JOB No.

105574
DOCUMENT No. REV

REVISION
105574-DTS-Z-0005 0
Junction Boxes PAGE 2 OF 6
GENERAL
1 Service: Mansuriys pipelines cathodic protection. Site : Mansuriya, Iraq
2 Equipment/Material: Junction boxes for cathodic protection service.
3
4 Application: Main positive (anode groundbed), anode distribution boxes for pipelines and plant facilities
5
6 To Be Completed / Confirmed : By Purchaser By Manufacturer / Vendor By Purchaser or Manufacturer / Vendor
7 GENERAL
8
9 Installation Location:
10 Onshore, above grade (outdoor service).
11 Design Life:
12 30 years.
13
14 ENVIRONMENTAL DATA (Ref. 4)
15
16 Temperature : Minimum : 4 °C Relative Humidity : Minimum : 60 %
17 Maximum : 58 °C Maximum : 95 %
18 Black body radiation temperature : 85 °C Average : - %
19 m
20 Rainfall : Maximum : 51 mm
21 Average : - mm
22
23
24
25 MATERIAL DETAILS
26
27 Manufacturer : Incoming : 1 x 35mm2, XLPE/PVC dc positive header cable
28 Stock / Part № : from CP transformer rectifier (note 3).
29 Unit Weight : Outgoing : 14 x 16mm2, XLPE/PVC anode cable tails, plus 2
30 Dimensions : Sized to suit application and heat spare (notes 3 and 4).
31 dissipation requirements. Current Rating : Groundbed design current output of 75 A.
32 Material : 316L Stainless Steel Internal Fittings : Brass (c/w double nut, flat and lock washers.
33 Coating System : As per 105574-SPC-Z-0002 RAL 1004 Copper bus.
34 Degree of Protection : IP 65 minimum Security : Padlockable / Lockable (c/w multiple key sets.
35 Mounting : Hot dip galvanised MS angle frame, (3 minimum).
36 by Vendor. Door : Hinged (left hand side), removable
37 Fixing Board / Panel : Phenolic 6mm thick Connections : Bolted or compression terminals
38
39 INTERNAL HARDWARE
40
41 Cabling : Tri Rated High Temperature Cable
42 Cable Identification : Numerical Cable Identification by Circuit Number (By Ferrule)
43 Circuit ID: By Traffolyte Label
44 Shunt : Current measuring shunts (5A = 100mV) RS Holloway type (or Company approved equivalent)
45 Variable Resistor : Grid coil variable resistor (0-5 W)
46 Blocking Diode : Rating to Suit Power Requirement
47 Earthing : M10 Bolt
48
49 EXTERNAL HARDWARE
50
51 Cable Entry : Via removable gland plate arranged for bottom cable entry. Gland plate to be drilled to suit glanded entry, and
52 supplied blanked for shipping
53 Cable Transitions : Cable transition to be via Nickel plated glands through bottom entry removable gland plate.
54 Cable Runs : Cable runs above grade to be run via cable tray.
55 Marking : Name plate / tag №‘s shall be in accordance with Material Requisition and ES 30.99.37.0003
56 Units shall be identified as a “ADCO – CATHODIC PROTECTION JUNCTION BOX”.
57 Name plates (stamped or engraved on 316L stainless steel plate) shall contain the following information as a
58 minimum:
59 Name of manufacturer / date of manufacture
60 Service, e.g. “Positive (Anode) Junction Box”
61 Earthing : M10 Bolt
62
 JOB No. 105574
DOCUMENT No. REV

REVISION
105574-DTS-Z-0005 0
Junction Boxes PAGE 3 OF 6

1 INSPECTION AND TESTING

2
3 Vendor to submit proposed testing procedures and frequency for COMPANY review and approval.
4 Certification: To EN 10204, subclause 3.1 (Ref. 3) and per the document requirements detailed in the MR.
5
6 MARKING
7
8 In accordance with project requirements.
9
10 PACKING AND SHIPPING
11
12 In accordance with project requirements.
13 Vendor to confirm shipping weight, dimensions, and storage requirements. To be supplied crated for shipping or storage, strapped
14 with adequate protection against damage.
15
16 VENDOR DOCUMENT REQUIREMENTS
17
18 Vendor to supply: To EN 10204 (Ref. 3) and per the document requirements detailed in the Material Requisition
19 GA drawing with component layout and mounting details.
20 Design type approval (certificate) for enclosures
21 Shop / Fabrication Drawings
22 Wiring Schematics
23 Heat dissipation calculations
24 Installation, assembly Instructions and foundation requirements
25
26 NOTES
27
28 1) SUPPLIER shall be fully responsible for the mechanical design, manufacture, testing, certification, & supply of materials
29 2) All nameplates and labels shall be in English.
30 3) Cable gauges subject to volt drop requirements (to be verified).
31 4) Circuit quantity to suit individual application (in accordance with material requisition).
32
33 CODES, STANDARDS, & PROJECT DOCUMENTS
34
35 1) NACE SP0169 Control of External Corrosion of Underground or Submerged Metallic Piping Systems
36 2) IEC 60529 Degrees of Protection Provided by Enclosures (IP Code)
37 3) EN 10204 Metallic Products - Type of Inspection Documents
38 4) 105574-BOD-P-0002 Basis of Design
39 5) 105574-DTS-Z-0003 Cathodic Protection Data Sheet - Cable
40
41
42
43
44
45
46
47
48
49
50
51
52 REVISION DESCRIPTION
53 Rev. Section Reason For Revsision
54
55
56
57
58
59
60
61
62
 JOB No. 105574
DOCUMENT No. REV

REVISION
105574-DTS-Z-0005 0
Junction Boxes PAGE 4 OF 6
GENERAL
1 Service: Mansuriya pipelines cathodic protection. Site : Mansuria, Iraq
2 Equipment/Material: Junction boxes for cathodic protection service.
3
4 Application: Main negative distribution boxes for pipelines and plant facilities
5
5 To Be Completed / Confirmed : By Purchaser By Manufacturer / Vendor By Purchaser or Manufacturer / Vendor
6 GENERAL
7
8 Installation Location:
9 Onshore, above grade (outdoor service).
10 Design Life:
11 30 years.
12
13 ENVIRONMENTAL DATA (Ref. 7)
14
15 Temperature : Minimum : -10 °C Relative Humidity : Minimum : 5 %
16 Maximum : 55 °C Maximum : 100 %
17 Black body radiation temperature : 85 °C Average : - %
18
19 Rainfall : Maximum : - mm
20 Average : 254 mm
21
22
23
24 MATERIAL DETAILS
25
26 Manufacturer : Incoming : 1 x 35mm2, XLPE/PVC dc negative header cable
27 Stock / Part № : from CP transformer rectifier (note 3).
28 Unit Weight : Outgoing : 14 x 16mm2, XLPE/PVC negative distribution/anode
29 Dimensions : Sized to suit application and heat header cables (as appropriate), plus 2 spares (note 4).
30 dissipation requirements. Current Rating : Groundbed design current output of 75 A.
31 Material : 316L Stainless Steel Internal Fittings : Brass (c/w double nut, flat and lock washers.
32 Coating System : As per 105574-DTS-Z-0002 RAL 1104 Copper bus.
33 Degree of Protection : IP 65 minimum Security : Padlockable / Lockable (c/w multiple key sets.
34 Mounting : Hot dip galvanised MS angle frame, (3 minimum).
35 by Vendor Door : Hinged (left hand side), removable
36 Fixing Board / Panel : Phenolic 6mm thick Connections : Bolted or compression terminals
37
38 INTERNAL HARDWARE
39
40 Cabling : Tri-rated high temperature cable
41 Cable Identification : Numerical Cable Identification by Circuit Number (By Ferrule)
42 Circuit ID : By Traffolyte Label
43 Shunt : Current measuring shunts (0.01 W RS Holloway type or Company approved equivalent)
44 Variable Resistor : Grid coil variable resistor (0-5 W)
45 Earthing : M10 Bolt
46
47
48 EXTERNAL HARDWARE
49
50 Cable Entry : Via removable gland plate arranged for bottom cable entry. Gland plate to be drilled to suit conduit entry, and
51 supplied blanked for shipping
52 Cable Transitions : Cable transition to be via conduit through bottom entry removeable gland plate.
53 Conduit Details : Galvanized steel conduit, hubs, nipples, and insulated bushings required to suit.
54 Marking : Name plate / tag №‘s shall be in accordance with Material Requisition.
55 Units shall be identified as a “CATHODIC PROTECTION JUNCTION BOX”.
56 Name plates (stamped or engraved on 316L stainless steel plate) shall contain the following information as a
57 minimum:
58 Name of manufacturer / date of manufacture
59 Service, e.g. “Negative Distribution Junction Box”
60 Earthing : M10 Bolt
61
62
 JOB No. 105574
DOCUMENT No. REV

REVISION
105574-DTS-Z-0005 0
Junction Boxes PAGE 5 OF 6

1 INSPECTION AND TESTING

2
3 Vendor to submit proposed testing procedures and frequency for COMPANY review and approval.
4 Certification: To EN 10204, subclause 3.1 (Ref. 3) and per the document requirements detailed in the MR.
5
6 MARKING
7
8 In accordance with project requirements
9
10 PACKING AND SHIPPING
11
12 In accordance with project requirements
13 Vendor to confirm shipping weight, dimensions, and storage requirements. To be supplied crated for shipping or storage, strapped
14 with adequate protection against damage
15
16 VENDOR DOCUMENT REQUIREMENTS
17
18 Vendor to supply: To EN 10204 (Ref. 3) and per the document requirements detailed in the Material Requisition
19 GA drawing with component layout and mounting details
20 Design type approval (certificate) for enclosures
21 Shop / Fabrication Drawings
22 Wiring Schematics
23 Heat dissipation calculations
24 Installation, assembly Instructions and foundation requirements
25
26 NOTES
27
28 1) SUPPLIER shall be fully responsible for the mechanical design, manufacture, testing, certification, & supply of materials.
29 2) All nameplates and labels shall be dual language (Russian (first) and English (second)).
30 3) Cable gauges and conduit details for transitions subject to volt drop requirements (to be verified).
31 4) Circuit quantity to suit individual application (in accordance with material requisition).
32
33 CODES, STANDARDS, & PROJECT DOCUMENTS
34
35 1) NACE SP0169 Control of External Corrosion of Underground or Submerged Metallic Piping Systems
36 2) IEC 60529 Degrees of Protection Provided by Enclosures (IP Code)
37 3) EN 10204 Metallic Products - Type of Inspection Documents
38 4) 105574-BOD-P-0002 Basis of Design
39 5) 105574-DTS-Z-0003 Cathodic Protection Data Sheet - Cable
40
41
42
43
44
45
46
47
48
49
50
51
52 REVISION DESCRIPTION
53 Rev. Section Reason For Revsision
54
55
56
57
58
59
60
61
62
 JOB No. 105574
DOCUMENT No. REV

REVISION
105574-DTS-Z-0005 0
Junction Boxes PAGE 6 OF 6

SKETCH

1
2
3 Galvanised MS Angle (50x50x5) Support
4 Frame

5
6
7
8
316L Grade Stainless Steel Sheet Enclosure to IP65,
9 With Hinged Gasketed Key Lockable Door, c/w 4 No.
Mounting lugs, & Internal Earth Stud.
10
11
12 6 mm thk. Phenolic Insulating Panel
13
14 Solid Copper Bus Bar
15
16 Tri Rated Cable
17
Grid Coil
18 Resistor
19
20
21
22
23
MAIN -VE

24
25
26
27
28
29
30
31
LINE X

SPARE
LINE Y

32
33 5A = 100mV Current Shunt
34
35
36
Traffolyte Label
37
38 Typical Installation Detail
39 (Main Negative Distribution Box)
40 TYPICAL PANEL DETAIL
2 way + 1 “spare” circuit shown
41 (actual № of circuits to be per MR)
42
43
44
45