PETRONAS TECHNICAL STANDARDS

Cathodic Protection Systems For Onshore Buried and

Shore Approach Pipelines

PTS 11.32.01
June 2015

© 2015 PETROLIAM NASIONAL BERHAD (PETRONAS)

All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form
or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright
owner. PETRONAS Technical Standards are Owner’s internal standards and meant for authorized users only.
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FOREWORD

PETRONAS Technical Standards (PTS) has been developed based on the accumulated knowledge,
experience and best practices of the PETRONAS group supplementing National and International
standards where appropriate. The key objective of PTS is to ensure standard technical practice across
the PETRONAS group.

Compliance to PTS is compulsory for PETRONAS-operated facilities and Joint Ventures (JVs) where
PETRONAS has more than fifty percent (50%) shareholding and/or operational control, and includes
all phases of work activities.

Contractors/manufacturers/suppliers who use PTS are solely responsible in ensuring the quality of
work, goods and services meet the required design and engineering standards. In the case where

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specific requirements are not covered in the PTS, it is the responsibility of the

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Contractors/manufacturers/suppliers to propose other proven or internationally established
standards or practices of the same level of quality and integrity as reflected in the PTS.

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In issuing and making the PTS available, PETRONAS is not making any warranty on the accuracy or
completeness of the information contained in PTS. The Contractors/manufacturers/suppliers shall
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ensure accuracy and completeness of the PTS used for the intended design and engineering
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requirement and shall inform the Owner for any conflicting requirement with other international
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codes and technical standards before start of any work.

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PETRONAS is the sole copyright holder of PTS. No part of this document may be reproduced, stored
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in a retrieval system or transmitted in any form or by any means (electronic, mechanical, recording or
otherwise) or be disclosed by users to any Owner or person whomsoever, without the prior written
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consent of PETRONAS.
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The PTS shall be used exclusively for the authorised purpose. The users shall arrange for PTS to be
kept in safe custody and shall ensure its secrecy is maintained and provide satisfactory information to
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PETRONAS that this requirement is met.

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Table of Contents
1.0 INTRODUCTION ..................................................................................................... 5
1.1 SCOPE ............................................................................................................................ 5
1.2 GLOSSARY OF TERMS..................................................................................................... 5
1.3 SUMMARY OF CHANGES ............................................................................................... 7
2.0 DESIGN REQUIREMENTS ........................................................................................ 8
2.1 DESIGN INFORMATION .................................................................................................. 8
2.2 BASIC DESIGN ................................................................................................................ 8
2.3 DETAILED DESIGN .......................................................................................................... 8

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2.4 PROTECTION CRITERIA .................................................................................................. 9

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3.0 SITE SURVEYS ...................................................................................................... 10
3.1 GENERAL TERRAIN DESCRIPTION ................................................................................ 10
3.2
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RESISTIVITY OF SOIL ..................................................................................................... 10
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3.3 SOIL INVESTIGATION ................................................................................................... 11
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3.4 CURRENT DRAINAGE TEST ........................................................................................... 11

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3.5 STRAY CURRENTS ......................................................................................................... 11

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4.0 ELECTRICAL ISOLATION ........................................................................................ 12

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4.1 ISOLATION JOINTS ....................................................................................................... 13

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4.2 ISOLATING SPOOLS ...................................................................................................... 13

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4.3 INSULATED FLANGES ................................................................................................... 14

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4.4 EARTHING .................................................................................................................... 14

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5.0 ELECTRICAL CONTINUITY ..................................................................................... 16

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6.0 COATING, DESIGN LIFE AND CURRENT DENSITY REQUIREMENTS.......................... 17

6.1 PIPELINE COATING ....................................................................................................... 17
6.2 DESIGN LIFE ................................................................................................................. 17
6.3 CURRENT DENSITY REQUIREMENTS ............................................................................ 17
7.0 CHOICE OF CATHODIC PROTECTION SYSTEM ........................................................ 19
8.0 IMPRESSED CURRENT CATHODIC PROTECTION (ICCP) SYSTEM ............................. 20
8.1 SOURCE OF DC VOLTAGE ............................................................................................. 20
8.2 GROUNDBEDS .............................................................................................................. 22
8.3 CURRENT CONTROL AND DISTRIBUTION..................................................................... 24
8.4 CIVIL WORKS ................................................................................................................ 24
9.0 SACRIFICIAL ANODE CATHODIC PROTECTION (SACP) SYSTEM............................... 25
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9.1 ZINC ANODES ............................................................................................................... 26

9.2 MAGNESIUM ANODES ................................................................................................. 26
9.3 CHEMICAL BACKFILL .................................................................................................... 26
9.4 CABLES AND CABLE CONNECTIONS ............................................................................. 27
10.0 MONITORING FACILITIES ..................................................................................... 28
10.1 POTENTIAL MONITORING STATIONS ........................................................................... 28
10.2 FOREIGN PIPELINE BONDING FACILITIES ..................................................................... 28
10.3 TEST FACILITIES AT CASINGS........................................................................................ 28
10.4 TEST FACILITIES AT ISOLATION JOINTS / FLANGES ...................................................... 28
10.5 DRAIN POINT TEST FACILITIES ..................................................................................... 28

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10.6 MISCELLANEOUS MONITORING FACILITIES................................................................. 29

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10.7 CABLES, TEST POSTS AND DISTRIBUTION BOXES ........................................................ 29

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11.0 SPECIAL FACILITIES .............................................................................................. 30
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11.1 TEMPORARY PROTECTION........................................................................................... 30
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11.2 PROTECTIVE CASING .................................................................................................... 30

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11.3 PARALLEL POWER LINES .............................................................................................. 31

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11.4 LIGHTNING PROTECTION ............................................................................................. 31

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11.5 SURGE ARRESTOR ........................................................................................................ 31

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11.6 MONITORING EQUIPMENT.......................................................................................... 31

12.0 CABLES AND CABLE ACCESSORIES ........................................................................ 33
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12.1 CABLES ......................................................................................................................... 33

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12.2 ANODE CABLE CONNECTIONS ..................................................................................... 33

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12.3 CONNECTION OF CABLES TO THE PIPELINE ................................................................. 33

12.4 TEST POSTS AND DISTRIBUTION BOXES ...................................................................... 35
13.0 DOCUMENTATION............................................................................................... 36
13.1 DESIGN DOCUMENTS .................................................................................................. 36
13.2 MATERIAL SCHEDULES................................................................................................. 36
13.3 INSTALLATION PROCEDURES ....................................................................................... 37
13.4 COMMISSIONING PROCEDURES .................................................................................. 37
14.0 SAFETY ................................................................................................................ 39
15.0 BIBLIOGRAPHY .................................................................................................... 40
APPENDIX 1: SPECIMEN COPY OF DATASHEET ................................................................. 42
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1.0 INTRODUCTION

This PTS specifies the minimum technical requirements for the design of cathodic protection
systems for onshore buried pipelines and based on PETRONAS lesson learnt and best
practices.

1.1 SCOPE

1.1.1 This PTS applies for onshore pipeline system and shore approach section.

1.2 GLOSSARY OF TERMS

1.2.1 General Definitions of Terms and Abbreviations

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Refer to PTS Requirements, General Definition of Terms, Abbreviations & Reading Guide PTS

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00.01.03 for General Definition of Terms & Abbreviations.

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1.2.2 Specific Definition of Terms

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No Term Definition
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1 Cathodic Protection Protection of metal surfaces which are in

electrolyte environment from corrosion via
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process flow of direct current from the

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electrolyte into the metal surfaces.

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2 Cathodic Protection Station Equipment at site for the purpose of

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providing cathodic protection for the

pipeline system e.g. Transformer Rectifier
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Unit (TRU) and Test Point.

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3 Coating Breakdown Factor The factor represents the ratio of exposed

metal area due to coating breakdown from
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the total coverage area for CP protection.

Extent of current density reduction due to
application of coating is determine using this
factor.

4 Current Density Cathodic protection current per unit of bare

metal surface area of pipeline.

5 Drain Point Point of connection of the anode sled to the

pipeline.

6 Electrolyte Electrically conductive medium i.e. soil or

seawater.

7 Foreign Structures/Pipelines Metal objects i.e. structures, pipelines, and

debris etc, located adjacent to the pipeline
with cathodic protection which present in
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No Term Definition
the same electrolyte and may cause
interference to the existing cathodic
protection system.

8 Groundbed Buried or submerged electrodes system that

conduct the required current to protect the
steel surface through the electrolyte.

9 Midpoint The point on pipeline with generally lowest

protection level, located between two
cathodic protection station and the influence
of both stations on the point are expected to

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be equal.

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10 Natural Potential Pipe to soil potential taken without the

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application of cathodic protection system.
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11 "OFF" Potential Pipe to soil potential taken prior to the
decrease of pipeline polarization once the
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cathodic protection system is switched off

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and the electrical current stops flowing to

pipeline surface.
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12 "ON" potential Pipe to soil potential taken during the

operation of cathodic protection system.
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13 Pipeline Pipeline(s) and associated equipment to be

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covered under cathodic protection design

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contract.
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14 Pipe to Soil Potential Electrochemical potential difference

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between a pipeline and a reference

electrode in contact with the electrolyte.

15 Polarization Pipe to soil potential difference caused by

electrical current flow between electrolyte
and a steel surface.

16 Polarization Cell (Kirkcell) An electrochemical device that shunt

hazardous voltages to ground in case of
installations not grounded via metal
conductors.

17 Reference Electrode An electrode that used as a reference for

pipe to soil potential measurements.
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No Term Definition

18 Stray Currents Current flow in the electrolyte that does not

originate from the cathodic protection
system designed to protect the pipeline.
Table 1: Specific Definition of Terms

1.2.3 Specific Abbreviations

No Abbreviations Description
Silver/Silver Chloride type of reference
Ag/AgCl
1 electrode

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Copper/Copper Sulphate type of reference
Cu/CuSO4

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2 electrode

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AC Alternating Current
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DC Direct Current
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GRE Glass reinforced epoxy

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Table 2: Specific Abbreviations

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1.3 SUMMARY OF CHANGES

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The PTS 11.32.01 replaces PTS 30.10.73.31 (November, 2011).

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2.0 DESIGN REQUIREMENTS

2.1 DESIGN INFORMATION

2.1.1 The Owner shall submit all the technical information required for cathodic protection design
to the Contractor which shall include but not limited to items below:

i. Pipeline details i.e. length, size, type of coating, intended protection scope.

ii. Intended cathodic protection design life.

iii. Cathodic protection system requirements and/or materials.

iv. Pertinent drawings i.e. pipeline route, existing systems, and foreign

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structures/pipelines.

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v. Environmental and operating conditions

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2.2 BASIC DESIGN lU
2.2.1 A basic cathodic protection design shall be submitted by the Contractor to the Owner for
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review and approval. The design submitted shall include the documentation list as in
subsection 13.1. Detailed design shall only commence once the basic design is approved,
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unless requested by the Owner to be conducted concurrently.

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2.3 DETAILED DESIGN

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2.3.1 All necessary information to procure cathodic protection equipment and to construct,
commission and hand over the cathodic protection system shall be covered in the detailed
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design as per requirements listed in subsection 13.1.

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2.4 PROTECTION CRITERIA

"OFF" POTENTIALS, mV
REFERENCE ELECTRODE :
Cu/CuSO4 Ag/AgCl/ Zinc
seawater
Protection potential for steel -850 -800 +250
aerobic
in environment
Protection potential for steel -950 -900 +150
in
anaerobic environment
Overprotection limit for -1150 -1100 -50

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carbon
steel

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Table 3: Potential Limits for Cathodic Protection of Pipelines
NOTE: Cu/CuSO4 reference is used for pipelines in soil,

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Ag/AgCl/seawater reference is used in seawater.
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Zinc reference is used in both soil and seawater for special monitoring purposes only.
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In this specification the pipe-to-soil potential is used as a criterion for effective cathodic protection.
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2.4.1 The "OFF" potential on all parts of the pipeline shall be equal to or more negative than the
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protection potential value stated in Table 3 fo the pipeline to be considered fully cathodically
protected.
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2.4.2 The "OFF" potentials for carbon steel shall not be more negative than the overprotection limit
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value as stated in Table I to avoid detrimental effects on the applied coating or on the pipeline
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due to overprotection.
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2.4.3 The protection criteria for corrosion resistant steel and some high strength steel pipelines
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shall be determined by taking into account the material susceptibility to hydrogen induced
stress cracking. This shall include cathodic protection design for pipeline crossing or
approaching another pipeline made of such materials.

2.4.4 Presence of active sulphate reducing bacteria in anaerobic soil shall be confirmed via soil
investigation to determine the imminent protection for anaerobic environments.
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3.0 SITE SURVEYS

A pre-design site survey shall be carried out prior to execution of cathodic protection design.

Seasonal changes shall be taken into consideration if the surveyed area is affected and
different seasonal condition surveys shall be performed if possible. The worst case out of the
surveys shall be taken as the basis for the design.

Below are the integral items of the site survey:

3.1 GENERAL TERRAIN DESCRIPTION

3.1.1 General information of the terrain along the pipeline route shall be acquired from the survey
including:

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i. Terrain and vegetation types e.g. urban areas, industrial areas, farm land, forests,

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open fields, desert, swamps, and rocks

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ii. Visible relevant features and crossings e.g. rivers, canals, railways, main roads,
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overhead power lines, other pipelines
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iii. All other information that is considered relevant to the design of a cathodic
protection system.
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iv. Identification of hilly, rocky and graphitic area.

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3.2 RESISTIVITY OF SOIL

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3.2.1 Resistivity of soil shall be measured along the pipeline route at pipeline depth. The
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measurements should at least be performed when there are changes in the soil characteristic
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visually. However the number of measurements should be determined locally.

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3.2.2 Readings should be taken in at least two different locations for each type of soil. Minimum of
2 measurements shall be taken at each location.
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3.2.3 Below standard methods for soil resistivity measurements:

i. Four terminal resistivity method (Wenner)

ii. Two terminal resistivity method (Shepard)

iii. Soil sample (soil box) resistivity method

3.2.4 For the purpose of determining the appropriate location for surface groundbeds, the four
terminal methods shall be used to measure resistivity at greater depths (10m maximum).

3.2.5 Any other methods for soil resistivity measurement shall require approval by the Owner.
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3.3 SOIL INVESTIGATION

3.3.1 Chemical and bacterial soil analysis shall be carried out, if corrosive condition assumed to
occur due to presence of bacterial activity. Reference for test methods can be made to BS
1377 parts 3 and 9. This shall also applied for imported backfill used for pipeline construction.

3.3.2 Soil boring shall be conducted for hilly and rocky area and the characteristic of soil that can
affect the cathodic protection flow e.g. graphitic soil, shall be analysed and determined from
the coring sample.

3.4 CURRENT DRAINAGE TEST

3.4.1 Current drainage test should be performed to determine current requirement and optimal
current distribution for cathodic protection system design of existing pipelines.

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3.4.2 Prior to performing current drainage test, pipeline isolation equipment and monitoring

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facilities should be installed to obtain relevant results.

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3.4.3 To determine the current requirement, total polarisation of pipeline length should be
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achieved and “OFF” potentials taken at regular points along the pipeline should be within the
potential limits outlined in Table 3. Allowance for probability of coating damage throughout
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the pipeline remaining life shall be made by adjusting the current demand.
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3.5 STRAY CURRENTS

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3.5.1 Potential sources of hazardous AC and/or DC stray currents shall be investigated by the
Contractor and the mitigation of stray current effects shall be proposed in the design.
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3.5.2 The contractor shall carry out a stray current survey during commissioning, in the event that
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the stray current effect is unpredictable.

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3.5.3 Source of stray current shall be eliminated by appropriate insulation. Other means such as
installation of current drainage system shall be designed if insulation is not applicable.
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4.0 ELECTRICAL ISOLATION

Electrical isolation shall separate pipeline cathodic protection system from other plant, foreign
structures/pipeline and electrical and instrument earthing systems.

The Contractor shall justify his decision for any isolation omittance in his basic design i.e.
incorporation of short branch line, small pipeline facilities and/or crossing of small rivers into
main pipeline cathodic protection system, subject to Owner’s approval.

Where appropriate, monoblock isolation joints shall be used.

Isolation joint/flange shall be installed above ground or in inspection pits; and shall not be
buried. Each isolation joint/flange shall be provided with test facilities.

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The isolation joint/flange shall be equipped with earthing or surge arrestors in areas with risk

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of high voltages presence on the pipeline i.e. due to adjacent power systems or lightning.

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For ease of identification, isolation joint/flange should be painted in a contrasting colour. The

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paint shall be compatible with the pipeline coating and colour code used should be consistent
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in one area i.e. red paint or black coal tar epoxy are commonly used. Isolation joint/flange
shall not use paints containing metallic pigments such as zinc or aluminium.
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Locations for isolation joint/flange should be as follows:

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i. At both extremities of a buried section of pipeline;

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ii. At branch lines;

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iii. Between pipeline sections with different external coating systems;

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iv. Between pipeline sections running in different types of electrolyte (e.g. river
crossings) and/or different method of installation (e.g. HDD for river crossings,
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highway crossings, railway crossings etc.);

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v. In areas of high telluric activity.

Unless running in the same trench and having the same coating system, parallel pipelines shall
be electrically isolated from each other.

Pipelines should avoid touching or near any metal; and should be electrically isolated from
pipe supports.

The Contractor shall ensure adequate arrangement for effective cathodic protection if the
pipeline isolation is designed by other party.

In case of designing for existing pipelines, the Contractor shall determine the quality of
available pipeline isolation system and propose any improvements required to achieve
appropriate isolation together with his basic design.

Safety or instrument earthing shall be compatible with the cathodic protection system.
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4.1 ISOLATION JOINTS

4.1.1 Isolation joints shall be designed with materials, dimensions and constructed to meet the
pipeline design requirements.

4.1.2 Manufacturer shall internally coat the isolation joints with an amine cured epoxy coating,
applied on a blast cleaned surface (Sa 2½, ISO 8501-1). 50mm allowance for welding at both
ends shall be left uncoated.

4.1.3 All sealing and isolation materials shall not react with the product transported.

4.1.4 The isolation joints shall withstand for 5 minutes without bridging or reduction in electrical
resistance, a voltage of 1500 volt AC, 50 Hz across the joint.

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4.1.5 The joint shall achieve electrical resistance higher than 1 M Ω measured at 1000 volt DC in dry

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air.

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4.1.6 The overall length of the isolation joint shall be at least one metre, if the product transported

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by the pipeline is dry gas, dry crude oil, or oil products.
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4.1.7 The following requirements shall apply for pipeline transporting an electrolyte or anticipated
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to contain an electrolyte at any time throughout the pipeline life:

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i. The overall length of the isolation joint shall be four times the pipe diameter (with
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a minimum of one metre), if the resistivity of the electrolyte is higher than 100
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ohm.cm, or the volume occupied by the electrolyte is less than 5% of the pipeline
volume.
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ii. Isolating spools shall be used if the resistivity of the electrolyte is below 100
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ohm.cm and the volume of electrolyte is more than 5% of the pipeline volume.
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iii. Immediately prior to welding the isolation joints onto the pipeline, the resistance
across the joints shall be shall be measured. The minimum resistance shall be 1
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MΩ.

4.2 ISOLATING SPOOLS

4.2.1 Isolating spools shall be used if required by the rules above.

4.2.2 Below is the formula to determine the length of isolating spool:

400
𝐿=( )×𝐷
𝜌

Where:

𝐿 length of spool (cm);

𝜌 electrolyte resistivity (Ohm.cm);

𝐷 nominal pipe diameter (cm).

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4.3 INSULATED FLANGES

4.3.1 Insulated flanges shall be used as an electrical isolation when application of i isolation joints
is not possible i.e. cathodic protection retrofit for existing pipelines.

4.3.2 Flanges and insulation kits shall meet the design requirements of the pipeline. Raised face or
full face flanges should used insulating gasket of neoprene coated phenolic resin type.

4.3.3 Both sides of the bolts shall be insulated with full length phenolic or composite sleeves and
phenolic resin insulating washers and steel washers.

4.3.4 Prior to welding onto the pipeline, insulated flanges should be assembled and tested. The
insulated flange shall withstand a voltage of 1500 volt DC across the flange assembly for one
minute without causing breakdown of the insulation or flash over. The resistance across the

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assembled flange shall be taken successively and shall read higher than 1 MΩ.

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4.3.5 The bolt-to-pipe resistance shall be measured for application on existing flanges and the
overall isolated flange efficiency shall be determined after cathodic protection is in placed.

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This can effectively been done by measuring the current through the attached pipe using a
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"Swain-type" current clamp/meter.
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4.3.6 With the exceptional of sour service condition, flange protectors or protective tape shall be
applied to protect insulated flanged from dirt and moisture ingress.
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4.4 EARTHING
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4.4.1 Cathodic protection system for pipeline should be electrically isolated from common or plant
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earthing system to prevent current leakage.

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4.4.2 Electrical earthing devices installed on the protected pipeline may be required for safety
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reasons or pipeline earthing may be required to mitigate the effect of induced electrical
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voltages.
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4.4.3 Electrical safety earthing application shall be made compatible with the cathodic protection
systems as per following requirements:

i. Installation of polarization cells or diode circuits.

ii. Suitably specified and rated for the purpose.

iii. Install in the earthing circuit or by the installation of separate earthing electrodes.

iv. Made of zinc or galvanized steel.

v. Buried in low resistivity backfill.

vi. No direct continuity with other earthing systems.

4.4.4 For the purpose of mitigating the AC induced voltages effects on pipeline, earthing should be
installed at the following locations:
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i. Anticipated or measured highest voltages to the ground.

ii. Exposed pipeline.

iii. Pipeline accessible by personnel.

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5.0 ELECTRICAL CONTINUITY

Isolation joints installed at coating/electrolyte changes shall always be bonded at test posts;
to keep the pipeline electrically continuous when the cathodic protection is operational.

For non-welded pipeline applications, the continuity of the cathodic protection shall be
maintained and shall be tested i.e. by carrying out overlapping potential measurements. This
can be ensured by erection of permanent bonds over high resistance flanges/couplings, using
cables and approved attachment methods.

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6.0 COATING, DESIGN LIFE AND CURRENT DENSITY REQUIREMENTS

6.1 PIPELINE COATING

6.1.1 The Owner shall provide the existing or planned coating system to the Contractor upon
request.

6.1.2 The appropriate design parameters for each coating type shall be used in the design in case
of adjacent structures having different type of coatings or significant difference in coating
condition. Pipeline isolation shall be provided should the interference is expected.

6.2 DESIGN LIFE

6.2.1 Unless stated otherwise by the Owner, the cathodic protection system shall be designed for

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the pipeline design life.

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6.2.2 In the event that the above requirement cannot be realized, due to normal life of cathodic
protection system components lesser that pipeline design life or incompatible control of

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cathodic protection levels at the beginning and at the end of the design life, the Contractor
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shall take into account and justify this shorter life on its installation system, methods and
instructions for future upgrading of the system in his basic design.
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6.3 CURRENT DENSITY REQUIREMENTS

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6.3.1 As required during the pipeline design life, the Contractor shall determine the pipeline current
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demand and spacing between cathodic protection stations by calculating the attenuation. For
new construction projects, the minimum design values shall be based on current densities in
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Table 4.
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6.3.2 A current drainage test shall be carried out to determine the current requirement for existing
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pipelines, where the actual condition of the applied coating is unknown.

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6.3.3 The higher of the two values computed by above methods; pipeline current demand and
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current drainage test, shall be used as the cathodic protection system capacity.

6.3.4 The minimum design current densities given in Table 4 shall be increased by 25% per 10°C rise
in temperature above 30°C for protection of pipelines with elevated operating temperatures.
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PIPELINE LIFE (years)

0-5 5-15 15-30
2
COATING TYPE CURRENT DENSITY (mA/m )

Asphalt bitumen, 6 mm
Butyl rubber tape 0.040 0.100 0.200
Asphalt mastic
Fusion bonded epoxy
Liquid epoxy Coal
tar epoxy 0.010 0.020 0.05

Polyethylene 0.002 0.005 0.010

Polypropylene

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Table 4: Design current densities for different pipeline coatings (operating temperature up

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to 30 °C)

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NOTE: The current densities given in Table 4 already include the current requirements due to the expected

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coating breakdown during the pipeline life.
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7.0 CHOICE OF CATHODIC PROTECTION SYSTEM

By means of requisition, the type of cathodic protection system shall be indicated. In case not
specified, the type of cathodic protection system shall be proposed by the Contractor with his
justification included in the basic design.

The selection criteria should be considered as follows:

i. Soil resistivity

ii. Total current demand

iii. Economic considerations

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iv. Presence of stray currents

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v. Availability of power supply

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vi. Site layout lU
vii. Presence of other conductors
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viii. Maintenance
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ix. Possibility to use existing Owner owned cathodic protection systems.

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Impressed current shall be used if the above criteria do not clearly justify one particular
system.
AS
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8.0 IMPRESSED CURRENT CATHODIC PROTECTION (ICCP) SYSTEM

8.1 SOURCE OF DC VOLTAGE

By means of requisition, the DC voltage source shall be indicated if required. The Contractor
shall propose one of the DC sources alternative if it was not specified in the requisition.
Justification of his choice shall be provided and shall be made based on local geographical
circumstances and infrastructure.

DC power source maximum output voltage shall be 50 volts.

8.1.1 Transformer/rectifiers

i. Transformer/rectifiers shall comply with IEC 146.

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ii. Transformer/rectifiers shall be of a special design for cathodic protection service

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and should be 3-phase units if available.

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iii. Transformer/rectifiers shall be fit to operate under the normal service conditions.
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The output voltage shall be adjustable from zero to the maximum rated output
when on load. Tapping switches shall be front-mounted; if required, with a step-
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size of maximum 3% of maximum output. Transformer tapping using relocation

of jumpers shall not be used.
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iv. Transformer/rectifiers shall not be installed in the same cathodic protection

-I

circuit whether in series or in parallel.

AS

v. The rectifier shall be fabricated to provide full wave rectification using high
current density selenium cells or silicon diodes. The current rating of the diodes
N

shall be higher than 1.25 times the maximum current rating of the rectifier and
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have a minimum peak inverse voltage of 1200 V.

TR

vi. The output rms ripple current shall not exceed 5% of the DC output current
PE

between 5% and 100% of the rated current output.

vii. The transformer/rectifier shall consists of an isolator or Moulded Case Circuit

Breaker (MCCB) on its incoming circuit and, where appropriate, on its AC sub-
circuits. Additionally, the transformer/rectifier’s phase AC sub-circuits and the
negative DC output circuits shall be installed with suitably sized fuses (type gG to
IEC 269).

viii. The transformer/rectifier shall be able to withstand a short circuit of up to 15

seconds duration at the output terminals without damaging any of its devices.

ix. Meters of approximately 70mm diameter or similarly sized square pattern meters
with measuring accuracy better than 2% of full scale shall be provided to the
transformer/rectifier to read the output voltage and current.

x. The polarity of the DC terminals and AC supply terminals shall be clearly marked.
AC and DC cables shall be separated by an insulating panel.
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xi. Unless otherwise stated, a built-in timer unit shall be required. The timer unit shall
be capable of switching the full output current in a sequence of 50 seconds on
and 10 seconds off and may be mechanical or electronic. All transformer/rectifier
timer units should be provided with a facility for synchronous switching in the
event that a pipeline system is cathodically protected by more than one
transformer/rectifier. The timer shall be bypassed during normal operation.

xii. The incoming cables shall terminate in separate non oil filled cable boxes and
penetration into the tank shall be via bushings above oil level for an oil cooled
transformer/rectifier. A sight glass and thermometer shall be provided.

xiii. Transformer/rectifiers should be installed in a non-hazardous area. If this is

unlikely, the construction of the rectifier units shall fulfill the requirements of the
site hazardous area classification. The Owner shall provide the required

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information on area classification to the Contractor.

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xiv. The enclosure shall have a minimum degree of protection IP 54 in accordance with

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IEC 529, if installed outdoors.
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8.1.2 Engine generator sets
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A remote survey unit with alarms shall be installed. If not possible, a two generator system
shall be used (one running, one on standby) with an automatic change-over system.
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8.1.3 Batteries, solar and wind generators

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i. For batteries powered cathodic protection system, a suitable output voltage

AS

and/or current control equipment and a load cut off system shall be provided to
protect the batteries from damages due to a complete discharge.
N
O

ii. Battery chargers and generators shall be equipped with regulators to ensure that
TR

the recommended charging rates are practiced and shall be provided with a
protection system to avoid overcharged batteries.
PE

iii. Wind and solar generators shall be designed based on extensive local weather
reports, stating average and minimum sun and/or wind periods and intensity
during all seasons, generally a one year period, to determine the capacity of the
system.

iv. Wind and solar generators shall be rated to recharge the batteries in less than 48
hours from a partially discharged state due to extended period of no wind/sun.

v. In tropical areas the generators and batteries shall be designed to operate in the
high ambient temperatures. Solar generators should be designed to maintain the
design capacity at the highest ambient temperature.

8.1.4 Thermoelectric generators

The use of thermoelectric generators shall be justified by the Contractor; and shall obtain
approval from the Owner for their use.
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8.2 GROUNDBEDS

8.2.1 The groundbed of an impressed current cathodic protection system shall be designed such
that:

i. Its mass and quality is sufficient to last for the design life of the system.

ii. Its resistance to earth allows the maximum predicted current demand to be met
at 80% or less of the voltage capacity of the DC source during the design life of
the system.

iii. Its location is remote from the pipeline and any other buried structure, to provide
a regular distribution of current along the pipeline.

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iv. The risk of causing harmful interference on other buried structures is minimized.

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8.2.2 The selection of the location and the type of groundbed shall depend on local conditions such
as:

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i.
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Soil conditions and resistivity at various depths.
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ii. Groundwater levels and resistivity.

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iii. Strong seasonal changes in surface soil conditions.

nt

iv. Available terrain (for surface groundbeds).

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AS

v. Risk of shielding (especially for parallel pipelines).

vi. Risk of damage by excavation (surface groundbeds).

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8.2.3 Deepwell groundbeds

TR

Deepwell groundbeds should be used:

PE

i. If the soil conditions at the required depth are suitable to meet the requirements
in subsection 8.2.

ii. If there is a risk of shielding by other pipelines or buried structures.

iii. If the available space is limited.

iv. If there is a risk of stray currents on adjacent installations.

8.2.4 The Contractor shall include and specify information below in his basic design:

i. Groundbed resistance calculation using established methods and formula, based

on the most accurate soil resistivity data available.

ii. Deepwell drilling method.

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iii. Soil resistivity establishment at depth.

iv. Borehole completion.

v. Anodes installation method.

vi. Backfilling.

The design and construction of borehole shall prevent any undesirable transfer between
water bearing formations and pollution of underlying strata from the surface (e.g. tank farms).

Casing at depth shall be electrically isolated from metal casing and structures at the surface.

To prevent gas blocking of the well, adequate venting pipes shall be provided to the deepwell

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groundbeds. The vent pipe shall be of chlorine resistant material. Vent pipe blockage by coke

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backfill shall be avoided using filter gravel.

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8.2.5 Surface groundbeds

Shallow surface groundbeds should be used:

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i. If the soil conditions at the proposed groundbed depth, are suitable to meet
the requirements in subsection 8.2.
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ii. If sufficient distance from the pipeline can be achieved and there is no risk of
shielding.
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The anodes or the highest point of the carbonaceous backfill shall be not less than 1 metre
below ground level.
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8.2.6 Impressed current anodes and backfill

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TR

Anode material shall be selected from:

PE

i. Graphite.

ii. High silicon iron /chromium alloy.

iii. Magnetite.

iv. Metal oxide plated metal.

v. Platinised titanium/niobium.

The selected anode material, weight and dimensions shall be demonstrated suitable to cater
for the required anode current output, to cover the design life of the cathodic protection
system and shall be compatible with the soil composition.

Unless the ground conditions dictate otherwise, a carbonaceous backfill or other low
resistivity backfill material shall be used.
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For the purpose of measuring anode current outputs, individual anode circuits shall be
provided with shunts.

8.3 CURRENT CONTROL AND DISTRIBUTION

8.3.1 Current control

i. An individual negative connection shall be provided for each pipeline.

ii. If required, variable resistors shall be installed in the negative drain circuit to
balance the current to each of the adjacent pipelines. An appropriately sized
shunt and diode shall be provided at the DC source for each of the negative circuit.

iii. A distribution box for all cables, diodes and current measurement facilities shall

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be installed.

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8.3.2 Automatic potential control

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By the means of requisition, the DC voltage source shall be provided with automatic potential
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control. The suitable permanent reference electrode shall be buried close to the pipeline to
achieve this.
na

The potential measuring circuit shall have a minimum input resistance of 100 MΩ. The control
er

system shall have an accuracy of 10 millivolts and shall be provided with adjustable voltage
nt

and current limiting circuits and/or alarms to protect the pipeline against overprotection in
-I

case of failure of a reference cell. A panel mounted meter to read the pipe-to-soil potential
shall be provided.
AS

8.3.3 Cables
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All cables, cable connections and cable accessories shall be in accordance with section 12.
TR

8.4 CIVIL WORKS

PE

The Contractor shall specify in the detailed design the civil works required to install the
cathodic protection system. Such works should include transformer/rectifier plinths, deepwell
head works, mounting details of distribution boxes and test posts, cable trenches, security
fencing etc.
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9.0 SACRIFICIAL ANODE CATHODIC PROTECTION (SACP) SYSTEM

The use of a SACP system may be considered:

i. If the pipeline (section) runs in low resistivity soil, water, swamps or marshes.

ii. On short pipeline sections, for economic reasons.

iii. If no power for impressed current is available.

iv. For temporary protection on newly laid pipelines.

v. For temporary protection of existing pipelines, if pipeline isolation cannot be

immediately installed.

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vi. If it can be assumed that maintenance of electrical equipment associated with

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and Impressed current system cannot be carried out by the operator.

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vii. For localised (hot-spot) protection to supplement impressed current systems.
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If cathodic protection by sacrificial anodes is selected, the Contractor shall prove by
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measurement and calculation that:

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i. The resistivity of the soil is sufficiently low to allow successful application of

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sacrificial anodes.
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ii. The selected type of anode is capable of continuously supplying the maximum
AS

current demand.

iii. The total mass of anode material is sufficient to supply the required current during
N

the design life of the system.

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TR

The anodes should be buried in low resistivity chemical backfill to obtain the required output.
PE

The Manufacturer/Supplier of sacrificial anodes shall supply anodes which are clearly marked
with the type of material (trade name), anode weight (without backfill), and charge number.
The supplier shall provide full documentation of number, types, weight, dimensions, chemical
analysis and performance data of the anodes.

The anodes shall be inspected for mechanical damage, casting quality and the bonding of the
anode core/cable.
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9.1 ZINC ANODES

9.1.1 Zinc anodes should not be used if the resistivity of the electrolyte is greater than 1500
ohm.cm.

9.1.2 Zinc anode composition for standard applications shall be in accordance with Table 5.
Cu 0.005 max. %
Al 0.10 - 0.50 %
Si 0.125 max. %
Fe 0.005 max. %
Cd 0.025 - 0.07 %
Pb 0.006 max. %

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Zn remainder

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Table 5: Chemical composition for Zinc Anodes

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9.1.3 For non-standard applications (e.g. high temperature) special alloys may be used which shall
be approved by the Owner.
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9.2 MAGNESIUM ANODES
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9.2.1 Magnesium should not be used if the resistivity of the electrolyte is higher than 3000
ohm.cm.
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9.2.2 The use of chemical backfill around buried anodes shall be used to increase current output
and to avoid passivity.
AS

9.2.3 Magnesium anode composition for standard applications shall be in accordance with Table 6.
N
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Cu 0.02 max. %
TR

Al 5.3 - 6.7 %
Si 0.1 max. %
PE

Fe 0.003 max. %
Mn 0.15 min. %
Ni 0.002 max. %
Zn 2.5 - 3.5 %
Mg remainder

Table 6: Chemical composition of magnesium anodes

9.2.4 For special applications (e.g. high output in high resistivity soil) special alloys may be used,
which shall be approved by the Owner.

9.3 CHEMICAL BACKFILL

9.3.1 Backfill for sacrificial anodes shall consist of a mixture of gypsum, bentonite clay and sodium
sulphate. The ratio of the components shall be such to obtain optimum results in the
prevailing resistivity and soil wetness.
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9.3.2 The supplier shall include the composition of the backfill material in the anode
documentation.

9.4 CABLES AND CABLE CONNECTIONS

9.4.1 All cables, cable connections and cable accessories shall be in accordance with section 12.
Sacrificial anode cables shall be connected to the pipeline via a bondbox and shunts to allow
anode current monitoring.

9.4.2 For magnesium anodes it should be allowed to install a resistor in the anode circuit to limit
the protection levels to within the protection criteria.

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10.0 MONITORING FACILITIES

The contractor shall include in his design sufficient monitoring facilities to ensure effective
survey of the level of the cathodic protection along the pipeline. The minimum requirements
for monitoring facilities are given below.

10.1 POTENTIAL MONITORING STATIONS

10.1.1 To monitor pipe to soil potentials, test posts shall be installed at distances of maximum 1000m
along the pipeline. In urban or industrial areas a closer distance (maximum 200m) should be
taken. At least one test post shall be installed between major obstacles such as waterways,
main roads and railways to allow unobstructed close interval potential surveys.

10.1.2 Two separate cables shall be attached to the pipeline and terminated in the test post.

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10.1.3 If pipelines are running in parallel regardless in the same trench or not, each pipeline shall be

O
provided with separate potential monitoring facilities. Test posts should be installed not more
than 2.5m away from the pipeline.

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10.2 FOREIGN PIPELINE BONDING FACILITIES
na

At crossings with foreign pipelines, a bonding facility shall be provided, consisting of two
separate cables attached to each individual pipeline, terminating in a test post with suitable
er

facilities to install direct or resistive bonds. The cables to each pipeline shall be identified by
nt

colour coding or tags.

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10.3 TEST FACILITIES AT CASINGS

AS

10.3.1 If the casing is longer than 10 metres, a test facility shall be installed at both ends of the casing.
N

Shorter casings shall be provided with a test facility at one end only.
O
TR

10.3.2 In each test facility, one test cable shall be connected to the pipeline and, if a steel casing is
used, one test cable shall be connected to the casing. Both cables shall be terminated in one
PE

test post.

10.4 TEST FACILITIES AT ISOLATION JOINTS / FLANGES

10.4.1 At all isolation joints/flanges, two cables shall be connected to each side of the joint or flange.
All cables shall be separately terminated in one test post with suitable facilities to install direct
or resistive bonds.

10.4.2 The cables to each side of the isolation joint shall be identified by colour coding or tags.

10.5 DRAIN POINT TEST FACILITIES

10.5.1 At the drain points each negative connection to the pipeline shall be provided with current
measurement facilities. Where multiple negative connections are installed separate shunts
and blocking diodes shall be provided, installed in a distribution box.
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10.5.2 At the drain point a potential monitoring station shall be installed; except on an above ground
section of the pipeline, using a separate test cable connected to the pipeline for the
measurement of the drain point potential.

10.6 MISCELLANEOUS MONITORING FACILITIES

The Contractor should propose other test facilities which he considers necessary for cathodic
protection monitoring. Such test facilities may include in-line current measurement facilities,
buried polarization coupons, etc.

10.7 CABLES, TEST POSTS AND DISTRIBUTION BOXES

All cables, test posts and distribution boxes shall be designed and installed in accordance with
section 12.

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11.0 SPECIAL FACILITIES

11.1 TEMPORARY PROTECTION

11.1.1 In the case that the pipeline is to be buried in highly corrosive soil and the installation of the
permanent cathodic protection system cannot be finalized before the pipeline is buried or if
specified by the Owner, a temporary cathodic protection system shall be installed. Such a
system shall be designed in the same way as a permanent cathodic protection system with
the exception that material quantities and quality shall be adequate to cover a lifetime equal
to the time of the pipeline construction until the expected commissioning of the permanent
cathodic protection system. Anode connections shall be constructed such that they can easily
be connected/disconnected during and/or after commissioning of the permanent system.

11.1.2 The permanent monitoring facilities connected to the pipeline shall be constructed

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simultaneously with the pipeline to allow monitoring of the performance of the temporary

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system.

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11.2 PROTECTIVE CASING

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To obtain effective cathodic protection the use of pipeline casings should not be
recommended. However, if their use is mandatory, the design of the casing should be such as
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to cause minimal interference with or shielding of cathodic protection.

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11.2.1 Steel casings

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i. Steel casings shall not be coated.

AS

ii. The pipeline shall be electrically insulated from the casing using non-metallic
spacers (thinsulators).
N
O

iii. Test facilities shall be installed according to subsection 10.3.

TR

iv. The casing should be sealed using non-metallic end seals and provided with vent
PE

pipes at both ends.

11.2.2 Non-metallic casings

Non-metallic casings which act as a shield preventing the flow of protective current to the
carrier pipe shall be dried and suitable end seals and vent pipes installed. Additional cathodic
protection shall be provided to the carrier pipe inside the casing, by installing ribbon anodes
together with a zinc reference cell. Magnesium ribbons shall be attached to the carrier pipe
via a cable in a test post.
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11.3 PARALLEL POWER LINES

11.3.1 If the pipeline runs in the vicinity of high voltage power lines, the Contractor shall investigate
whether high AC voltages can be present on the pipeline by induction or otherwise and
whether devices have to be installed for protection of the pipeline and personnel.

11.3.2 The Contractor shall show (by calculation or otherwise) that no harmful voltages can be
present or design additional facilities to prevent excessive voltages.

11.4 LIGHTNING PROTECTION

In areas of lightning activity the Contractor shall install suitable lightning protection to protect
the pipeline isolation and cathodic protection equipment. This should consist of suitably rated
surge arrestors. Surge arrestors shall be mounted across isolation joints/flanges and across

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the output terminals of DC voltage sources.

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11.5 SURGE ARRESTOR

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11.5.1 Surge arrestors required to prevent elevated voltages due to faults in adjacent electrical
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power systems or lightning shall be of the spark gap type and shall be designed such that:
na

i. The impulse breakdown voltage of the electrodes is lower than that of the
isolation joint across which they are mounted.
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nt

ii. The spark gap is capable of discharging the expected lightning currents
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without sustaining damage.

AS

iii. The spark gaps are fully encapsulated to prevent sparks in open atmosphere and
to protect the spark gaps from moisture.
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11.6 MONITORING EQUIPMENT

TR

11.6.1 For regular monitoring of cathodic protection systems the equipment to be used shall meet
the following requirements:
PE

i. Portable voltmeters to measure DC voltages of cathodic protection equipment

shall have an accuracy of no worse than 1% of the voltage to be measured.

ii. In-line current meters shall not be used except for trouble shooting. Cathodic
protection currents shall be measured using fixed shunts or resistors or clamp-on
current probes.

iii. Voltmeters and other monitoring equipment used to measure pipe to soil
potentials shall have an accuracy of better than 5 millivolts and shall have an input
resistance of at least 100 MΩ.

iv. Data loggers used to monitor pipe to soil potentials over prolonged periods shall
have an input resistance of at least 100 MΩ (also in a "dormant" mode, otherwise
shall be disconnected from the pipeline or reference electrode while the data
logger is in the "dormant" mode, e.g. by an automatic relay switch).
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v. Cu/CuSO4 reference electrodes shall be used in combination with soil and fresh
water.

vi. Ag/AgCl/seawater reference electrodes shall be used in combination with saline

waters (e.g. seawater).

vii. Zinc reference electrodes shall only be used as permanent reference electrodes
in combination with soil and seawater.

viii. Reference electrodes shall be constructed such to avoid polarization of the

electrodes during monitoring in combination with the used voltmeters.

ix. Permanent reference electrodes shall be buried in moisture retaining backfill to

ensure their functioning during the design life under the prevailing conditions.

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12.0 CABLES AND CABLE ACCESSORIES

12.1 CABLES

12.1.1 All cables shall be single core stranded copper cables, suitable for DC use and shall be double
insulated and sheathed to withstand the prevailing chemical and mechanical (soil) conditions.
The minimum cable size shall be 6 mm2.

12.1.2 All cables shall be sized such that no excessive voltage drops occur which reduce the capacity
of the system.

12.1.3 Resistance of anode cables may be used to balance the output of different anodes or
groundbeds. The detailed design shall give calculations to support this design detail.

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12.1.4 In industrial or urban areas armoured cables should be used.

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12.1.5 All cables shall be laid without coils or kinks, buried in soft sand at a depth of at least 0.5m,
provided with cable protection tiles or warning tape as considered suitable for the area.

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12.1.6 All buried cables shall be of one continuous length without splices. Cable to cable connections
should be made above ground inside distribution boxes to reduce the risk of damage and to
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allow monitoring.
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12.1.7 Cable routes shall be clearly marked using cable markers. These should be installed at
nt

approximately 100 metre intervals and at every change of direction of the cable route.
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12.2 ANODE CABLE CONNECTIONS

AS

12.2.1 Minimum anode cable size shall be 10 mm2. Cable connections shall be insulated using epoxy
N

resin and/or heat shrinkable insulation sleeves.

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12.2.2 The cables of impressed current anodes shall be connected to the positive feeder cable inside
TR

an above ground distribution box to enable current monitoring. The cables of sacrificial
anodes shall be connected to the pipeline via an above ground distribution box to allow
PE

current monitoring and disconnection.

12.3 CONNECTION OF CABLES TO THE PIPELINE

12.3.1 General

i. The connections of cables to the pipeline shall be designed to ensure adequate

mechanical strength and electrical continuity and to prevent damage to the
pipeline.

ii. The Contractor shall include in the design detail procedures of processes to be
used for cable connections. The detail procedures shall be approved by Owner.
Welders shall be fully qualified for the applicable welding process.

iii. Welding of cable connections shall not be carried out on bends or within 200mm
from welds.
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iv. All below ground electrical connections shall be fully encapsulated to comply with
the original coating standards before backfilling.

v. The following guideline for the selection of cable connections shall be followed:
a) Drain cables shall be connected using welding or studwelding.
b) Bond cables shall be connected using welding, studwelding or pinbrazing.
c) Potential measuring cables shall be connected using any of the referred
methods.

12.3.2 Welding

i. A metal plate, 50x50mm minimum, provided with a welded M10 threaded stud
bolt, shall be welded to the pipeline by two continuous welds in the

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nl
circumferential direction of the pipe only. The plate shall be made of the same
material as the pipeline.

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ii. The cables shall be connected to the threaded studbolt using crimped or brazed
cable lugs, nuts and serrated washers.
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12.3.3 Stud welding
na
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i. Stud welding may be done using an electrical (resistance welding) or mechanical

(friction welding) process which shall be approved by the Owner.
nt
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ii. The stud material and consumables shall be compatible with the pipeline
material. The process shall not influence the pipeline material properties to fall
AS

outside the original specifications.

N

iii. The size of threaded studs shall be 8mm or more to suit the cable size. The cables
O

shall be connected to the stud using crimped or brazed cable lugs, nuts and
TR

serrated washers.
PE

12.3.4 Pinbrazing

i. The pinbrazing process shall use specially designed cable lugs and brazing pins to
braze the cables to the pipeline and shall be approved by the Owner.

ii. The brazing materials shall be compatible with the pipeline material. Penetration
of copper and/or other brazing metals into the pipeline shall not be deeper than
1mm and the hardness shall remain inside the original pipeline requirements.

iii. Pinbrazing shall not be used on austenitic stainless steel and duplex stainless steel
pipelines.

12.3.5 Thermit welding (Cadwelding)

i. Thermit welding process shall be such that copper penetration into the pipeline
material shall not be deeper than 1mm and that the hardness shall remain inside
the original pipeline requirements.
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ii. Thermit weld charges shall not be greater than 15 grams and cable cores shall not
be heavier than 16mm2. If heavier cables need to be attached, the core shall be
separated into smaller strands of less than 16mm2 each and welded separately.

iii. Thermit welding shall not be used for austenitic stainless steel and duplex steel
pipelines.

12.3.6 Glued connections

Where welding, brazing or thermit welding is not possible, e.g. for safety reasons, the
Contractor may design glued electrical connections using metal plates bonded with electrically
conductive epoxy resin. This method shall not be used for current carrying cables (drain
cables, bond cables). The materials to be used and the installation procedure shall be
approved by the Owner.

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12.4 TEST POSTS AND DISTRIBUTION BOXES

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12.4.1 Test posts shall provide sufficient room for the termination of test cables and for the

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installation of bonding cables and/or resistors as required by the design.
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external insulated contacts fitted, to allow easy connection of test clips for regular monitoring.
Cable entry shall be at the bottom through protective tubes.
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12.4.3 If test stations are required to be installed underground, they shall have adequate water
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drainage facilities and they shall be provided with a closure to avoid ingress of dirt.
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12.4.4 Distribution boxes shall provide sufficient room for control and test equipment. All cables shall
be connected to individual terminals.
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12.4.5 Distribution boxes shall always be installed above ground and shall be provided with hinged
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doors giving access to all internal components.

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12.4.6 Distribution boxes shall be weatherproofed in accordance with the minimum degree of
protection IP 54 in accordance with IEC 529.

12.4.7 Test posts and distribution boxes shall be accessible during all seasons and shall be designed
such that they are not prone to vandalism or damage.

12.4.8 Distribution boxes and test posts used for bonding of current carrying cables (including bonds
between pipelines/structures or across isolation joints) shall be located outside hazardous
areas. If this is not possible, a box approved for the relevant area classification shall be used.

12.4.9 The Contractor shall propose the type of test post and distribution box for each application in
the detail design.
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13.0 DOCUMENTATION

13.1 DESIGN DOCUMENTS

13.1.1 The basic design documents shall be submitted for approval by the Owner, covering the
following requirements:

i. Results of any site surveys and soil investigations that have been carried out.

ii. Results of any current drainage tests that have been carried out for retrofitting on
existing pipelines.

iii. Any requirements for modifications to existing pipeline systems such as

electrical separation or coating repair.

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iv. Justification of the selected cathodic protection system and anode materials if the

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choice is made by the Contractor.

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v. Calculations of current requirement, pipeline attenuation, resistance and current
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output of groundbeds.
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vi. A summary of the used formulae and standards.

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vii. A schematic diagram of the proposed cathodic protection system.

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viii. A list of the estimated number and types of cathodic protection monitoring
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facilities.
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ix. Any sensitivities in the proposed cathodic protection system that requires
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special attention.
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x. Any other information that is regarded by the Contractor as essential for this stage
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of the cathodic protection design.

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13.1.2 The detailed design documents shall be submitted to the Owner for approval before
construction starts and shall cover the following requirements:

i. A schedule of materials.

ii. A complete set of design drawings.

iii. Installation procedures.

iv. Commissioning procedures.

v. Operation and maintenance instructions.

13.2 MATERIAL SCHEDULES

13.2.1 To demonstrate that all materials to be procured are in accordance with this specification a
complete schedule of materials to be used for the installation of the cathodic protection
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system shall be necessary. This schedule shall include the required quantities and grades of all
materials to construct the cathodic protection system and the proposed manufacturers and
suppliers.

13.2.2 The Contractor shall include in the material schedule a list of proposed monitoring
equipment required to carry out regular surveys of the cathodic protection system.

13.2.3 The Contractor shall also include a list of proposed tools and spare parts required for
maintenance of the system during the first 5 years of operation.

13.2.4 Colour coding for cables shall be as indicated on the requisition. The Owner shall indicate on
the datasheet if existing colour codes shall be followed.

13.3 INSTALLATION PROCEDURES

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13.3.1 In ensuring that the system will be installed in accordance with this specification full

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construction details and installation procedures of the cathodic protection system shall be
necessary.

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13.3.2 These shall include:
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i. Written procedures for the installation of DC voltage sources, groundbeds, cables,

test facilities and all civil works, procedures for cable connections to the pipeline.
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ii. A time schedule for the installation of the system, where required in relation to
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the construction schedule of the pipeline.

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iii. Written procedures of all tests required to demonstrate the specified quality of
installation.
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iv. All relevant construction drawings including but not limited to plot plans,
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locations of cathodic protection stations and test facilities, cable routing, single
line schematics, wiring diagrams, groundbed construction and civil works,
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v. Written procedures to ensure safe working practices during the installation and
operation of the cathodic protection system.

13.3.3 The installation of the cathodic protection system shall start only after approval of the
installation procedures by the Owner.

13.4 COMMISSIONING PROCEDURES

13.4.1 Commissioning procedures shall prove that the installed cathodic protection system is in
accordance with the design.

13.4.2 This document shall include as a minimum:

i. Procedures for the testing of pipeline isolation.

ii. Procedures for natural potential surveys.

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iii. Procedures for energizing cathodic protection hardware.

iv. Procedures for full ON/OFF potential surveys.

v. Requirements for polarization of the pipeline.

vi. Procedures for interference testing if applicable.

vii. A time schedule for the commissioning of the system, where applicable in
conjunction with the construction or commissioning schedule of the pipeline.

viii. Required format of the commissioning report.

ix. Procedures for operation and maintenance of cathodic protection system (in

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compliance with ASME B31.4 or B31.8 which ever relevant).

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14.0 SAFETY

The Contractor shall address in his design all safety related topics regarding the cathodic
protection systems and indicate, in the installation and operating documentation, procedures
to ensure safe working practices. The Contractor shall be familiar with local safety rules and
practices and implement these in his work.

Related safety topics are:

i. General safety requirements for electrical equipment.

ii. Hazardous area classification.

iii. Accidental sparking.

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iv. Isolation flange protectors.

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v. Hydrogen and chlorine evolution.

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15.0 BIBLIOGRAPHY

In this PTS, reference is made to the following Standards/Publications. Unless specifically

designated by date, the latest edition of each publication shall be used, together with any
supplements/revisions thereto:
PETRONAS TECHNICAL STANDARDS
Index to PTS PTS 00.01.01
Requirements, General Definition of Terms, Abbreviations & PTS 00.01.03
Reading Guide
Index to Requisitions PTS 00.11.03

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BRITISH STANDARDS

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Methods of tests for soils for civil engineering purposes BS1377

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Part 3 Chemical and electrochemical tests,

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Part 9 In-situ tests
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Issued by:
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British Standards Institution

2 Park Street, London
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W1A 2BS UK
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NATIONAL ASSOCIATION OF CORROSION ENGINEERS

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Control of external corrosion on underground or NACE SP0169-2007

submerged metallic piping systems
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Issued by:
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1440 South Creek Drive,

Houston, TX,
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USA 77084-4906

INTERNATIONAL STANDARDS
Degrees of protection provided by enclosures (IP code) IEC 529
Semiconductor convertors IEC 146

Issued by:
Cental Office of the IEC,
3, Rue de Varembé,
CH 1211 Geneva 20,
Switzerland.

Preparation of steel substrates before application of paints and related ISO 8501-1
products; visual assessment of surface cleanliness
Issued by:
International Organisation for Standardisation,
1, Rue de Varembé,
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CH-1211 Geneva 20,

Switzerland.

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APPENDIX 1: SPECIMEN COPY OF DATASHEET

A specimen copy of sheet 1 of the data/datasheetsheet(s) is shown below. The latest revision
of this sheet (and its continuation sheet) shall be used and can be found in the Requisitioning
binder (PTS 00.11.03).

PROJECT NAME:
DATASHEET FOR DESIGN OF CATHODIC PROTECTION SYSTEM FOR ONSHORE
BURIED AND SHORE APPROACH PIPELINES PROJECT NO:

ORDER/ENQUIRY NO:

A PIPELINE DATA
1 Pipeline Name/Code:
2 Pipeline Route:

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3 Product(s) Transported: Sour Service

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4 Years of Construction:

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5 Design Life: years

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6 Pipeline Length: m
7 Nominal Diameter: inches
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8 Pipeline Material
9 External Coating:
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10 Backfill Type:
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11 Route Characteristic:
12 Branch Lines (use separate datasheet for each branch lines):
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13 Attached Drawings:
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B CATHODIC PROTECTION DESIGN REQUIREMENTS

1 Design Scope: Basic Detailed Both
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2 Site Survey: Required By Contractor By Others

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3 Electrical Isolation: Required By Contractor By Others

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4 Type of System: Impressed Current Voltage Source: Transformer Rectifier Other

5 Groundbeds: Deepwell Surface
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6 Horizontal Vertical
7 Autopotential Required
Control:
8 Sacrificial Anode Material: Magnesium Zinc
9 Monitoring Facilities: Required By Contractor By Others
10 Temporary Protection: Required By Contractor By Others
11 Materials Schedule: Required By Contractor By Others
12 Installation Procedure: Required By Contractor By Others
13 Test/Commissioning Procedure: Required By Contractor By Others
14 Operating/Maintenance Manual: Required By Contractor
15 Colour Code for Cables: As specified below
16 CABLE COLOUR CABLE COLOUR
17 Positive feeder Negative drain
18 Test own Test foreign
19 Bond own Bond foreign
20 I.J. side line I.J. plant side
21 Carrier Casing
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22
In shaded boxes, use ‘Y’, ‘N’ or ‘Check Mark’ to indicate selection

C INFORMATION TO BE SUBMITTED WITH THE TENDER

1 Completed datasheet (i.e. all data fields not already completed by the Principal)
2
3
4
5
D REMARKS AND/OR DESCRIPTION OF REVISIONS
1 Cathodic protection system design shall comply with PTS 11.32.01)
2
3
4
5

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Made by Date Equipment: Rev.

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letter

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Checked by Date Plant: Date

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Approved by Date Consignee: lU Sign
Sheet No 1 (cont.d on sheet No.)
Eng. by : Equipm. No.
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Owner : Req. No.

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