ENGINEERING DESIGN BASIS CATHODIC PROTECTION

(CP) SYSTEM (SMMS)

PROJECT :

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 CONTENTS

SL NO. DESCRIPTION PAGE NO

1. CP SYSTEM DESIGN BASIS 3

TEMPORARY CP SYSTEM (TCP) 3

1.1

1.2 PERMANENT CP SYSTEM (PCP) 5

AVERAGE DISTANCE BETWEEN CONSECUTIVE CP

2. 7
STATIONS AND THEIR MONITORING SYSTEM

2.1 SPECIAL REQUIREMENT FOR SCADA SYSTEM 8

ANNEXURE- I: SPECIFICATION FOR COLD INSTALLED PETROLEUM JELLY

CASING FILLER

1.0 CP System design basis

This design basis defines the design requirements applicable for this project
in addition to the specification for sacrificial anode cathodic protection system
specification for impressed current cathodic protection system, NACE SP-
0169- 2007 & NACE SP- 0177- 2007 and all applicable PNGRB
regulations. In case of conflict, the requirements mentioned in this
document or stringent shall be considered.

1.1 Temporary Cathodic protection (TCP) : Within 60 days of lowering of each

continuous segment of pipe, it should be protected at minimum -850mV potential
level by Mg anode as part of TCP. Where soil resistivity is 150 ohm-m or more,
achievement of -850mV potential level shall not be mandatory. However,
minimum acceptable shift of potential level over and above natural potential at
such locations (where soil resistivity is 150 ohm-m or more) shall be decided by
OWNER on the case to case basis. For the soil resistivity profile for the Trunk
line & Spur line attached elsewhere in the tender, at locations where soil
resistivity is more than 100 ohm-m, those locations shall be treated as high soil
resistivity areas.

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A. Type : Sacrificial magnesium anode
B. Design life : 2 Years or till commissioning of PCP
whichever is later
C. Pipeline coating : Three Layer Polyethylene/ Three Layer

D. Protective current density at 300C : Polypropylene

Protection current density TCP (µA/

Pipeline surrounding
Sq.mtr)
Marshy ( < 10 Ohm Mtr ) 60

Normal (10 Ohm Mtr–100 Ohm Mtr) 40

High resistivity > 100 Ohm Mtr 20

Where operating temperatures of U/G pipeline is above 30 deg. C,such as CP

Stations located near Compressor stations, protective current density shall be
corrected @ 0.5mA/ m2/ deg. C up to a temperature of 60 deg. C.

The current density mentioned above shall over ride the same mentioned
vide cathodic protection system standard

E. Anode material (for sacrificial CP system): Zinc (1.1 V) / low potential

Magnesium (1.55 V)

Electrical resistance probes :

F. Shall be provided
(ER Probes)

One each ER Probe for each section and

a. Quantity of E/R probes : location in consultation with OWNER by
CP Contractor

b. No. of E/R probe reading section

One each ER Probe reader for each
instrument

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G. Polarisation coupons : Shall be provided

a. Size of exposed area of : 100mm x 100mm

coupon
b. No. of coupons: Location in consultation with
OWNER ( 1 no. Each for each
section.)

c. No. of magnet devices for -DO-

:operation of magnetic reed switch
H. Polarisation cell : Solid state type

I. Additional tests to evaluate the Shall not be conducted for TCP

coating defects
K. CPL survey Shall not be conducted during TCP.
:
L. DC interference & AC induced
voltage survey Shall be conducted during TCP stage
: for
DC interference areas and HT
crossings
(11 kV and above), reading shall be
taken
for 24 hrs at 60 seconds interval.

M. Test stations : Test stations shall be provided at

an average distance of 1Km interval
along the
Pipeline ROW for monitoring the
Performance of the cathodic protection
system. The following locations shall
also be considered for Test statio
a) At the locations of TCP anodes.
b) At both sides of metalled road crossings where cased crossing is considered for
the crossing. At one side of the road crossing where casing pipe is not
considered for the crossing. In case more than one such uncased road crossing
occurs within 1Km, then only one such uncased road crossing shall be provided
with test station within 1Km.
c) At all insulating joints.
d) At locations of reference cells, surge diverters, polarisation coupons, Electrical
Resistance probes, pipeline grounding through polarisation cells, zinc and
magnesium anodes.
e) At railway line crossings both side.
f) At both sides of major river crossings
g) At EHV/ HV AC/ DC overhead line crossings and along routes where\
EHV/ HV overhead line are running in parallel.

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 h) In the vicinity of DC networks or grounding systems and HVDC grounding
systems where interference problems are suspected.
i) At crossings of other pipelines/ structures.
j) Locations where interference is expected.
k) At locations of (SV/ IP/ DT/ RT) stations.
l) Current measurement test station for each leg of each SV cum CP stations.
m) At any other locations considered necessary by OWNER/ OWNER's
representative.

The test station locations mentioned above shall override the same mentioned vide
cathodic protection system standard

1.2. Permanent Cathodic Protection System (PCP)

A. Type Impressed current type

B. : Design life of protection 30 Years

C. : Three Layer Polyethylene/ Three

Layer
Polypropylene
Pipeline coating :
D. Design protection current density : Refer item D of TCP

E. Current drainage & coating

resistance measurement survey : Shall be carried out

F. Type of Anodes for anode ground : Tubular mixed metal oxide (MMO).
bed

G. Electrical resistance probes : Refer item F of TCP

H. Computerised test stations (CTSU) : Shall be provided

a. No. of computerised test stn : One each CTSU for each section
and location of CTSU in
consultation with OWNER by CP
Contractor.

b. No. of computerised test : One each CTSU reader for each

station readers/ portable data

collection & storage
instruments.

c. Interval for data acquisition/ : Once every day

storing

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I Polarisation coupons Refer item G of TCP
:
J Polarisation cell Solid State Type
:
K. Acquisition of land for By EPC Contractor
: Anode ground bed in the name of
Owner including installation of anode
junction boxes (AJB) and ROU for
anode ground bed cable laying
L.
between AJB & TRU
Chain link fencing around the ground : Shall be provided as per anode ground b.
bed

M. Close interval potential logging survey : Shall be carried out by CP contractor

N. Additional tests to be conducted for : CAT survey followed by DCVG

identifying pipe coating defects/
holidays

O. Proposed location of Anode Ground bed (For impressed current CP System)

at proposed CP stations/: To be decided by CP contractor based
on detailed engineering, specification and at availability of power source &
land. At each CP Station location soil resistivity shall be measured up to
50m depth for 3 plots, for selection of the anode bed for the owest
resistivity plot. Horizontal shallow depth anode bed shall be considered where
soil resistivity up to 2m depth is lower compared to higher than 2m
depth, deep well anode bed shall be considered where soil resistivity at
higher than 2m depth is lower compared to surface soil resistivity up to 2m
depth.

P. Proposed location of E/R probes/: To be decided by CP contractor

Computerised test stations/ during detail engineering based Polarisation
Coupons on specifications and in Consultation with the Client.

Q. CP stations/ anode ground bed for Impressed current system:-

a) CP stations shall be located coinciding with SV/ IP/ DT/ RT
stations, as far as possible.
b) At dispatch terminals & Receipt Terminal, SV cum CP stations,
IP cum CP stations, power supply to PCP system shall be
through transformer rectifier unit fed from UPS. However, for
locations where grid power is not available, cathodic protection
power supply module (CPPSM) will be provided with solar &
battery as power source

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R. Additional requirements (if any):

a) External Corrosion Sensing probe and reader should be very sensitive even
to read minute corrosion rates to a tune of 1 mil per year.
b) For each IP,SV,DT/RT stations, insulating joint (IJ) shall be provided
by EPC contractor for isolating the incoming Trunk line / Spurline,
outgoing Trunk line / Spurline, including Compressor stations, existing
consumer tapping (whichever is applicable) from the station piping, earthing
grids/ pits etc.
c) For protection of the carrier pipe inside casing pipe, any one of the
following two alternative options shall be considered by the pipeline EPC
contractor. The selection of any of the alternative options shall be as per sole
discretion of OWNER:
d) Bentonite filling at the annular space between casing and carrier shall be
provided for protection of carrier pipe inside the casing pipe. Discrete
Mg anode (quantity as required to achieve -850mV potential level), shall be
connected to casing pipe at the cased crossings in case casing and carrier
pipe is shorted (i.e. become in mechanical contact with each other) and the
short is not cleared after filling of Bentonite.
e) Petroleum jelly (as per ANNEXURE-I or equivalent) filling at the
annular space between casing and carrier without installation of zinc ribbon
& discrete Mg anode.
f) it alternate SV station, current measurement provision along with PSP
measurement to be provided. Converter for PSP and current output for
SCADA connectivity along with cable to be provided by CP contractor.

The pipeline shall be grounded through polarization cell with Zinc galvanic anode,
wherever the pipeline is either crossing or running in parallel with overhead EHV/
HV transmission lines of voltage grade 66 KV and above.

vi) Further additional requirements (if any) shall be included during

detailed engineering stage, if required.

2. Average distance between consecutive CP Stations and their

monitoring system:
a) Average distance between consecutive CP Stations shall be considered
between
b) 30-50 Km for the entire CP System project. All CP Stations & CTSU
shall be centrally monitored from pipeline SCADA system.

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2.1. Special requirements for SCADA input:
(I) For CPPSM UNIT:

DIGITAL
SL. NO. OF
MONITORING (M) (D) /
No DESCRIPTION SIGNAL TAG NO.
/ CONTROL (C) ANALOGU
. S
E A)

CPPSM OUT PUT A

1 M 1 CPPSM-V
VOLTAGE I
CPPSM OUT PUT A
2 M 1 CPPSM-A
CURRENT I
PIPELINE OVER D
3 M 1 PL-OV
PROTECTED I
PIPELINE
4 UNDER M D 1
PROTECTED PL-UV
I
ALL REFERENCE D
5 CELLS FAILED M 1 REFC-F
I
REFERENCE CELL-1 A
6 VOLTAGE M 1 REFC1-V
I
REFERENCE CELL-2 A
7 VOLTAGE M 1 REFC2-V
I
8 CPPSM IN AUTO MODE M D 1 CPPSM-AU
I
D CPPSM-
9 CPPSM IN MANUAL MODE M 1
I MAN
CURRENT D
10 INTERRUPTER START C 1 CI-ST
O
CURRENT D
11 INTERRUPTER STOP C 1 CI-STP
O
CURRENT D
12 INTERRUPTER RESET C 1 CI-RST
O

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(II) For CPTRU:

MONITORI DIGITAL (D) NO. OF

SL. N G (M) / SIGNAL
No. DESCRIPTION /CONTRO ANALOGUE S TAG NO.
L (C) (A)

1 CPTR OUT PUT VOLTAGE M AI 1 CPTR-V

2 CPTR OUT PUT CURRENT M AI 1 CPTR-A

PIPELINE OVER
3 M DI 1 PL-OV
PROTECTED

PIPELINE
4 UNDER M 1
PROTECTED DI PL-UV

ALL REFERENCE
5 CELLS FAILED M DI 1 REFC-F

REFERENCE CELL-1
6 VOLTAGE M AI 1 REFC1-V

REFERENCE CELL-2
7 VOLTAGE M AI 1 REFC2-V

8 CPTR IN AUTO MODE M DI 1 CPTR-AU

9 CPPSM-
CPTR IN MANUAL MODE M DI 1
MAN

CURRENT
10 INTERRUPTER START C DO 1 CI-ST

CURRENT
11 INTERRUPTER STOP C DO 1 CI-STP

12 CURRENT INTERRUPTER C DO 1 CI-RST

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Legend:

1 AI: Analogue monitoring signal from Equipment to PLC/

Telemetry interface cabinet (TIC)
2 AO: Analogue control signal from PLC/ (TIC) to Equipment

3 DI: Digital Monitoring signal from Equipment to PLC/ (TIC)

4 DO: Digital control signal from PLC/ (TIC) to Equipment

Notes:
1 For any control signal the signal shall be available from
SCADA for less than 2 seconds only.
2 The rating of the potential free contact for digital input and
output signals from Equipment/ PLC/ RTU shall be 24 V DC,
1.5 A DC. Analogue signals shall be 4-20 mA, galvanically
isolated.
3 Provision for minimum two nos analogue and two nos of
digital input signal to SCADA System shall be available for
future use.
4 Provision for monitoring of current measurement with
PSP measurement at alternate SV station to SCADA System.

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 ANNEXURE-I

(Specification for cold installed Petroleum jelly casing filler)

Specification for cold installed Petroleum jelly casing filler:

Petroleum wax-based corrosion preventive compound, to be considered to fill the

pipeline casing annulus, It shall be specifically designed for pumping at the casing
annulus at ambient temperature. It should remain in a firm gel condition at ground
temperature. It should displace the existing water (if any) present inside the
casing also it should prevent water from re-entering, for mitigating galvanic and
atmospheric corrosion for the carrier pipe inside the casing pipe at the cased
crossings.

Specifications:

Color........................................ ...................dark brown. Specific Gravity @

60°F...................................80 to 90
Pour Point.........................................................80 to
100°F Flash
Point........................................................300°F
Dielectric constant............................................2.1 to 2.5

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