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1 Scope.................................................…........ 3
2 Applicable Documents..........................…...... 3
3 Definitions and Abbreviations......................... 4
4 Safety.....................................................….... 7
5 Responsibilities.............................................. 7
6 Qualifications…………………………………... 8
7 General Commissioning Procedures…….….. 8
8 Marine Structures………………………........ 15
9 Buried Pipelines........................................... 17
10 Vessel and Tank Internals............................ 20
11 Plant Facilities.............................................. 23
12 Onshore Well Casings................................. 27
13 Concrete Structures..................................... 29
14 Report Forms............................................... 32
Page 2 of 33
Document Responsibility: Cathodic Protection Standards Committee SAEP-332
Issue Date: 25 December 2011
Next Planned Update: 25 December 2016 Cathodic Protection Commissioning
1 Scope
This procedure covers cathodic protection for all Saudi Aramco facilities. It provides
instructions and establishes responsibilities for commissioning a new cathodic
protection (CP) system or for reactivating an existing system that has been inoperative
for more than 90 days. Compliance with this Engineering Procedure will promote the
following:
a. Installation of all CP equipment in accordance with the design documents.
b. Commissioning of all CP equipment within specified design and manufacturer’s
parameters.
c. Adequate and optimized levels of cathodic protection on all structures addressed by
the cathodic protection design.
d. Minimization of detrimental effects on other structures to acceptable tolerance
levels.
2 Applicable Documents
Page 3 of 33
Document Responsibility: Cathodic Protection Standards Committee SAEP-332
Issue Date: 25 December 2011
Next Planned Update: 25 December 2016 Cathodic Protection Commissioning
Bond Cable: A cable installed between two metallic structures to provide electrical
continuity between the structures for the purpose of cathodic protection.
CP System Operating Circuit Resistance: The total effective resistance seen by the
output terminals of the cathodic protection power supply, or the total working resistance
in a galvanic anode system.
CP System Rated Circuit Resistance: The cathodic protection power supply rated
output voltage divided by the rated output current. For photovoltaic power supplies, the
rated output current for this calculation is the design current.
Cross Country Pipeline: A pipeline between; two plant areas, another cross-country
pipeline and a plant area, or between two cross-country pipelines.
Deep Anode Bed: Anode or anodes connected to a common CP power supply installed
in a vertical hole (typically 25cm diameter) with a depth exceeding 15 m (50 ft).
Design Agency: The organization or company contracted by Saudi Aramco for the
design of a CP system. The Design Agency may be the Design Contractor, the Lump
Sum Turn Key Contractor or an in house design organization of Saudi Aramco.
Drain Point: The location on the cathodically protected structure where the negative
cable from the rectifier or negative junction box is fastened to the structure.
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Document Responsibility: Cathodic Protection Standards Committee SAEP-332
Issue Date: 25 December 2011
Next Planned Update: 25 December 2016 Cathodic Protection Commissioning
without the requirement for an external cathodic protection power supply. Galvanic
anodes are also referred to as sacrificial anodes.
Hazardous Areas: Those areas 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).
Impressed Current Anodes: Anodes fabricated from materials such as High Silicon
Cast Iron (HSCI) or Mixed Metal Oxide (MMO) that are immersed or buried and are
connected to the positive terminal of a DC power supply to provide cathodic protection
current.
Perimeter Fence: The fence which completely surrounds an area designated by Saudi
Aramco for a distinct function.
Pipeline: The term “pipeline” is used generically in this standard and can be used to
refer to any type of pipeline.
Plant Area: A plant area is the area within the plot limits of a process or hydrocarbon
storage facility. Scraper trap and launcher areas are not Plant areas.
Page 5 of 33
Document Responsibility: Cathodic Protection Standards Committee SAEP-332
Issue Date: 25 December 2011
Next Planned Update: 25 December 2016 Cathodic Protection Commissioning
Plot Limit: The plot limit is the boundary around a plant, process or hydrocarbon
storage 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.
PMT: Project Management Team used as a truncated version of Saudi Aramco Project
Management Team (SAPMT).
Process Pipeline: A pipeline typically associated with a plant process and typically
above ground within a plant facility.
RSA: Responsible Standardization Agent - usually the Saudi Aramco CSD cathodic
protection Subject Matter Expert or the Supervisor of the CSD Cathodic Protection
Team.
Soil Transition Point: The on grade 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): For the purposes of this document, the SME shall be
the assigned Consulting Services Department cathodic protection specialist.
Test-line: A pipeline that is used for testing an individual well or group of wells.
Page 6 of 33
Document Responsibility: Cathodic Protection Standards Committee SAEP-332
Issue Date: 25 December 2011
Next Planned Update: 25 December 2016 Cathodic Protection Commissioning
Utility-line: A pipeline designed to deliver an end use service product (typically water,
gas or air).
4 Safety
5 Responsibilities
Page 7 of 33
Document Responsibility: Cathodic Protection Standards Committee SAEP-332
Issue Date: 25 December 2011
Next Planned Update: 25 December 2016 Cathodic Protection Commissioning
6 Engineer/Technician Qualifications
7.1.3 Check all test leads for continuity and integrity. Always have spares
readily available.
Page 8 of 33
Document Responsibility: Cathodic Protection Standards Committee SAEP-332
Issue Date: 25 December 2011
Next Planned Update: 25 December 2016 Cathodic Protection Commissioning
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Document Responsibility: Cathodic Protection Standards Committee SAEP-332
Issue Date: 25 December 2011
Next Planned Update: 25 December 2016 Cathodic Protection Commissioning
Commentary Note:
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Document Responsibility: Cathodic Protection Standards Committee SAEP-332
Issue Date: 25 December 2011
Next Planned Update: 25 December 2016 Cathodic Protection Commissioning
Page 11 of 33
Document Responsibility: Cathodic Protection Standards Committee SAEP-332
Issue Date: 25 December 2011
Next Planned Update: 25 December 2016 Cathodic Protection Commissioning
Page 12 of 33
Document Responsibility: Cathodic Protection Standards Committee SAEP-332
Issue Date: 25 December 2011
Next Planned Update: 25 December 2016 Cathodic Protection Commissioning
To verify that the wattage of the resistor is adequate, verify that the voltage
dropped across the resistor, multiplied by the current through the resistor is
less than the rated wattage of the resistor.
d. Measure the potentials of the pipelines associated with the bond box.
Measure the pipe-to soil potentials directly over each pipeline, or as near
as practical.
Page 13 of 33
Document Responsibility: Cathodic Protection Standards Committee SAEP-332
Issue Date: 25 December 2011
Next Planned Update: 25 December 2016 Cathodic Protection Commissioning
c. Faulty isolating devices shall be recorded as exception items, but shall not
delay commissioning unless the cathodic protection levels on the associated
structures are below acceptable commissioning criteria. In such cases, the
CP systems should be left on to provide as much CP as possible until the
isolation issue is resolved.
Page 14 of 33
Document Responsibility: Cathodic Protection Standards Committee SAEP-332
Issue Date: 25 December 2011
Next Planned Update: 25 December 2016 Cathodic Protection Commissioning
b. With the ICCP power supply adjusted to supply the CP power supply rated
current output, measure the current through each anode using the shunts
provided in the anode junction box, or using a clip on ammeter on each
anode cable.
c. With the ICCP power supply adjusted to supply the CP power supply rated
current output, measure the voltage difference between the anode junction
box enclosure and the anode connection bus bar in the anode junction box.
If this is greater than 12 volts, the anode junction box should be replaced
with a non-metallic junction box.
d. Verify that the anode junction box has not been connected to the system
ground.
Follow the check lists provided with the commissioning forms in Appendix A
for rectifiers and Appendix B for solar systems.
Acceptable protection levels for commissioning CP systems designed for the cathodic
protection of marine structures are specified in SAES-X-300. Marine structures include
all marine structures and associated equipment addressed by the scope of SAES-X-300.
8.1.3 If there are anodes in the area where the measurements are being taken,
try to place the reference electrode midway between the anodes.
Page 15 of 33
Document Responsibility: Cathodic Protection Standards Committee SAEP-332
Issue Date: 25 December 2011
Next Planned Update: 25 December 2016 Cathodic Protection Commissioning
8.3.1 Measure and record the operating data for the ICCP power supplies
and the current discharge levels for the associated anodes.
Page 16 of 33
Document Responsibility: Cathodic Protection Standards Committee SAEP-332
Issue Date: 25 December 2011
Next Planned Update: 25 December 2016 Cathodic Protection Commissioning
8.4.1 Measure and record the operating data for the ICCP power supplies
and the current discharge levels for the associated anodes.
8.4.2 Verify that each well head is electrically connected to the platform
jacket through a bond cable or a welded continuity bar.
8.4.3 Measure potentials on each main platform jacket leg, on each pipeline
riser, and on each well conductor. The minimum required potential
measurements are as follows:
In water depths of 15 meters or less, take potential measurements at
three locations: the sea bed, the midpoint, and one meter below the
surface.
In water depths of 15 to 30 meters, take potential measurements at
four locations: the sea bed, three meters above the sea bed, the
midpoint, and one meter below the surface.
In water depths of 30 meters or more, take potential measurements
at five locations: the sea bed, three meters above the sea bed, two
intermediate depths, and one meter below the surface.
Acceptable protection levels for commissioning CP systems designed for the cathodic
protection of buried pipelines are specified in SAES-X-400. Buried pipelines include
all pipelines and associated equipment addressed by the scope of SAES-X-400.
Page 17 of 33
Document Responsibility: Cathodic Protection Standards Committee SAEP-332
Issue Date: 25 December 2011
Next Planned Update: 25 December 2016 Cathodic Protection Commissioning
9.1.4 Avoid placement of the reference electrode near buried anodes, bare
copper grounding cables, or steel reinforced concrete pilings or
foundations.
Conduct the as-designed survey with the new ICCP power supplies
adjusted to operate at the design current level specified in the CP
detailed design document.
Commentary Note:
Page 18 of 33
Document Responsibility: Cathodic Protection Standards Committee SAEP-332
Issue Date: 25 December 2011
Next Planned Update: 25 December 2016 Cathodic Protection Commissioning
9.3.1 Measure the operating outputs for the ICCP power supplies.
9.3.3 Measure the current magnitude and direction at all galvanic anode
installations.
9.3.4 Measure the current magnitude and direction at all junction boxes,
bond stations, and any other connection point (mechanical or
electrical), where current may come on or off the new pipeline.
9.3.6 If there are high voltage AC power lines that are within 50 meters of
the pipeline and paralleling the pipeline for more than 500 meters,
measure the structure-to-electrolyte AC voltage potentials at the test
stations, bond stations and any other above ground appurtenance
within 500 meters of the power line. Voltage levels over 12 volts AC
are hazardous and require mitigation.
Page 19 of 33
Document Responsibility: Cathodic Protection Standards Committee SAEP-332
Issue Date: 25 December 2011
Next Planned Update: 25 December 2016 Cathodic Protection Commissioning
Acceptable protection levels for commissioning CP systems designed for the cathodic
protection of vessel and tank internal surfaces are specified in SAES-X-500. Vessel and
tank internals include all vessels, tanks and associated equipment addressed by the
scope of SAES-X-500.
10.1.2 When portable electrodes can be used, place the portable reference
electrode as close as possible to the structure to minimize measurement
error associated with the voltage (IR) drop in the electrolyte.
10.1.3 If there are anodes in the area where the measurements are being taken,
try to place the reference electrode midway between the anodes.
Page 20 of 33
Document Responsibility: Cathodic Protection Standards Committee SAEP-332
Issue Date: 25 December 2011
Next Planned Update: 25 December 2016 Cathodic Protection Commissioning
10.2.2 For new vessels and tanks with internal surfaces protected only by
galvanic anodes that cannot be readily disconnected or adjusted, the
commissioning structure-to-electrolyte potential survey is completed
only with the anodes connected.
10.3.1 If the new CP equipment includes ICCP power supplies, measure and
record the operating data and the current discharge levels for the
associated anodes.
10.3.2 Conduct the CP system commissioning for water tank internal surfaces
when the tank is near its normally full level and when practical also
verify that adequate protection is being achieved on the internal surface
of the tank bottom when the water in the tank is at its lowest normal
operating level.
10.3.3 For water tanks with access holes in the tank roof, measure the
structure-to-electrolyte potentials at three depths: 1) at the tank bottom,
2) at the midpoint, and 3) one foot below the water level.
Page 21 of 33
Document Responsibility: Cathodic Protection Standards Committee SAEP-332
Issue Date: 25 December 2011
Next Planned Update: 25 December 2016 Cathodic Protection Commissioning
continuity between all anodes and the tank can be verified prior to
filling the tank.
Measure and record the resistance of the ohm-meter test leads.
Measure and record the resistance between any two anodes or
between any anode and the tank shell external surfaces (e.g., at an
uncoated flange face).
The measured resistance minus the resistance of the test leads
should be less than 0.1 ohm.
10.4.1 If the new CP equipment includes ICCP power supplies, measure and
record the operating data and the current discharge levels for the
associated anodes.
10.4.3 If the vessel has been constructed with a monitoring anode or anodes
that are electrically continuous with the vessel shell through a
connection to the external side of the vessel:
Measure the current in the associated shunt.
Commentary Note:
Page 22 of 33
Document Responsibility: Cathodic Protection Standards Committee SAEP-332
Issue Date: 25 December 2011
Next Planned Update: 25 December 2016 Cathodic Protection Commissioning
Acceptable protection levels for commissioning CP systems designed for the cathodic
protection of plant facilities are specified in SAES-X-600. Plant facilities include all
buried pipelines, tank bottoms, piles etc. addressed by the scope of SAES-X-600.
11.1.4 Avoid placement of the reference electrode near buried anodes, bare
copper grounding cables, or steel reinforced concrete pilings or
foundations. If there are anodes in the area where the measurements
are being taken, try to place the reference electrode midway between
the anodes.
Page 23 of 33
Document Responsibility: Cathodic Protection Standards Committee SAEP-332
Issue Date: 25 December 2011
Next Planned Update: 25 December 2016 Cathodic Protection Commissioning
11.2.2 For structures protected only by galvanic anodes that cannot be readily
disconnected or adjusted, the commissioning structure-to-electrolyte
potential survey is completed only with the anodes connected.
Page 24 of 33
Document Responsibility: Cathodic Protection Standards Committee SAEP-332
Issue Date: 25 December 2011
Next Planned Update: 25 December 2016 Cathodic Protection Commissioning
11.3.2 If the new CP equipment includes ICCP power supplies, measure and
record the operating data and the current discharge levels for the
associated anodes.
11.3.3 Standard methods for measuring the protection levels beneath a tank
bottom are:
Stationary reference electrodes placed beneath the tank during the
construction of the tank.
Portable reference electrode on an extension inserted through
access tubes installed through the ring wall during tank
construction.
Portable reference electrode connected to a drag cable and pulled
through a perforated non-metallic monitoring pipe installed
beneath the tank, extending the full diameter of the tank.
Portable reference electrode placed at soil access points typically
installed around the perimeter of the tank midway between anodes.
Commentary Note:
11.3.4 Measure the protection level for tank bottoms installed with grid
anode systems, or individual anodes beneath the tank bottom using
the reference electrode measurement system(s) included with the tank
construction, i.e., stationary reference electrode, access tubes, or
perforated pipe.
11.3.5 The protection level for tank bottoms installed with perimeter anode
systems should be measured using the reference electrode
measurement system(s) provided with the tank construction. If no
below tank measurement system is provided, potential measurements
should be taken around the perimeter of the tank through soil access
holes or with the reference electrode placed midway between anodes
and as close as practical to the tank. Do not take measurements
directly above buried bare copper grounding cables.
Page 25 of 33
Document Responsibility: Cathodic Protection Standards Committee SAEP-332
Issue Date: 25 December 2011
Next Planned Update: 25 December 2016 Cathodic Protection Commissioning
11.4.1 Measure and record the operating data for the ICCP power supplies
and the current discharge levels for the associated anodes. The current
output from each anode should not exceed the maximum allowable
current discharge for commissioning as specified in SAES-X-600.
11.4.2 Measure and record the current magnitude and direction at all galvanic
anode installations.
11.4.3 Measure and record the current magnitude and direction at all junction
boxes, bond stations and any other connection point (mechanical or
electrical) where current may come on or off the new pipeline.
11.5.1 Measure and record the operating data for the ICCP power supplies
and the current discharge levels for the associated anodes. The current
output from each anode should not exceed the maximum allowable
current discharge for commissioning as specified in SAES-X-600.
11.5.2 Measure and record the current magnitude and direction at all galvanic
anode installations.
11.5.3 Measure and record the current magnitude and direction at all junction
boxes, bond stations and any other connection point (mechanical or
electrical) where current may come on or off the sheet piling.
Page 26 of 33
Document Responsibility: Cathodic Protection Standards Committee SAEP-332
Issue Date: 25 December 2011
Next Planned Update: 25 December 2016 Cathodic Protection Commissioning
Connection of the test lead to the structure will typically be made at the
nearest bollard to the respective reference electrode measurement
location.
Acceptable protection levels for commissioning CP systems designed for the cathodic
protection of onshore well casings are specified in SAES-X-700. Onshore well casings
include all well casings and associated equipment addressed by the scope of SAES-X-700.
Page 27 of 33
Document Responsibility: Cathodic Protection Standards Committee SAEP-332
Issue Date: 25 December 2011
Next Planned Update: 25 December 2016 Cathodic Protection Commissioning
The survey to determine if adequate protection levels are being achieved for
commissioning of a CP system for onshore well casings shall be conducted as
detailed below.
Conduct the as-found survey with nearby pre-existing CP power supplies
operating as near as practical to their respective target outputs and the new
CP power supply turned “off”.
Conduct the optimized output survey with the ICCP power supplies (pre-
existing and new) adjusted to supply the optimum amount of current to the
well casing as specified in SAES-X-700 Table 1.
Commentary Note:
The optimization of the CP power supply outputs will often involve readjustment
of the outputs of existing nearby CP power supplies that are influenced by, or
have an influence on the new CP system or well casing.
12.3.1 Measure and record the operating data for the ICCP power supply and
the current discharge levels for the associated anodes. Compliance with
the criteria specified in SAES-X-700 for commissioning performance
is mandatory.
12.3.2 At the well casing, measure and record the current magnitude and
direction on the flowline and on the negative cable connected to the
well casing. To determine the amount of current flowing up the well
casing, consider positive current as current flowing away from the well
in the flowline or the cable. Negative current is current flowing
towards the well in the flowline or the cable. The current in the casing
will then be the mathematical sum of the current measured in the cable
and the current measured in the flowline (see example below).
Page 28 of 33
Document Responsibility: Cathodic Protection Standards Committee SAEP-332
Issue Date: 25 December 2011
Next Planned Update: 25 December 2016 Cathodic Protection Commissioning
12.3.4 For each well casing record the current data and associated
measurements on the Commissioning Report contained in Appendix F.
Acceptable protection levels for commissioning CP systems designed for the cathodic
protection of existing reinforced concrete structures are specified in SAES-X-800.
Page 29 of 33
Document Responsibility: Cathodic Protection Standards Committee SAEP-332
Issue Date: 25 December 2011
Next Planned Update: 25 December 2016 Cathodic Protection Commissioning
Existing reinforced concrete structures include all structures addressed by the scope of
SAES-X-800.
Page 30 of 33
Document Responsibility: Cathodic Protection Standards Committee SAEP-332
Issue Date: 25 December 2011
Next Planned Update: 25 December 2016 Cathodic Protection Commissioning
i. Once the 100 mV shifts from the natural potentials have been
achieved, monitor and maintain the rectifier output voltage each
week for four weeks (28 days). At the end of 28 days:
Record the “ON” and instantaneous “OFF” potentials using
an interrupted cycle.
Turn the rectifiers off and conduct a depolarization test for
168 hours (7 days). Measure the potential at 24 hours and
168 hours.
13.2.2 Consider that each system has commissioned satisfactorily when the
following three criteria are met:
a. 100 mV decay or more measured up to 24 hours from
instantaneous 'OFF'.
b. 150 mV decay or more measured up to 168 hours from
instantaneous 'OFF'.
c. The instantaneous 'OFF' potentials shall not be more negative
than -1100 mV vs. Cu/CuSO4.
Commentary Note:
13.2.3 Repeat the depolarization test quarterly for the first 12 months.
a. If the 100 mV criterion is not achieved at all locations or for any
one channel, then increase the output of the respective rectifier
channel by increments of not greater than 20% and repeat the
above tests until the criterion is met. If the upper limit is
exceeded, then reduce the output by 20%.
b. If the criteria are not achieved within three months of the initial
energizing of the system, the contractor shall conduct further
investigation and shall complete the required repairs or upgrades
to the installed system as necessary to achieve the above noted
criteria.
c. Submit all commissioning data as part of the as-built
documentation prior to final acceptance.
Page 31 of 33
Document Responsibility: Cathodic Protection Standards Committee SAEP-332
Issue Date: 25 December 2011
Next Planned Update: 25 December 2016 Cathodic Protection Commissioning
14 Report Forms
Revision Summary
25 December 2011 Major revision.
Page 32 of 33
Document Responsibility: Cathodic Protection Standards Committee SAEP-332
Issue Date: 25 December 2011
Next Planned Update: 25 December 2016 Cathodic Protection Commissioning
Attachments (Appendices A to K)
- Hold down Ctrl key and click => SAEP-332A to view the Appendices.
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