Pipeline Project

TCP Installation Procedure

TRANSFORMER RECTIFIER/ CPPSM UNIT INSTALLATION

Table of Contents

1.0 PURPOSE ................................................................................................................. 2

2.0 SCOPE ..................................................................................................................... 2
3.0 MATERIALS & EQUIPMENTS ......................................................................................... 2
4.0 REFERENCE............................................................................................................... 2
5.0 PROCEDURE.............................................................................................................. 3
6.0 PRECAUTIONS ........................................................................................................... 3
7.0 TEST REPORTS ........................................................................................................... 4
8.0 ANNEXURE ............................................................................................................... 4

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 Pipeline Project
TCP Installation Procedure
TRANSFORMER RECTIFIER/ CPPSM UNIT INSTALLATION

1.0 PURPOSE

To describe the procedure for installation of transformer rectifier unit (TRU) / CP System
power supply module (CPPSM) of CP system along pipeline route at specified distances as in
design document and provide adequate quality assurance / control of workmanship and
inspection at site.

2.0 SCOPE

This procedure covers the installation of Transformer Rectifier / CPPSM unit for Cathodic
Protection System as per standard drawing & EIL technical specifications.

3.0 MATERIALS & EQUIPMENTS

 Equipments : Calibrated portable multi meter /DC Clip-on meter, Megger,

Crimping Tool kit, Measuring tape, etc.

 Materials : Foundation, shuttering, reinforcement and concrete/’c’

channel frame, Cable glands, lugs and ferrules as per enclosed Drawing .

4.0 REFERENCE

 Drawing No :
 Scope Doc. :
 Spec. : 6 – 51 – 0027 Rev.2 & 6 – 51 – 0028 Rev.2

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 Pipeline Project
TCP Installation Procedure
TRANSFORMER RECTIFIER/ CPPSM UNIT INSTALLATION

5.0 PROCEDURE

The location of the transformer rectifier unit (TRU) / CPPSM shall be marked at site as per
approved document with their connection scheme and other related information on alignment
sheet.

 Carefully unpack the unit and inspect the outside of the unit and check that there is no
damage in transit.

 Install the unit on the foundation frame. Take care to ensure that the horizontal level of the
foundation is correct. Incorrect foundation level will affect the alignment of the panel
doors which may cause difficulty in closing / opening the doors.

 Open the front and back doors of the unit and visually inspect the inside of the unit
carefully. Check all the components inside to ensure that there is no damage in transit.
Tighten all connections

 Check the insulation between the AC input terminal and panel body by means of a DC
Megger. (Min 500V)

 Earth the unit by a bare copper conductor. Connect the copper conductor between the
station earth and the earthing bolt provided on the base channel of the unit.

 Pull up various cables such as AC input, anode header, cathode header, reference cell and
negative cables from test station through the cable entry pipes

 Take the cable entry into the unit through suitably sized double compression glands, which
are fixed on the bottom plate of the unit.

6.0 PRECAUTIONS
 Cables used shall be of sufficient length so as to reach termination point without any joint
provide sufficient care for feature maintenance purpose.

 All cables are to be appropriately tagged & all the connections should be checked for proper
tightening.

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TCP Installation Procedure
TRANSFORMER RECTIFIER/ CPPSM UNIT INSTALLATION

 In case colour code is used for cables, define which colour is considered for which cable.

 Cable core ferrules are to be provided at end before final termination & cable should be
neatly dressed inside the trench and to be terminated inside test station.

 One set of drawing / documents should be site supervisor at work place.

 Use of helmet, Safety Shoe, safety goggles and hand gloves is compulsory

 Conduct polarity check using DC Clip-on meter and multi meter to ensure that the positive
header cable/anode lead cable is connected to the positive terminal of the TRU/CPPSM and
negative header cable/cathode cable is connected to the negative terminal of the
TRU/CPPSM.

7.0 TEST REPORTS

Record and document all inspection results obtained in the standard inspection report formats
attached below.

8.0 ANNEXURE

 Annexure 1 - Inspection and Test Plan for TRU/ CPPSM Installation

ITP. No:

Note : In case of any Conflict between the above Procedure and Contract Specifications, the
later shall govern.

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 Pipeline Project
TCP Installation Procedure
TRANSFORMER RECTIFIER/ CPPSM UNIT INSTALLATION

Annexure – 1

TRU/ CPPSM INSTALLATION

PROJECT
CLIENT
CONSULTANT Engineers India Limited
MAIN CONTRACTOR
CP CONTRACTOR
DATE
ITP NO
REFERENCE DOCUMENT Contract Specifications & Approved Document
REFERENCE DRAWING NO.
CP
SR. NO. ACTIVITY EIL / CLIENT REMARKS
CONTRACTOR
APPROVAL OF INSTALLATION
1 S A
PROCEDURE OF TEST STATION
TYPE OF TRU/ CPPSM AS PER
2 APPROVED DESIGN / CLIENT W RM / R
REQUIREMENT / SITE REQUIREMENT
LOCATION OF T/R UNIT TO BE
3 MOUNTED ON FOUNDATION / INSIDE W RM / R
SUB STATION ROOM
CONCRETE FOUNDATION SIZE, PCC
4 W RM / R
MIXTURE, REINFORCEMENT & CURING
5 MOUNTING OF T/R UNIT W RM / R
6 INSULATION TEST W RM / R
7 CHECK ON TAGS W RM / R
POLARITY CHECK USING DC CLIP-ON
8 W W
METER
LEGEND :
A – APPROVAL / ACCEPTANCE H – HOLD POINT
R – REVIEW OF RECORD RM – RANDOM CHECK
W – WITNESS ALL S- SUBMITTED BY
For CONTRACTOR For EIL / CLIENT
Name: Name:
Sign: Sign:
Date: Date:

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