................................................................................................... 3 GENERAL ................................................................................................................. 3 INSTALLATION ........................................................................................................ 3 GENERAL ................................................................................................................. 3 MMO RIBBON & CONDUCTOR BAR ....................................................................... 3 SPOT WELDING PROCEDURE ............................................................................... 4 POWERFEED CONNECTORS ................................................................................. 6 POTENTIAL MONITORING FACILITIES .................................................................. 7 NEGATIVE TANK CONNECTION ............................................................................. 7 POSITIVE AND NEGATIVE HEADER CABLES ........................................................ 8 JUNCTION BOXES ................................................................................................... 9 TRANSFORMER RECTIFIER UNIT .......................................................................... 9 INTERNAL GALVANIC ANODE .............................................................................. 10 PRE-COMMISSIONING TESTS .............................................................................. 11 COMMISSIONING .................................................................................................. 12 MAINTENANCE SCHEDULE ................................................................................. 13 CRITERION FOR ACHIEVING CATHODIC PROTECTION .................................... 14
Document Title Document No CPCL Project No
Installation Manual 23881-CP-07-IM P23881-CP
Date Revision Page
28/04/2016 0 2 of 14
Ergil Group Middle East Zubair Plant Project, Iraq Installation Manual
1
INTRODUCTION 1.1
GENERAL This document is the installation manual relating to the permanent cathodic protection systems installed to protect the tanks at the Zubair Plant, Iraq.
2 2.1
INSTALLATION GENERAL All installation works associated with the Cathodic Protection system shall be conducted in accordance with this specification and the appropriate design drawings. Any conflict between this specification and the drawings and / or other project specifications and drawings shall be brought to the attention of the CPCL Engineer in writing for clarification as soon as it is discovered.
2.2
MMO RIBBON & CONDUCTOR BAR For the successful operation of the Cathodic Protection system it is imperative that the MMO Ribbon is installed at a depth of 350 mm minimum below the tank bottom where possible. It must be noted that the MMO Ribbon anodes and conductor bar assembly should be placed above the leak containment membrane.
The membrane should be at least 50 mm below the proposed location of MMO ribbon grid. In addition, it is essential that the membrane shall cover the entire inner face of the concrete ringbeam foundations to isolate the reinforcing rebar from the anode network. The Tank Construction Contractor shall confirm the membrane is a uniform depth below the proposed bottom of the tank.
A layer of chloride free, clean washed sand shall be installed directly above the membrane which shall be compacted as normal and the anode shall be installed in this layer. The pattern of the anodes and conductor bar is shown in the design drawings. The Tank Construction Contractor shall confirm the sand layer is uniform and at least 50 mm above the membrane level.
Document Title Document No CPCL Project No
Installation Manual 23881-CP-07-IM P23881-CP
Date Revision Page
28/04/2016 0 3 of 14
Ergil Group Middle East Zubair Plant Project, Iraq Installation Manual
The anodes shall be rolled out onto the sand base layer in the pattern as shown in the relevant design drawing. Where appropriate the anodes shall be temporarily weighed down to avoid movement, however great care shall be taken to ensure that the coating of the anodes is not scratched or damaged in any way.
As the anode ribbons are being laid out the conductor bars shall be placed over them in the pattern shown in the relevant design drawing. At each and every crossover of the anode ribbon with the conductor bar, the anode shall be resistance welded, (spot welded) to the conductor bar. Prior to conducting the spot welding for each tank a sample spot weld shall be made and inspected by Cathodic Protection Co Ltd Engineer or other suitably authorised person. Refer to section below on spot welding procedure.
At each and every crossing of the perpendicular and parallel conductor bars, they shall be resistance welded to each other. The welding equipment shall be operated in accordance with the manufacturers Operation Manual. Where necessary, anodes and conductor bars shall be extended using the same procedure. 2.3
SPOT WELDING PROCEDURE The personnel used for welding must fulfill project certification requirements. A recommended welding procedure that is compliant with the Project Specification API 650 Standard is required. API 650, Section 7-Welding Procedure and Welder Qualifications terms relate to all welding shall be interpreted as defined in Section IX of the ASME Code.
The scope of the work for this procedure is responsibility of the installing contractor.
Document Title Document No CPCL Project No
Installation Manual 23881-CP-07-IM P23881-CP
Date Revision Page
28/04/2016 0 4 of 14
Ergil Group Middle East Zubair Plant Project, Iraq Installation Manual
ASME IX.par.QW-285 spot welding procedure
ASME IX.par.QW-196 testing
ASME IX .par. QW – 462.8
Document Title Document No CPCL Project No
Installation Manual 23881-CP-07-IM P23881-CP
Date Revision Page
28/04/2016 0 5 of 14
Ergil Group Middle East Zubair Plant Project, Iraq Installation Manual
ASME IX.par.QW -462.9
2.4
POWERFEED CONNECTORS The powerfeed connections locations shall be identified as per the design drawings.
Power feed connectors shall be field connected to the 1c 25 mm² PVDF/HMWPE stranded cable using a line tap and splice kit with the instruction supplied with the splice kit. Once installed in the correct location the conductor bar tail from the powerfeed cable encapsulation shall be connected to the conductor bar using where appropriate resistance welding (spot welding).
Document Title Document No CPCL Project No
Installation Manual 23881-CP-07-IM P23881-CP
Date Revision Page
28/04/2016 0 6 of 14
Ergil Group Middle East Zubair Plant Project, Iraq Installation Manual
Upon completion of the powerfeed assembly, the powerfeed cable shall be routed to the chosen exit point from the foundations and routed out of the foundations via a suitable conduit, (cast into the concrete ringbeam), as shown in the design drawings. A 25 mm ‘sand bridge’ shall be made at each powerfeed cable / anode crossing location to ensure that they are not in direct contact. Once the cables have been routed out of the foundations, the entire anode, conductor bar and cable assembly shall be covered with another layer of chloride free, clean washed sand, which shall be smoothed flat and compacted. The installation contractor shall confirm the sand layer is uniform and at least 50 mm above the MMO Ribbon layer.
The powerfeed cables shall be routed from the tank to the location of the positive / negative junction box installed adjacent to the tank, outside of the bunded area. At all times the cables shall be laid in a single length without further splicing, free from kinks and excessive bends. 2.5
POTENTIAL MONITORING FACILITIES When at least a 150 mm layer of backfill over the MMO ribbon has been completed the slotted monitoring pipe shall be installed as shown in the relevant design drawing, ensuring that the pipe is straight and flat to allow a reference electrode to pass without hindrance.
Inside the pipe a loop of 8 mm polypropylene rope to pull the reference electrode through should be installed and connected to the end cap by the eyebolts.
Also the permanent reference electrodes should be buried and surrounded by 100 mm of soft clean washed sand. Note each reference electrode has different length of cable tail and must be installed in the correct location to allow termination in the test box. Cable tails to should be routed appropriately back the test box without damage to insulation. 2.6
NEGATIVE TANK CONNECTION Negative tank connections shall be supplied and welded to each tank at two locations by the main contractor in accordance with the appropriate project welding specification. These shall be near to the positive / negative junction box for ease of laying cables and at 180o from the first. The connection shall be a prefabricated assembly designed for welding to the side of the tank as shown in the relevant design drawing.
Document Title Document No CPCL Project No
Installation Manual 23881-CP-07-IM P23881-CP
Date Revision Page
28/04/2016 0 7 of 14
Ergil Group Middle East Zubair Plant Project, Iraq Installation Manual
After completion of each connection the following tests shall be done:
The electrical resistance of the connection shall be recorded by placing one resistance probe on the bare metal of the connection and the other on the cable lug. The measured resistance shall be recorded and if the recorded resistance value is greater than 0.01 Ohm the connection shall be recorded as having failed. In the event of a failure the cable connection shall be re-made.
Test the mechanical strength of the connection hit the connection with a sharp blow with a 2.2 kg copper headed hammer or exert a pull of 240 kg on the connection cable.
Where the connection has a satisfactory resistance the cable shall be inspected by Cathodic Protection Engineer or other suitably authorised person. In the event of failure of the connection or cable strands the connection shall be re-made.
Upon successful testing of the connection it shall be encapsulated taking care to avoid any damage to either the cable connection and/or the cable. 2.7
POSITIVE AND NEGATIVE HEADER CABLES All positive and negative header cables shall be laid in a single length without splicing where possible, free from kinks and excessive bends.
A minimum depth of 600 mm shall be
maintained at all times. The cable shall be laid in the centre of a 100 mm thick soft sand bed and care shall be taken to avoid any damage to the cable insulation.
A stress relief loop shall be left in cable prior to entering equipment to prevent damage to the cable in the event that the junction box is accidentally displaced and the cables are pulled.
During construction and prior to installation of the test facilities to prevent accidental damage to or theft of the cable, the cable shall be looped and buried at a depth of 500 mm and a wooden board placed over the cable to prevent damage when the cable is retrieved.
The location of the buried cable shall be suitably marked on the surface to ease location of the cable when it is required.
Document Title Document No CPCL Project No
Installation Manual 23881-CP-07-IM P23881-CP
Date Revision Page
28/04/2016 0 8 of 14
Ergil Group Middle East Zubair Plant Project, Iraq Installation Manual
2.8
JUNCTION BOXES The positive / negative junction boxes shall be installed on a concrete plinth in a location shown in the marked up design drawings. The concrete plinth shall be provided with cable conduits and support bolts. The DC cables shall be installed in the junction boxes but not terminated. Termination shall be done by an experienced CP Engineer at the time of commissioning. The DC cables shall be routed to / from the Transformer Rectifier Unit as per the details of the design drawings.
The junction boxes shall be located in electrically rated locations according to their electrical classification rating. The final location of the junction boxes shall be decided on site by the CP Engineer in consultation with the Project Engineers. They shall, where practicable, be installed in such a fashion that easy access to the junction boxes is maintained.
Under no
circumstances shall a junction box unit be installed in a location where it could be damaged, stolen and / or cause an obstruction or interference to the legitimate activities of the operator.
2.9
TRANSFORMER RECTIFIER UNIT The Transformer Rectifier Unit shall be installed in non-hazardous location near to the tank, outside of the bunded area on a concrete plinth in a location shown in the marked up design drawings. The concrete plinth shall be provided with cable conduits and support bolts. The Transformer Rectifier shall be mounted on the plinth and provided with AC power by the main contractor.
The DC output cables shall be installed in the Transformer Rectifier but not terminated. Termination shall be done by an experience CP Engineer at the time of commissioning. The DC output cables shall be routed to / from the Transformer Rectifier to the positive / negative junction box, as per the details of the design drawings.
The unction boxes shall be located in electrically rated locations according to their electrical classification rating. The final location of the Transformer Rectifier units shall be decided on site by the CP engineer in consultation with the main contractor and client. The Transformer Rectifier units shall, where practicable, be installed in such a fashion that easy access to the Transformer Rectifier unit is maintained. Document Title Document No CPCL Project No
Installation Manual 23881-CP-07-IM P23881-CP
Date Revision Page
28/04/2016 0 9 of 14
Ergil Group Middle East Zubair Plant Project, Iraq Installation Manual
Under no circumstances shall a Transformer Rectifier unit be installed in a location where it could be damaged, stolen and / or cause an obstruction or interference to the legitimate activities of the operator.
2.10 INTERNAL GALVANIC ANODE This procedure assumes that the tanks are fully constructed apart from coating patch repairs on the tank internals: Prior to anode installation, anode stand-off brackets shall be installed between the anode insert and the tank as shown on the installation drawing. These should have been welded in location during fabrication of the tanks. In order to maximize galvanic anode water immersion and in turn maximize cathodic protection of the tank bottom, installation of anode on support brackets shall be as close to the tank bottom as possible. Anode to floor distance shall be at least 100 mm but not more than 150 mm, unless field owner engineers determines this spacing is not achievable. There shall be a redundant welded metallic path established from the anode core bar or rod to the tank bottom. In order to prevent tank interior coating damage from the act of welding anode core rod to the pre-installed support bracket, floor coating shall be protected utilizing protective blankets". For each anode installation the following method shall apply:
Secure the anode in place by installation of ‘U’ bolts across steel anode inserts to the relevant mounting holes on each of the stand-off brackets.
Re-coat the freshly welded sections and the stand-off bracket with project approved re-coating material Do not coat the anode as this will render the anode useless in water
Visually inspect all anode insert to stand-off bracket connection
Visually inspect all stand-off brackets to tank welds
Record the anode locations
Document Title Document No CPCL Project No
Installation Manual 23881-CP-07-IM P23881-CP
Date Revision Page
28/04/2016 0 10 of 14
Ergil Group Middle East Zubair Plant Project, Iraq Installation Manual
3
PRE-COMMISSIONING TESTS The following sections outline the pre-commissioning tests and procedures that shall be used to determine that the CP system and materials as installed shall operate correctly and provide the tanks with a satisfactory level of protection. Any conflict between this specification and the drawings and / or other project specifications and drawings shall be brought to the attention of the Main Client Engineer in writing for clarification as soon as it is discovered.
The tests shall include as a minimum: A visit to each piece of CP equipment installed to ensure that it is correctly installed. Trial operation of power sources to their maximum capacity. Measurements and testing should be carried out to confirm satisfactory connection of all cables and circuits. Resistance to earth testing of groundbeds. Calibration of permanent electrodes.
All the results shall be properly documented and signed off by all the relevant parties. This documentation will form part of the final handover documentation.
Document Title Document No CPCL Project No
Installation Manual 23881-CP-07-IM P23881-CP
Date Revision Page
28/04/2016 0 11 of 14
Ergil Group Middle East Zubair Plant Project, Iraq Installation Manual
4
COMMISSIONING The purpose of the commissioning procedure should be used to show that the installed systems operate as specified and that the required design criteria have been met.
The test shall include as a minimum the following:
Standard forms for recording commissioning results.
Recording of natural potentials
Activating the cathodic protection systems
Measurement of potentials (“ON” and IR free / “instant OFF”)
A commissioning report will be prepared by CP Engineer, 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.
Document Title Document No CPCL Project No
Installation Manual 23881-CP-07-IM P23881-CP
Date Revision Page
28/04/2016 0 12 of 14
Ergil Group Middle East Zubair Plant Project, Iraq Installation Manual
5
MAINTENANCE SCHEDULE Inspection Type
Works to be Conducted
Monthly
Transformer Rectifiers:
Three Monthly
Record the output voltage and current.
Record structure-to-electrolyte potential for permanent reference electrode
As above plus: Transformer Rectifiers:
Calculate the circuit resistance from the output voltage and current.
Record general appearance, condition and efficiency of the TR unit.
Adjust output as required to achieve protection
Structures:
Annually:
Record structure-to-electrolyte potentials at each test facility.
As above plus: Transformer Rectifiers:
Document Title Document No CPCL Project No
Installation Manual 23881-CP-07-IM P23881-CP
Recalibrate to zero all output meters.
Date Revision Page
28/04/2016 0 13 of 14
Ergil Group Middle East Zubair Plant Project, Iraq Installation Manual
5.1 CRITERION FOR ACHIEVING CATHODIC PROTECTION The protection criteria for items in contact with soil are in line with document industry standard and in summary:
Steel in Soil -0.850 Volts verses vs. Cu/CuSO4 reference electrode.
As an alternative a minimum of 100 mV of cathodic polarisation between the structure and a stable electrode contacting the electrolyte.
All above potentials are IR free or “OFF” potentials.
Document Title Document No CPCL Project No
Installation Manual 23881-CP-07-IM P23881-CP
Date Revision Page
28/04/2016 0 14 of 14
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