Vol-I Scope of Wotk & Design Basis, QAP & Data Sheets

BARMER- PALANPUR PIPELINE
OIL & GAS SBU

PROJECT (BPPL)
MECON LTD, DELHI

HPCL
TITLE DOCUMENT NO. Page 1 of 2

TABLE OF CONTENT
REVISION 0
TABLE OF CONTENT
Sl No. Description Document No./ Drawing Rev. No. Pages

No.
MATERIAL REQUISITION, DESIGN BASIS, SCOPE OF WORK
1 Design Basis for CP MEC/23VE/05/E9/E/000/001 Rev. 1 17
system
Scope of Work MEC/23VE/05/E9/E/000/002 Rev. 1 44
STANDARD SPECIFICATIONS
3 Corrosion Survey MEC/S/05/21/016C Rev. 3 4
4 Temporary Cathodic MEC/TS/05/E9/016A Rev. 4 21
Protection System
5 Permanent Cathodic MEC/TS/05/E9/016B Rev. 4 33
Protection System
6 Cathodic protection MEC/TS/05/E9/082A Rev. 3 9
Transformer rectifier
(TR) unit
STANDARD DATA SHEETS & QAP (Quality Assurance planning)
8 Cathodic protection MEC/DS/05/E9/082A Rev. 1 6
Transformer rectifier
(TR) unit
11 Quality Assurance Plan MEC/05/E9/QAP/23VE/001 Rev. 0 2
STANDARD DRAWINGS
12 Prepacked Zinc Anode MEC/SD/05/E9/E/CP/1601 Rev. 1
13 Prepacked Mg Anode MEC/SD/05/E9/E/CP/1602 Rev. 1
14 Details of Test Station MEC/SD/05/E9/E/CP/1604 Rev. 1
for TCP
15 Test Station Connection MEC/SD/05/E9/E/CP/1605 Rev. 2
Schemes
16 Galvanic Anode MEC/SD/05/E9/E/CP/1606 Rev. 1
Installation
17 Zinc Ribbon Anode for MEC/SD/05/E9/E/CP/1607 Rev. 1 N/A
Cased Crossings with
Coated Casings
18 Pipeline Grounding MEC/SD/05/E9/E/CP/1608 Rev. 1
Through Polarisation
Cell and Galvanic
OIL & GAS SBU
PROJECT (BPPL)
MECON LTD, DELHI

HPCL
TITLE DOCUMENT NO. Page 2 of 2

TABLE OF CONTENT
REVISION 0
Anodes
19 Details of Zinc MEC/SD/05/E9/E/CP/1609 Rev. 1
Grounding Cell
20 Permanent Copper – MEC/SD/05/E9/E/CP/1610 Rev. 0
Copper Sulphate
Reference Cell &
Installation Details
21 Shallow Anode Ground MEC/SD/05/E9/E/CP/1611 Rev. 1
Bed (PCP)
22 Anode Lead Junction MEC/SD/05/E9/E/CP/1612 Rev. 2
Box
23 Casing Pipe Detail MEC/SD/05/E9/E/CP/1613 Rev. 1
24 Test station for MEC/SD/05/E9/E/CP/1614 Rev. 1
polarization cell
25 Deep well anode bed MEC/SD/05/E9/E/CP/1615 Rev. 1
26 Connection scheme for MEC/SD/05/E9/E/CP/1616 Rev. 1
hoocking through
CJB/TLP
27 Details of thermit weld MEC/SD/05/E9/E/CP/1618 Rev. 1
for cable to pipe joint
28 Installation details of MEC/SD/05/E9/E/CP/1619 Rev. 0
Polarization Coupons
29 Earth Electrode in Test MEC/SD/05/E9/02/1601 Rev. 1
Pit
LIST OF ATTACHMENTS (For Tender Purpose)
29 P&ID’s
30 Schematic route diagram
31 Plot Plan
32 Alignment & Crossing
Sheets
HINDUSTAN PETROLEUM CORPORATION LTD
DESIGN BASIS FOR CATHODIC PROTECTION

SYSTEM
BARMER- PALANPUR PIPELINE PROJECT (BPPL)
MECON LIMITED DELHI

(ELECTRICAL SECTION)
Document No. Revision No. Date
MEC/23VE/05/E9/CP/001 1 26.06.2020
© Copyright MECON Limited – All rights reserved.
THIS DOCUMENT IS THE SOLE PROPERTY OF MECON AND ISSUED FOR THE SPECIFIC PROJECT MENTIONED HEREIN. THIS IS NOT TO
BE COPIED OR USED FOR ANY OTHER PROJECTS UNLESS EXPLICITLY PERMITTED BY MECON.
MECO
ON LIMITED BARMER- PALANPUR P
PIPELINE
Ele
ectrical Sectio
on, Delhi
DELHI PROJECT (BPPL)
Basic Engineering De
esign Basis--Cathodic Protection
P MEC/23
3VE/05/E9/C
CP/001 Page 1 of 17
7
System
Conten
nts
Sl. No. DESCRIIPTION
1. IN
NTRODUC
CTION
2. S
SCOPE
3. C
CODES & STANDAR
S RDS
4. S
SITE COND
DITIONS
5. A
AREA CLA
ASSIFICAT
TIONS
6. P
POWER SU
UPPLY DE
ETAILS FO
OR CP SYS
STEM
7. C
CATHODIC
C PROTEC
CTION SYS
STEM DES
SIGN
8. P
PROTECTI
ION OF PIIPELINE AT
A HT LINE
E CROSSIING
9. C AT CAS
CP SED CROS
SSINGS
10. CATHODIC
C C PROTEC
CTION DES
SIGN CRIT
TERIA
11. CP
C CABLE
ES
12. STATUTOR
S RY APPRO
OVAL
13. DRWINGS
D AND DES
SIGN DOC
CUMENTS
APPENDIX-I : LIS
ST OF ABB
BREVIATIO
ONS
Rev. No
o. Datte Prepared By
B Checke
ed By App
proved By
Aashis Moyyal,
A M.K.Jaisswara, D.G. Majumder,
M
0 17.04.2
2020 Sr.MGRR Sr.MG GR GMM (E&I)
1 26.06.2
2020 A
Aashis Moyyal, M.K.Jaiswara, D.G. Majumder,
M
© Copyrigh
ht MECON Limite
ed – All rights res
served.
THIS DOCUUMENT IS THE SOLE PROPERTY Y OF MECON ANDD ISSUED FOR THE
T SPECIFIC PR
ROJECT MENTIO
ONED HEREIN. TH
HIS IS NOT TO BE
COPIED ORR USED FOR ANY Y OTHER PROJE ECTS UNLESS EX
XPLICITLY PERM
MITTED BY MECOON.
MECO
PIPELINE
Ele
ectrical Sectio
on, Delhi
P MEC/23
3VE/05/E9/C
CP/001 Page 2 of 17
7
System
1.0 INTRODUCT
TION
HPPCL proposses to lay crross countryy POL pipeline from ne

ew Barmer Station in Rajasthan to
exxisting receiiving Palan
npur Installlation of MD
DPL in Gujjarat.
Th
he project iss named as Barmer-Pa
alanpur Pip
peline (BPP
PL) Projectt.
Sa
alient feature
es of the prroject are ass below:
Orriginating Po
oint : Barmer Cross Country P/L Sta
ation (in HR
RRL Refinerry).
SV
Vs,IPS : Total 4 SVs
S and 01 IPS.
En g Terminal : Existing Palanpur POL

nd Marketing P Installation (MDPL
L)
Pro
oducts : MS, HS
SD and SKO
O
Crross-countryy PL (18” x 216.3 km approx.)

a from
m DT Barmer to RT Pa alanpur.- (SSection I- 18
8” x
10
06.8 km app prox. ; Section II- 18” x 109.5 km approx.) inccludes 4 No os. SV, 1 No.
N IP Statio on-
pip
ping & valve
e station including civil, structural
s works for SV pit – (cage / fencing)
Th
his documen nt presents design criteeria for TCP P & PCP syystem for 3 3LPE Coated multiproduct
pip
peline again
nst corrosion
n for a servvice life of 40
4 years. It indicates m quirements for
minimum req
de
etailed design of CP sysstem and eqquipments.
In case of anyy conflict be sis & codes// standards listed, the same shall be
etween the design bas
bro
ought to thee notice off Owner/Consultant forr final decission, stringe
ent of the same
s shall be
out any additional time and
followed witho a cost to HPCL.
H
2.0 SC
COPE
Suurvey, Design, detailed engineerring, supply y, packing, transportaation to site

e, installatio
on,
tessting and co
ommissionin ng of the temporary ca athodic prote
ection syste
em using Mg/ Zn galva anic
annodes for deesign life of minimum 2 years or till the comm missioning oof PCP systtem whichevver
is later, to protect the external su urface of 18” NB x 216.3
2 Kms. (approx.) pipeline fro om
Deespatch Terrminal at Ba armer (Ch 0.00km)
0 to Receiving Terminal
T att Palanpur (Ch
( 216.3 km)
k
aggainst corrossion. ICCP based Perm manent Cathodic Prote ection system is also envisaged fo or a
service life of 40 years to
o protect thee external surface
s of Pipeline.
P TCP & PCP sy ystem shall be
deesigned as per MECO ON’s stand dard Specification No o. MEC/S/0 05/E9/016A A & 16B for
Teemporary & Permanen nt cathodic protection system re espectively & Scope of o Work, Da ata
Shheets & Other relevant standards.
3.0 CO
ODES & STANDARD
S DS
Th
he system design, pe erformance and mate
erials to be
e supplied shall, unle
ess otherw
wise
specified, co onform to the requirements of
o the following late est relevant applicable
specificationss:
I) NACE Standard
S SP
P-0169 : Standard Practice Contro
ol of Extern
nal Corrosio
on
on
n Underground or Sub bmerged Metallic
M Piping
Sy
ystems.
MECO
PIPELINE
Ele
ectrical Sectio
on, Delhi
P MEC/23
3VE/05/E9/C
CP/001 Page 3 of 17
7
System
II) NACE Publication

P 10A190 : Meeasurement technique related to criteria
c for
CP
P of Underrground or Submerged d Steel Piping
Sy
ystem (as defined
d in N
NACE Stand dard RPO16 69-
83
3)
III) NACE Standard
S SP
P-0177 : Standard Practice Miitigation of o Alternating
Cu
urrent and d Lightning g Effects on Meta allic
Structures an
nd Corrosion n Control Sy ystem.
IV) NACE Standard
S SP
P-0186 : Ap
pplication off cathodic p
protection foor external
Su
urface of ste
eel well cassings
V) NACE Standard
S SP
P-0286 : Standard Practice the ele ectrical isolation of
Ca
athodically Protected
P P
Pipelines.
VI) NACE Publication

P No. 54276 : Caathodic Prottection Mon nitoring for Buried
B
Pipelines
VII) NACE Standard
S SP
P-0572 : Standard Prractice for Design, Installation &
Opperation of Impressed d Current Deep Grou und
be
eds
VIII) NACE Standard
S SP
P-200 : Standard Practice for Ste eel Cased Pipeline
P
Crrossings
IX) NACE Standard
S SP
P-0104 : Th
he Use of Coupons
C for Cathodic Protection
Mo onitoring Ap
pplications
X) BS 7361
1 Part I : Coode of Practice for Cathodic Prote ection for lan
nd
nd Marine applications
an
XI) VDE 0150 : Prrotection against Corroosion due to o Stray
Cuurrent from DC Installaations
XII) IS: 7098
8 Part I : XL
LPE insulate ed cables.
XIII) IS: 1554

4 Part I & II : VC Insulated heavy duty electricall cables.
PV
XIV) IS: 8062

2 : Coode of practtice for cath
hodic protec ction of
ste
eel structure
es
XV) NACE TM
T 0497 : Meeasurement Technique es Related to t Criteria
forr Cathodic Protection
P o
on Undergro ound or
Suubmerged Metallic
M Piping Systems s
XVI) NACE SP21424
S : Altternating Cuurrent Corroosion on Ca athodically
Prrotected Pippelines: Riskk, assessment, mitigation
& monitoring
XVII) ISO 155
589 : Peetroleum, peetrochemica al and naturral gas
ind
dustries — Cathodicc protection n of pipeline
sy
ystems —Pa art 1: On‐lannd pipeliness
XVIII)) OISD 11
13 : Classification of Area forr electrical installationss at
Hyydrocarbon processing g and handliing facilitiess
XIX) OISD 14
41 : De
esign and re
equirement of Cross Country
C
Pipelines
XX) OISD 18
88 : Co
orrosion Mo
onitoring of O
Offshore & Onshore
XXI) NACE TM0101

T : Meeasurement techniques related to
o criteria for
ca
athodic prote
ection
XXII) ASTM B418

B : Ca
ast and Wro
ought Galva
anic Zinc An
nodes
MECO
PIPELINE
Ele
ectrical Sectio
on, Delhi
P MEC/23
3VE/05/E9/C
CP/001 Page 4 of 17
7
System
XXIII)) ASTM B843

B : Maagnesium Alloy
A Anodees for cathod dic protectio
on
XXIV)) ASTM G57
G : Fie
eld measure
ement of so
oil resistivity
y using
we
enner four pin
p electrode method
XXV) BS EN 50162
5 Prote
ection again
nst corrosio
on by stray current
c from
m direct currrent system
ms
XXVI)) BS EN 15280: Eva aluation of AC corrosion likelihoo

od of buried pipelines applicable
e to
cathodiccally protected pipeline
es
XXVIII) IS 2148: Specificattion for Flam

meproof Enc
closures of Electrical A
Apparatus
XXVIIII) IS 3043: Code of practice

p for Earthing
E
- PNGRBB Guideline for Cross country

c pipe
elines
- A.W. PEABODY
P - Book
B on con
ntrol of pipe
eline corrosion
3.2 In case of imp

ported equipments sta andards of the
t country of origin shhall be applicable if the
ese
sta
andards aree equivalentt or stringen
nt than the applicable
a Indian stand
dards.
3.3 Th
he equipme ent shall allso confirm m to the provisions off Indian Ele
ectricity rulles and oth
her
sta
atutory regu
ulations currrently in forcce in the co
ountry.
3.4 In case of anny contradicction betwe een various referred sttandards/ sspecification
ns/ data sheeet
annd statutory regulationss the follow
wing order of
o priority shall
s governn with no additional
a time
annd cost to Owner,
O strin
ngent of thee same sha wed withoutt any additional time and
all be follow a
cost to HPCL.
 Staatutory regu
ulations.
 Daata sheets.
 Scchedule of rates.
 Deesign Basis.
 Sccope of Worrk/ Job speccification.
 Staandard Spe ecification.
 Coodes and standards.
4.0 SITE CONDITIONS
Thhe equipment offered and

a the insstallation sh
hall be suita
able for con
ntinuous op
peration und
der
the
e following site
s conditio
ons:
Am
mbient temp perature : 55°C/ 2˚C
C (max./min)
Maax relative humidity
h : 90%
Alttitude : less than 1000 m
Atmmosphere : To withsta
and site con
ndition
(Dust sto
orm & High Temperatur
T re during su
ummer and
Low temp perature du
uring winter))
5.0 AR
REA CLAS
SSIFICATIION
Cla
assification of hazardo
ous area will be in acco
ordance with
h BIS and IS
S: 5572.
MECO
PIPELINE
Ele
ectrical Sectio
on, Delhi
P MEC/23
3VE/05/E9/C
CP/001 Page 5 of 17
7
System
Fo
ollowing sele
ection will be
b considerred for prop
per selectio
on of electriical equipm
ment for use
e in
ha
azardous areea:
a) Area Classsification : Zone-1 & Zone 2
b) Gas Group
p : IIA and IIB
B
c) Temperature Classificcation : T3
All electrical equipment

e installed in hazardous
h area
a will be
e selected as per IS: 55
571.
All the electrrical equipm

ment for ha azardous areas shall be of Ex-d d type suitaable for temp
cla
assification T3. All ele be certified by CMIFR or
ectrical equiipment for hazardous area will b
equivalent inddependent testing
t ncy and valid PESO liccense shall be available
agen e.
6.0 PO
OWER SUPPLY DET
TAILS FOR
R CP SYS
STEM
Fo
or all statio
ons (DT, SVV, IP & RT
T) along the
e pipeline, Power su
upply to CP
P system (T
TR
un
nit) shall be
e as followss-
i) 230V AC+/- 10%

%, 50 Hz+//- 5% - Pow
wer Supplyy.
7.0 CA
ATHODIC PROTECT
TION SYSTEM DESIGN
7.1 Te
emporary Cathodic Protection (TCP) sy
ystem
A
A. Type
e Sa
acrificial
B
B. Prote
ection to Pipeline
P (TC
CP) Immediately after lowerring but no ot later
after lowering tha
an 15 dayss from the ttime of low wering of
pip
peline segm ments (Reffer penalty clause in
the
e scope of work for fu urther dely)
C
C. Desig
gn life 2 Year
Y or till commissio
c oning of PC
CP
whhichever is later. In ca ase of
com mmissionin ng of PCP is delayed d, Pipeline
con ntractor sh hall ensure that pipeline is fully
prootected by installing a additional anodes
a
forr extending g the life, In
n case PCP P is in
sep parate pacckage it is rresponsibility of the
PCCP contracttor withoutt any cost and a time
imp plication too Owner.
D
D. Pipeline coating Three Layer Polyethyle ene
E
E. Prote
ective curre
ent densities As mentioned
d in Table#
#1
F
F. Prote
ective curre
ent Densityy As per speciffication
G
G. Anod
de material (for sacrificial Sa
acrificial Mg
g/ Zn (Low Potential as
a per
CP System)
S spe
ecification)).
MECO
PIPELINE
Ele
ectrical Sectio
on, Delhi
P MEC/23
3VE/05/E9/C
CP/001 Page 6 of 17
7
System
H
H. Electtrical resisttance prob
bes Shall be provvided as pe
er specifica
ation
a) Qu
uantity of E/R
E probess 02 nos for ea
ach laying ssection
b) No
o. of E/R probe
p 01 nos for ea
ach laying ssection
reading instrum
ment
I. Polarization ce
ell So
olid state tyype (shall b
be provided
d as per
spe
ecification//scope of wwork)
J
J. Polarization co
oupons Shall be provvided as peer
spe
ecification//scope of w
work
a) Size of expo
osed area of
o 25mm x 25m mm in housing of 100x
x100 mm
couppon (as
s per the re
equirement of NACE
SPP104:2014))
b) Noo. of coupo
ons & maggnetic As per scope e of work (M Min 1 at ev
very 10
devissed with re
eed switch KMM with mag gnetic reed switches) and
addditional loccations in ccorrosion prone
p
are
ea observe ed during th he soil surv
vey.
Loccation To beb decided d by CP coontractor
in consultatio
c on with Ow wner/ Consultant
c) Prroposed loccation of E/R
E To be decid ded by CP P contracttor during
probes / Polarizzation Couupons dettail engineering base ed on
speecificationss and in cconsultation n with the
Owwner/Consu ultant
K
K. No. of
o test stations At an average distance e of 1Km innterval
alo
ong the pip peline ROW W and additional test
sta
ations as pe er standarrd specifica
ation for
TCCP.
L
L. Surgge Arrestorr (Spark-Ga ap Shall be provvided at Inssulating joints and
type))- Surge arrrestor shaall be shaall be rated
d for the lig
ghtning andd surge
suita
able for the
e installation in prootection (1000kA for -110/350 uS lighting
explo
osion proof area currrent and 8/20
8 uS surge current). There
shaall be no jo
oints in Surrge diverte
er cable
acrross the IJ.
M
M. Earth
hing of MO
OVs All MOVs in nstalled on n the crosss country
portion shall be doub ble earthed d through
sollid state de
e-coupler a and zinc anodes, so
tha
at it will noot allow CCP currentt to drain.
Armmour of ca ables of MO OVs installled on the
cro
oss couuntry poortion shall be
dis
sconnected d at MOV e end so thatt it will not
allo
ow CP current to drain.
N
N. All Cathodic
C Prrotection Eaarthing of CP
C unit will be carried d out with
equippment shaall be suitab
bly the
e station eaarthing. IECC 6230 5 shall
s be
earth
hed in accoordance wiith connsidered inn case of lightning onn the
MECO
PIPELINE
Ele
ectrical Sectio
on, Delhi
P MEC/23
3VE/05/E9/C
CP/001 Page 7 of 17
7
System
the requiremen nts of India

an peline and size of bon
pip nding
Electtricity Rule
es and IS: 3043
3 connductors/ggrounding cconductor for
f the
imppulse (10/3350 us) & ssurge (8/20
0 us)
shaall be acco
odingly.
No
ote -1 Po olarization
n coupon ns shall be installed along with the pipeline
co
onstruction activitie
es and cou
upons OFF PSP shaall be take
en during the month
hly
moonitoring of the TCPP system..
TC
CP Pipelin
ne Protectiion curren
nt density
Table#1
Pipeline surrou unding Minimum
M Protectio
on curren
nt density*@30
Resistivity d C
deg
Temporary CPP
(µ
µA/m²)
Normaal Soil (10--100 50
O
Ohm-Mtr)
Marshy Area/ HDD D (<10 125
O
Ohm-Mtr)
High Resistivity
R A
Area 35
(more th
han 100 ohm-mtr.
R
Resistivity)
Pip
pe to soil "ON"
" poten
ntial shall not
n be more
e negative
e than (-) 1.2V during TCP.
* Acctual curreent density to be ad dopted sha

all be decided based d upon so oil and oth her
ennvironmenta al conditioons, proximity of fo oreign pip pelines an nd structurres affectiing
intterference. Where co onsidered necessary y for satisffactory prootection of pipeline the
t
cuurrent density shall be
e suitably in
ncreased by
y contractoor as per de
esign and quoted
q pricces
shhall be inclu
usive of sa
ame. Wherre operating temperattures of U//G pipeline e is above 30
deeg. C, such as CP Stations lo ocated neaar Compre essor statio
ons, protecction Curre ent
Deensity shalll be increased in minimum by 25%
2 for eve
ery 10 °C rrise in temp
perature ovver
300 °C up to a temperatu ure of 60 deg.C.
7.2 Pe
ermanent Cathodic Protection (PCP) System
A
A. Type
e Im
mpressed current
c type
e
B
B. Desig
gn life of protection
p 5 Years
35
C
C. Pipeline coating hree Layerr Polyethylene
Th
D
D. Desiggn protection currentt As
s mentione
ed in Table
e#2
denssity
E.
E Pipeline coating resistancce Max.
M 15000 Ohm-M2
F
F. Loopp resistance of PCP <0
01 Ohm
syste
em
MECO
PIPELINE
Ele
ectrical Sectio
on, Delhi
P MEC/23
3VE/05/E9/C
CP/001 Page 8 of 17
7
System
G
G. Type
e of Anodes for anode
e Tu
ubular mixxed metal oxide titan nium tubular
ground bed with individu ermination in AJB.
ual cable te
H
H. Anod
de bed con
nfiguration Deep well or o Shallow bed (Perp pendicular to
Piipeline)
I. Backkfill materia
al Carbonaceo ous back-fill [lubricate
ed calcined d
pe
etroleum coke breeze e]
J
J. Polarization ceell Soolid state type (shall be provide ed where
ev
ver HT line e crossing a are there or
o running
pa
arallel as per
p specificcation)
Thheft proof provision
p sshall be proovided in th
he
TLLP by weld ding the neecessary cllamps over
th
he SSD.
K
K. Permmanent Reff Cell (PRCC) Peermanent Ref cell fo or PCP sys stem shall be
high purity zinc type. There shall be min n 3
no
os. of permane ent reference c
cell
(e
electrodes)) at each C CP station.
Addditional PRC
P shalll be provided on the
un
nprotected size of IJ to meas sure PSP of
un
nprotected side and d shall be e integrated
with CPTR//PLC, furth her PSP reading
r shhall
be
e taken to PLC//SCADA for remo ote
monitoring.
m CPTR sha all also haave provision
to
o terminate e the addittion reference cell and
4--20mA sign nal to interrface with PLC.
P
L
L. Commputerized test stationns Ass per scopes of work (L Location of
(GSM M based) co
omputerize ed test stattion shall be
b decided in
de
etail engin neering). Theft proof provision
sh
hall be proovided in th he TLP by y welding the
ne
ecessary clamps
c oveer the CTSU.
a) No.
N of computerizedd test Ass per sccope of work & Location in
statio
on readerss / portable
e data co
onsultationn with o owner/consultant (02
collection & storage no
os./sectionn)
uments.
instru
b) Intterval for data

d acquissition/ Once every day (Refer Note belo
ow)
storin
ng
M
M. Acqu uisition of la
and or Leaase Byy Bidder, Installatio
on location and type
(for 99
9 years/ass per statu uary sh
hall be decided byy CP sys stem Bidd
der
regulations) forr Anode be ed, ba
ased on detailed d engine eering, soil
s
Anod de junction n boxes and d re on and at
esistivity survey, sspecificatio
anod de ground bed ROU for f av
vailability of
o power so
ource and land.
cablee laying. (TTitle transfe
er in
the name
n of thee Owner)
N
N. Chain link fenccing around d the Sh
hall be pro
ovided arou
und the AG
GB.
ground Bed
MECO
PIPELINE
Ele
ectrical Sectio
on, Delhi
P MEC/23
3VE/05/E9/C
CP/001 Page 9 of 17
7
System
POST COM
P MMISSIONING SURV VEYS (Sha all be carrried our prreferably one
o
(1
1) month after
a the commissio
c oning of Im
mpressed Current C Cathodic Protection
P n
system, du
uring)
O
O. Close interval potential
p lo
ogging Sh hall be carrried out
surve
ey - Every 1meter
P
P. CAT Survey (F Full Length of Shhall be carrried out in
ncluding measureme
m ent
pipelline) @ eve
ery 50m off off depth of the
t buried pipeline
pipelline ROW.
Q
Q. Addittional testss to be DCVG or CATC with frrame ‘A’ su
urvey at Full
F
ducted for identifying pipe
cond length of pip
peline
coatiing defectss/ holidays
R
R. Pearrson Surve
ey Sh
hall be carrried out att full length
h of pipeline
e
S
S. AC/DDC Interferrence Dete
ection Shhall be carried o out throug
gh softwaare
& Its Mitigation simulations as per NA
ACE & OISD
D standard
ds.
T
T. Casing & Carrier short su
urveys Sh
hall be carrried out att all Cased crossings.
(Afte
er PCP sysstem
comm missioning
g)
U
U. Coatting conducctance surrvey at Sh hall be ca arried outt at Type B (Curre ent
B typ
pe stationss & Pipeline
e measureme
m ent test stations insta
alled at eve
ery
curre
ent mappin ng 100 KM pipelline and rivver crossinngs) and also
ca
alibration ofo the currrent measu urement teest
sttations for same
s thickkness pipeline span.
V
V. Soil Survey
S andd Chemica al Sh hall be carrried out
Analyysis
W
W. Propposed locattion of CP Too be deccided by C CP Bidder. (Howevver
statio
ons/Anode
e te
entative lo ocation oof CP station are a
mentioned
m in the Sccope of Work,
W Exa
act
location shall be decided in dettail
enngineering & approval of desig
gn docume ent
in consultation with Ow
wner/Cons
sultant)*
X. CP station
ns/ anode ground
g bed for Impre
essed curre
ent system
m:-
Y. Tentative
T lo
ocations off CP statioons are me entioned inn Scope off Work, acttual numbe ers
of CP stattions shall be finalize
ed during th
he approva al of design
n documennts submittted
by the Bidder, Anyy other prroposed lo ocation sh hall be inccluded during detailled
engineerinng, if required withouut any costt implication. Howeve er PCP sys
stem shall be
designed in such a mannerr that CP stations & anode bed shalll be locatted
coinciding
g with SV / IP stationss, as far as
s possible.
MECO
PIPELINE
Ele
ectrical Sectio
on, Delhi
P MEC/23
3VE/05/E9/C
CP/001 Page 10 of 17
System
* CP sttations sho ould be deecided in such

s mann ner that Od
dd Numbe er CP statiion
shall prote
ect the full section whenever
w the
t Even number CP station between tw wo
odd numb ber CP station fails / not workin
ng. Similarrly Even Number CP station sh hall
protect the full secttion wheneever an Od dd number CP statio on betwee en Two Evven
numbers CP station n fails / not working. Basis for such calculation, ye
et again sh
hall
be Theoreetical Atten
nuation Calculations.
PCP Pipe
eline Prote
ection current density
Table#2
Pipeline surrou unding Minimum
M Protection
P n current d
density*@
@30 deg C
Resistivity Temmporary C CP
(µA/m²)
Norma al Soil (10--100 50
O
Ohm-Mtr)
Marshy Area/ HDD D (<10 125
O
Ohm-Mtr)
High Resistivity
R A
Area 35
(more th
han 100 ohm-mtr.
R
Resistivity)
* 250μA/m2
2 is considered in de
esign to ta
ake care any
a bondin
ng/addition
nal mitigatiion
meeasures.
Noote -2: - For computterized tesst station: Interval off data acquisition/stooring may be
keept for once
e in every hour. Thiss feature will
w be help pful for dettecting/trou
uble shootiing
in case of encounterinng any inteerference. However in normal case, one e reading per
p
daay is enouggh.
Noote -3: - CPTRU sha all be able to handle the full length upto the next CP C Stationn in
caase of failu
ure in nextt CP Station. Same shall be consider in Design & Datashe eet
Nootes
8.0 ENCE STU

INTERFERE UDY AND MITIGATION PROT
TECTION OF PIPEL
LINE AT HT
H
LINE CROSSING
peline Inte
Pip erference study
s shall be carried
d out by modeling
m so
oftware’s fo
or short te
erm
an
nd long terrm interfere
ences for safe
s touch
h potentialss along with AC corrosion stud dy.
Reemedial measures shall be implemented d in accord
dance with h codes & standards to
briing down the steadyy state tou uch voltagge on pipeeline beloww 15V (rmms) for safe ety
reaasons. In addition, any
a AC vo oltage indicating a current
c de
ensity of 30
3 mA/m2 or
ab
bove (assu uming 1 cm m2 sized area
a of ho
oliday / de
efect) shalll be groun
nded throu ugh
so
olid state DC de-couppling devicee to reduce
e the AC corrosion and touch potentials.
p
Where high voltage (6 66 KV and above) trransmission line runss in paralle el or crossses
the
e pipeline, the pipelin
ne shall be
e grounded d through polarisation
p n cells of suitable ratiing
(so
olid state)) & Grounding (a continuou us length of Zn R Ribbon Anodes/Copp per
co w back fill materia
onductors with al shall be
e laid along the pipe eline) shall be done at
reg
gular intervvals of maxximum 1 km
k where transmissio
t on lines run parallel within
w 1km
m of
the
e pipeline and have e separatioon distance of 50 mtrm on both h side of the pipelin ne.
MECO
PIPELINE
Ele
ectrical Sectio
on, Delhi
P MEC/23
3VE/05/E9/C
System
Mitigations resulted
r fro
om interferrence study & mitiga
ation reportt to ground
d any surgges
on
n the pipe eline that would ap ppear in case
c of trransmission line fau ults shall be
implemented d.
If any
a AC intterference is observe ed along th
he pipeline
e due to lo
ow voltage electric lin
nes
(beelow 66kV), its mitiga
ation will be
e carried out
o by mea ans of earth
hing of pipe
eline throu
ugh
poolarization cell
c has alsso been co onsidered.
Intterference detection & mitigatioon due to DC source es (i.e. HV

VDC transm mission line
es.
DCC traction, foreign pipelines pa assing parrallel, crossing etc) sshall be ca
arried out as
peer DIN 57150/VDE 01 150:Protecction again
nst corrosio on due to sstray curre
ents from DC
D
insstallations and other applicable
e standards
s.
9.0 P AT CASED CROSSINGS

CP
a) Ca
asing shalll be avoided as far as possib ble. If case
ed crossingg is unavooidable, Ba are
ca
asing is alw
ways recom mmended with
w selectting higherr thicknesss allowance as per API A
1102.
b) An
ny type of Casing
C fille
er conductive or insu
ulating (waxx/bentonite
e etc) shall not be fillled
be
etween ann nular space e of casing
g and carrie
er.
c) No
o sacrificia
al anodes (ribbon an nodes) shaall be usedd inside caasing & caarrier annu ular
sp
pace.
10.0 CA
ATHODIC PROTECT
TION DES
SIGN CRITERIA
10.1 athodic Prrotection Design

Ca D Crriteria for Cu/Cuso4
C 4 Type Perrmanent Ref
R Cell
Ca
athodic pro
otection system shall be design
ned to mee
et the follow
wing criteria:
he pipe to soil potenttial measurements shall

a) Th s be between (-) 8
850 mV (O Off) polarizzed
po
otentials with respect to a coppe
er/ copper sulphate reference
r e
electrode.
b) A positive pootential sw
wing of 50 milli
m volts and
a above shall be cconsidered as sufficie ent
to indicate th
he presence of an in nteraction situation (i.e.
( Interfe
erence on the pipelin
ne)
req
quiring investigation and incorpporation of mitigation measuress by the BIDDER.
c) Ass such therre is no lim

mit for maxximum "ON N" negative
e potential; however, in generall, it
sh
hould not be more e negative than -2500- mVV (Cu/CuS SO4). If any speccial
cirrcumstance es exist where an “O ON” potenttial of morre than -25
500 mV (CCu/CuSO4)) is
req quired to be
b applied, then it shall be brou
ught forwarrd for Ownner/Consulttant approvval
with properr justifica ation supported by y the piipeline co oating Manufacture er's
reccommenda ations.
10.2 ATHODIC PROTECTIO

CA P ON DESIGN
N CRITERIA
A FOR Zn TYPE
T PERMANENT REF
R CELL
Ca
athodic prottection systtem shall be
b designed to meet the followin
ng criteria w.r.t. Zn tyype
pe
ermanent ref cell (Electtrode):
MECO
PIPELINE
Ele
ectrical Sectio
on, Delhi
P MEC/23
3VE/05/E9/C
System
i) Th
he pipe to so oil potential measuremments shall be
b between (+) 0.266 V (Off) & (-)) 0.084 V (O
Off)
witth respect to
o a Zn/ Zn sulphate
s refe
erence electtrode.
ii) A positive
p potential swing
g of 50 mill volts
v and ab bove shall be
b considere ed as sufficiient to indicate
the
e presence of an interaaction situattion (i.e. Inte
erference onn the pipelin
ne) requiringg investigattion
and incorporation of mitigation measu ures by the BIDDER.
Noote 2: - Forr computerized test sttation: Inte

erval of datta acquisitiion/storing
g may be ke
ept
forr once in every
e hour. This feaature will beb helpful for detecting/trouble e shooting in
ca
ase of enco ountering any
a interferrence. How wever in noormal case,, one reading per day y is
en
nough.
No
ote 3: - Zn reference electrode
e s
shall be of reputed make
m and m
manufactured from Hiigh
urity Zn (Hi-Pure Zinc 99.99% AS
pu STM B418-73 Type II).
10.3 Mo
onitoring and Contrrol Signal For SCAD
DA
Digital and analogue signals asa required for mon nitoring off CP syste
em shall be
ovided in CPTR
pro C Unitt for connection to SC
CADA systtem.
CPPTR unit shall

s be prroperly inte
erfaced witth SCADA A RTU throough Hardw wired link for
va
arious analogue and digital sig gnals. All digital me
eters (Inpu
ut voltage and curre ent,
Ouutput Volta
age and Current,
C PS
SP) shall have
h RS-4885 port for serial communicatiion
an
nd all meteers shall be
e pre-wiredd serially and
a commo on RS-4855 port shalll be provid
ded
at CP unit te
erminal blocck.
De
etails of SC
CADA mon
nitoring signals are giiven below
w-
Sl MONITER
RING/ ANALOUG GE
DE
ESCRIPTION
No. CONTRROL /DIGITAL
L
1 CP TR/CP
PPSM OUT
T PUT M AI (4-20mA)
VOLTAGEE
2 CP TR/CCPPSM OU
UT PUT M AI (4-20mA)
CURRENT T
3 PIPELINE
E OVER M DI
PROTECTTED
4 PIPELINE
E UNDER M DI
PROTECTTED
5 PIPE TO SOIL
S POTE
ENTIAL M AI (4-20mA)
6 PIPE TO SOIL POTTENTIAL M AI (4-20mA)

OF UNPROTECTED D SIDE
OF THE PIPELINE
P
7 ALL REFFERENCE CELLS M DI
FAILED
MECO
PIPELINE
Ele
ectrical Sectio
on, Delhi
P MEC/23
3VE/05/E9/C
System
8 REFERENNCE 1, 2, 3 FAIL M DI (4 nos.)

NG REF CELL ON
INCLUDIN
UNPROTEECTED SIIDE (IJ)
FAIL.
9 UNIT WOORKING IN
N AUTO M DI
REF MODDE
10 UNIT WORKING
G IN M DI
MANUAL MODE MO
ODE
11 AC INPUT
T FAIL M DI
12 Battey Low
w M DI For CPPSM
M
Onlyy
13 CURRENT
T INTERR
RUPTER C DO
O
START
14 CURRENT
T INTERR
RUPTER C DO
O
STOP
15 CURRENT
T INTERR
RUPTER C DO
O
RESET
AI-- Analogue input to SC CADA/RTU

DI--Digital inpu
ut to SCADA A/RTU
DOO- Digital input from SC CADA/RTU
Twwo nos. of spare
s AI con
nvertors and DI to be connected
c f
from CPTR
RU to SCAD
DA shall be supplied
(in
ncluded in base cost) fo or future use
e.
1 AI: Analogue
A e monitoring g signal fromm Equipment to PLC/T Telemetry in nterface cab binet (TIC)
2 D Digital Monitoring sig
DI: gnal from Equipment
E to
o PLC/(TIC
C)
3 M
M-Monitoring g signal
4 C
C-Control sig
gnal
5 For any conttrol signal th he signal shhall be available from SCADA
S for lless than 2 seconds
only.
6 T rating off the potential free contact for digital input and output sig
The gnals from Equipment/
E
P
PLC/ RTU sh hall be 24 V DC, 1.5 A DC. Analog gue signalss shall be 4--20 mA, galvanically
issolated.
P
Provision forr minimum twot nos ana alogue and two nos of digital inpu ut signal to SCADA
S
S
System shalll be availab e use, from CPTRU to SCADA. prre-installed AI converte
ble for future er,
D
Digital relayss for future use.
C
Control signa
al shall be provided
p nly for remote operation
on n of the current interrup
pter.
11.0 CP
P CABLES
S
TC
CP Cables
TCCP Cables shall be an nnealed higgh conductiv

vity, tinned,, stranded copper connductor, XLPE
inssulated 650
0/1100 V grrade, armou ured/un-arm
moured, PVC C sheathedd. The size of the coppper
conductor sha all be 6 sq mm for an node cable from anode e to buried junction bo
ox, 10 sq mm
m
fro
om junctionn box to te est station, 10mm² froom test sttation to piipeline. Thee size of the
t
conductor sha all be 6 sq mm for pottential measurement, 10 sq mm for current measureme ent
annd 25mm² for bondin ng, polariza
ation cell / grounding g cell/Earth
hing and surge
s diverrter
MECO
PIPELINE
Ele
ectrical Sectio
on, Delhi
P MEC/23
3VE/05/E9/C
System
connection purpose.
p The anode cable from m anode to t junction box (buried) shall be
un
narmoured. The length of anode tail
t cable shall be suffficient enou ugh to reach
h junction box
b
(bu
uried) in ca porary CP anodes and
ase of temp d up to tesst station in
n case of permanent
p CP
sacrificial ano
odes. PE Sle
eeves shall be provide
ed for unarm
moured cablles.
Noote- Underg
ground burried junctio
on box sha all be proviided only a
at locations
s where mo
ore
tha
an two (02)) nos. of an
nodes requ
uired for the pipeline protection.
CP Cables
PC
i) MO Anode tail/lead
MM t cab
ble (Size 1C
Cx10 Sqmm
m)-
An
node tail/lea
ad cable sha
all be 1Cx10 Sqmm siize, anneale
ed high con
nductivity tin
nned strand
ded
copper cond ductor (7 Strands), PVDF in nsulated (T
Thickness 0.040 Inc ch), HMWPE
sheathed/Jaccket (Thickness 0.065 Inch), un-armoured.
ii) An
node & Cath
hode Heade Size 1Cx35 Sqmm)-
er Cable- (S
Annode & Catthode Head der Cable shall be 1C

Cx35 Sqmm m size, annealed high conductivvity
tinned strand
ded copperr conductorr, XLPE inssulated, PV
VC sheatheed, FRLS, 1.1kV Graade
armmoured cab
ble as per IS
S: 7098.
iii) TR nput Power Supply Cab

R/CPPSM In ble - (Size 3Cx10
3 Sqm
mm)-
TRR/CPPSM Innput Power Supply Cable shall be

e 3Cx10 Sqmmm size, an nnealed higgh conductivvity
tinned strand
ded copperr conductorr, XLPE inssulated, PV
VC sheathe ed, FRLS, 1.1kV Gra ade
armmoured cab
ble as per IS:
I 7098 for Single Phhase TR Un or 3 phase TR
nits and 4 ccore type fo
unnits.
iv) Me
easurementt cable & Pe
ermanent Reference
R ce
ell tail cable
e- (Size 1Cxx6 Sqmm)-
Meeasurement cable & Permanent

P R cell taill cable from
Ref m Pipe/Tank k/Bullet/Ves ssel to CJB
B&
CJJB to TR/CP PPSM Unit shall be 1C Cx6 Sqmm size,
s anneaaled high conductivity tinned strandded
copper condu uctor, XLPE E insulated, PVC sheathed, FRLS S, 1.1kV Grrade armou ured, screenned
cabble as per IS: 7098 or o Multi-coree signal cab
ble of suitable pair shall be cons sidered for the
meeasurement cable & re eference cell cable from
m CJB to TR R unit. (For this bidderr may considder
8/1
12 pair, Multti-core, FRL
LS, 2.5 Sqmmm, 8/12 pair, twisted pa
air, shielded
d, armoured, signal cabbles
as per IS/BS).
v) Th
he colour off outer shea ath of the ca
ables shall be as per th
he PJS/Sco
ope of work
k/Design Ba asis
an
nd outer sheeath should d have markking of “CPP system Cable” in ea ach one meeter interval by
bla
ack colour fo
or identifica
ation purposse.
vi) Thhe cables fo ng various transducerrs from TR unit/ CPPS

or connectin SM to telem
metry interfa
ace
jun
nction box shall be twwisted pairr with indiv
vidual pair shielded and overall shielded with
w
alu
uminium baacked by myylar/polyste
er tape, PVC C sheathedd, armouredd, PVC over all sheath
hed
typ
pe.
CA
ABLING SY
YSTEM
Ca
able laying philosophy
p
MECO
PIPELINE
Ele
ectrical Sectio
on, Delhi
P MEC/23
3VE/05/E9/C
System
A. Paved area
a: Cable tray/RCC trench/
t Aboove ground cable trayss (on sleepe er /
overheead rack)
B. Process arrea: Abovee ground ca able tray (on
n sleeper / o ack) / directly
overhead ra
buried
d / RCC trennch
C. Unpaved area:
a Directly buried wiith sand cusshioning and brick cove
ered,
warning tape and ca able markerr.
D. Type of cable trays: Galvanized prefa abricated
E. Road crosssing for und
derground cables
c DPE Pipes / GI Pipes
: HD
12.0 ST
TATUTOR
RY APPROVAL
Thhe submissiion of application on behalf

b of the Owner to o Govt. Autthority/ Cenntral Electriccity
Auuthority, if re
equired along with cop pies of requ
uired certificcates comp
plete in all respects,
r shhall
bee done by th he contractoor well ahea
ad of time so
s that the actual com mmissioning of project are a
noot delayed forf want of approval frrom authority. The acttual inspecttion of work k by the Go ovt.
insspector sha all be arrang
ged by the Contractor
C and
a necesssary coordin nation and liaison
l workk in
this respect shall
s be the
e responsibility of the contractor. However a any fee paid d to the Go ovt.
Auuthority in this regard d shall be reimbursed d by the Owner
O on submission n of bills with
w
doocumentary evidence.
Th
he Inspectio
on and acce eptance of the work as above sh
hall not abssolve the Co
ontractor fro
om
an
ny of respon
nsibilities un
nder this con
ntract.
13.0 DR
RWINGS AND
A DESIGN DOCU
UMENTS
13.1 he following documentss shall be su

Th ubmitted alo
ong with the
e offer:
a) Filled up
p data sheett/Checklist.
b) HSE Po olicy
c) Bar Cha arts & Projecct completio
on schedule
d) QAP
e) Approx. dimensionss of the systtem
f) Catalogues for CP units,
u MMO & Sacrificiaal Anodes, polarization
p cells, spark gap arresto
ors,
ER Prob be, referencce cells etc.
13.2 Th
he following drawings (in ets) & documents shall be submittted for app
( three se proval within
n3
we
eeks of awaard of contra
act.
a) Various Proceduress of CP syystem Installation Like- Soil survey (TCP & PCP), P Therrmit
weld, Pin Brazing, Sacrificial
S a
anode (Zn/MMg/Ribbon) installations
i s, Test statio
ons & Juncttion
Boxes in nstallation, Cable
C laying
g, Installatio
on of polarizzation cell, E
External ERR probe, Surrge
diverter & groundin ng cell, con nnection & sealing of sacrificial a anode, Earthing of abo ove
ground pipeline,
p ano ode ground bed, CP un nits etc.
b) Soil survvey report and
a chemica al analysis report
r with marked
m locaation vulnerrable area with
w
all additional data ofo HT line, Foreign
F pipeeline, Cased d crossings, river crossings etc as perp
specificaation.
c) QA & QC Procedurres.
d) List of tw
wo years op peration and maintenanc ce spare.
e) Basis off system de esign and design
d calcuulations, equipment se election crite
eria and sizzing
calculatiions, formulae used
f) Detailed d design calcculations of TCP & PCP P system (C Complete De esign Packa age).
g) Equipme ent layout, Cable
C layout & schedule e.
MECO
PIPELINE
Ele
ectrical Sectio
on, Delhi
P MEC/23
3VE/05/E9/C
System
h) Construction drawin ng for fencin ng of anode bed & AJB..

i) Colour code
c identification for thhe various CP
C System cables
c used in the syste
em
j) Procedu ures for Varrious Post commission
c ing surveyss (CPL, CAT T, CAT Frame ‘A’ DCV VG,
Person survey
s & cooating condu uctance etc as per OISD D requireme ents).
k) Procedu ure for AC & DC interferrence detec ction & mitigaation.
l) Procedu ure for field testing,
t pre--commission ning & comm missioning o of TCP & PCCP.
m)) Procedu ure for Monittoring & ma aintenance of o CP system m.
n) Detailedd design of Anode
A grounnd bed, typical lay out drawings
d forr Anode bed
d connection
n&
installatiion for CP system.
s
o) Equipme ent layout, Cable
C layout & schedule e.
p) TLP’s & junction bo oxes installattion & erection details drawings.
d
q) Incorporration of Anode bed, Po olarisation cell,
c surge arrester,
a TLPP, Junction boxes & oth
her
relevantt feature in CP system m design in Alignment sheet,
s pipelline route diagram
d & Plot
P
plan.
r) G.A. of TR/CPPSM
T unit.
s) Schema atic
t) Wiring diagram
d for reference.
r
u) Tentativve Bill of Matterial
13.3 Aftter the job

b completioon, contracctor shall prepare
p AS
S-BUILT dra awings/data
a sheets and a
do
ocuments, submit
s catallogues/man
nuals (O&M M) of major brought outt items. Fin nal certified as
built drawingss, documennts and man nuals etc sh
hall be submmitted by thhe contractoor to ownerr in
bo
ound volume e with one set in soft copy (CD) plus five sets
s of printts to ownerr & one sett to
MEECON..
Other drawings and doocuments shall

s be su
ubmitted byy contracto
or along with
w AS-BUILT
Dra
awings/Data
asheets-
a) Orriginal deed OR Lease agreement for acquired d/leased lannd (In favour of M/s HP
PCL) for Ano
ode
ed, ROU for cable laying
Be g etc shall be
b handed over
o to M/s HPCL.
H
b) Te
est documen nts & drawin
ngs for bougght out items
s.
c) De
etailed comm missioning report
r of pipeline CP system (Both TCP and PCP).
-x-x-x
x-
MECO
PIPELINE
Ele
ectrical Sectio
on, Delhi
P MEC/23
3VE/05/E9/C
System
A
APPENDIX
X–1
LIST OF
O ABBRE
EVIATIONS
S
1) AC
A –Alterna
ating current
2) CAT –Curre
ent attenua
ation test
3) CJB – Cathode Junctiion Box
4) CP-Cathodic Protectio
on
5) CPPSM-Catthodic Protection Pow
wer Supply
y Module
6) DCVG –Dire
ect Current Voltage Gradient
G
7) DC –Direct Current
8) FR
RLS-Fire Retardant
R Low Smokke
9) GSM
G –Global System for Mobile
e
10) HMWPE – High
H Moleccular Weight Polyethylene
11) MMO–Mixed
M d Metal Oxxide
12) NACE- National Assocciation of Corrosion
C Engineers
E
13) PCP–Perma
anent Cath
hodic Prote
ection
VC – Polyvvinyl Chlorride
14) PV
15) PV
VDF– Polyyvinylidene
e Difluoride
e
16) ROU
R – Righ
ht Of Use
17) RTU
R – Rem
mote Termin
nal Unit
18) TC
CP–Tempo
orary Cath
hodic Prote
ection
19) TR
R- Transfo
ormer Recttifier
20) XLPE- Crosss Linked Poly
P Ethyle
ene
SCOPE OF WORKS
FOR
CATHODIC PROTECTION WORK
HINDUSTAN PETROLEUM CORPORATION LTD
BARMER- PALANPUR PIPELINE PROJECT (BPPL)

Section I- 18” x 106.8 km approx & Section II- 18” x 109.5 km approx.
DOCUMENT NO. - MEC/23VE/05/E9/E/002, R-1
(ELECTRICAL SECTION)
MECON LIMITED
DELHI 110 092
OIL & GAS SBU PROJECT (BPPL) SECTION-I &
SECTION-II
HPCL MECON LTD, DELHI
TITLE CATHODIC PROTECTION DOCUMENT NO. Page 1 of 44

WORK (TCP+PCP)
MEC/23VE/05/E9/E/002 REVISION 1
CONTENTS
SL.NO. DESCRIPTION
1. General
2. Project Description
3. Standards
4. Guarantee
5. Site Conditions
6. Power Supply Parameters
7. Abbreviations
8. Scope of Work (TCP+PCP)
9. Statutory Approval of Works & Permissions
10. Quality Assurance, Inspection & Testing
11. Testing & commissioning
12. Drawings, Standard Specification And Installation Standards
13. Resources/ Facilities
14. Project Scheduling & Monitoring
15. Construction
16. Documentation
17. Make of Material/ Bought Out Items
18. Inspection of Supply Items
19. Escalation
20. Documents to be submitted/ produced along with R.A. Bills

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WORK (TCP+PCP)
Appendix-I (List of Vendors for Bought out items)

Appendix-II (2 Years Operational & Maintenance Spares for Cathodic protection system)
Annexure-A (Format for Daily Progress Report for TCP system)
Annexure-B (Format for TCP/PCP system commissioning & Monthly Monitoring of TCP/PCP system)
Annexure-C Organogram for the CP work
Annexure-AA Compliance to the Technical Bid (CP Work).
PREPARED BY: CHECKED BY: APPROVED BY: ISSUE DATE :

(Aashish Moyal) (M.K.Jaiswara) (DG Majumder) ISSUE DATE: Apr 2020 R-0
(Aashish Moyal) (M.K.Jaiswara) (DG Majumder) ISSUE DATE: July 2020 R-1
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WORK (TCP+PCP)
1.0 GENERAL
1.1 Introduction
Special Condition of Contract shall be read in Conjunction with the General Conditions of Contract,
specification of work, Drawing and any other documents forming part of this contract wherever the
context so requires.
Notwithstanding the sub-division of the documents into these separate sections and volumes every
part of each shall be deemed to be supplementary to and complementary of every other part and
shall be read with and into the contract so far as it may be practicable to do so.
Where any portion of the General Condition of Contract is repugnant, to or at variance with any
provisions of the Special Conditions of Contract, unless a different intention appears, the provisions
of the Special Conditions of Contract shall be deemed to over-ride the provisions of the General
Condition of Contract and shall to the extent of such repugnancy, or variations, prevail.
The materials, design and workmanship shall satisfy the relevant INDIAN STANDARDS, the
TECHNICAL SPECIFICATIONS contained herein and CODES referred to. Where the technical
specification stipulate requirements in addition to those contained in the standard codes and
specifications, these additional requirements shall also be satisfied.
Wherever it is mentioned in the specifications that the CONTRACTOR shall perform certain work
or provide certain facilities, it is understood that the CONTRACTOR shall do so at his cost and the
VALUE OF CONTRACT shall be deemed to have included cost of such performance and
provisions, so mentioned.
It will be Contractor’s responsibility to bring to the notice any irreconcilable conflict in the contract
documents at the time of bidding during pre-bid stage. After award of contract, the stringent of
available technical/statutory/specifications/drawings shall be implemented at the no additional cost
to Owner.
In the absence of any specifications covering any material, design of work(s) the same shall be
performed/ supplied/ executed in accordance with Standard Engineering Practice as per the
instructions/ directions of the Engineer-in-charge, which will be binding on the Contractor at no
additional cost and time to Owner.
2.0 PROJECT DESCRIPTION
HPCL proposes to lay cross country POL pipeline from new Barmer Station in Rajasthan to
existing receiving Palanpur Installation of MDPL in Gujarat.
The project is named as Barmer-Palanpur Pipeline (BPPL) Project.
Salient features of the project are as below:
Originating Point : Barmer Cross Country P/L Station (in HRRL Refinery).
SVs,IPS : Total 4 SVs and 01 IPS.

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WORK (TCP+PCP)
End Marketing Terminal : Existing Palanpur POL Installation (MDPL)
Products : MS, HSD and SKO
Cross-country PL (18” x 216.3 km approx.) from DT Barmer to RT Palanpur.- (Section I- 18” x

106.8 km approx. ; Section II- 18” x 109.5 km approx.) includes 4 Nos. SV, 1 No. IP Station- piping
& valve station including civil, structural works for SV pit – (cage / fencing)

This document presents brief scope of work for TCP & PCP system for 3LPE Coated long line
against corrosion. It indicates minimum requirements for detailed design of CP system and
equipment.
2.1 PROJECT DETAIL
Details of Proposed Mainline-
Location Approx.
Pipeline Diameter Length
From To (Km)
106.8 km
Section I Barmer IP-01 18”
approx.
Section II IP-01 RT Palanpur 18” 109.5 km
– Material of Construction : Carbon Steel
– Line Size : 18” NB
– Length, in km : ~ As mentioned above
– Pipe Specification : As per P&ID
– Thickness : As per P&ID
– Design pressure : As per P&ID
– Corrosion Allowance : As per Pipeline data
– External Coating : 3-LPE
– Internal Coating : Liquid epoxy
– Design Code : ANSI/ ASME B31.8 (Latest Edition)
– Major Water Crossings : As per Alignment Sheet
– Major Road Crossings : As per Alignment Sheet
– Rail Crossings : As per Alignment Sheet
– HT line crossing : As per Alignment Sheet
3.0 STANDARDS
3.1 The work shall be performed in conformity with this specification, standard specifications and
installation standards enclosed elsewhere in this tender and code of practices of the Bureau of
Indian Standards. In case of any conflict, the stipulations under this specification shall govern.
In addition, the work shall also conform to the requirements of the following:
3.2 The Indian Electricity Act, and the rules framed there under.
The regulations laid down by the Chief Electrical Inspector of the state government/ Central
Electricity Authority (CEA).
The regulations laid down by the Factory Inspector.
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WORK (TCP+PCP)
The regulations laid down by the Chief Controller of Explosives.

Any other regulations laid down by the Central, State or Local Authorities from time to time
during the execution of this contract.
OISD Standards
PNGRB Regulations
HPCL’s Safety Standard
3.3 The design, selection and installation of equipment and materials shall also conform to the
requirements of the relevant latest standards of:
BS Specification and codes of practice
OISD Standard 188. 141, 113
IS: 8437 (Part-II)/ 8062 (Part-I)
NACE Standards
DNV Publications
IEEE Publications
4.0 GUARANTEE
4.1 The contractor shall guarantee the installation against any defects of workmanship and
materials (supplied by the contractor) for a period 12 months from date of commissioning (As
per DLP terms & conditions defined in the Contract volume). Any damage or defects connected
with the erection of materials, equipments of fittings supplied by the contractor that may be
undiscovered at the time of issue of the completion certificate, or may arise or come to light
thereafter, shall be rectified or replaced by the contractor at his own expense as deemed
necessary and as per the instruction of the Engineer-in-charge within the time limit specified by
Engineer-in-charge.
4.2 The above guarantee shall be applicable for the quality of work executed as well as for the
equipment/ cable/ fittings/ other materials etc supplied by the contractor.
Equipments installed or commissioned by others within the battery limit. This is for the purpose
of obtaining a comprehensive approval from competent authority.
5.0 SITE CONDITIONS
The equipment offered and the installation shall be suitable for continuous operation under the
following site conditions:
Ambient temperature : 55°C/ 2˚C (max.)

Max relative humidity : 95%
Altitude : less than 1000 m
Atmosphere : To withstand site condition
(Dry & dust storm during summer and low temp during
winter)
Hazardous area : Zone-II, Gas group IIA & IIB, Temp. Class T3
Classification
6.0 Power Supply Parameters for CP units-
AC Panel (From UPS/Inverter) 240 V AC ±10%, 1 Phase

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WORK (TCP+PCP)
7.0 Abbreviations
3LPE - Three layer Ploy Ethylene

AJB - Anode Junction Box
CJB - Cathode Junction Box
CPPSM - Cathodic protection power supply module
CTSU - Computerised Test Station Unit
CAT - Current Attenuation Test
DCVG - Direct Current Voltage Gradient
D/T - Despatch Terminal
ER Probe - Electrical Resistance Probe
ICCP - Impressed Current Cathodic Protection
IP - Intermediate Pigging
PCP - Permanent Cathodic Protection
PSP - Pipe to Soil Potential
R/T - Receiving Terminal
SV - Sectionalizing Valve
TCP - Temporary Cathodic Protection
TR Unit - Transformer Rectifier Unit
TLP - Test Location Point (Test Station)
QA/QC - Quality Assurance & Quality Control
XLPE - Cross Link Poly-Ethylene
8.0 ELIGIBILITY CRITERIA FOR CP CONTRACTOR (OTHER THAN LISTED IN VENDOR LIST)
AND CO-ORDINATION WITH OTHER CONTRACTORS
The Bidder or the CP Contractor engaged by the Bidder should have completed and
successfully commissioned at least one CP (TCP & PCP) system project of any single
cross country pipeline project during the last 7 years reckoned from the due date for
submission of bids, consisting of corrosion survey, design, detailed engineering, supply,
installation, testing & commissioning including the DC interference detection &
mitigation and AC high induced voltage detection & mitigation and post commissioning
surveys like CIPL, CAT or DCVG of at least one cross country pipeline of minimum 100
Km length and having minimum one (01) nos. of impressed current CP Stations.
Bidder / CP Contractor should have license of software (SES/Elsyca) simulation of AC

/DC interference & mitigation or Bidder can propose backup agency for the software
simulation of AC /DC interference. Successful Bidder shall submit the PTR (Past track
record of the CP Contractor i.e. work orders and completion certificate from end user) for
approval before engaging the CP Contractor on job.

Bidder and it’s CP contractor shall entirely be responsible for Co-ordination with other
contractors & shall mobilize necessary teams in each respective section as per the site
organisation chart (Annexure-C) enclosed with this tender with the key responsibility, education
qualification, designation, experience as defined and shall be responsible for the timely
execution of CP work.
If the contractor fails to execute the CP work within tender specified delivery period or fails
to mobilize CP teams/material as specified in the tender, necessary price reduction schedules
shall be applied as per the contract provisions.
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WORK (TCP+PCP)
9.0 SCOPE OF DESIGN AND ENGINEERING
The scope of design and engineering shall include preparation and submission for review of CP
system design & detailed engineering package, specification for procurement of CP System
equipment/ materials, equipment drawing/ document, preparation of site engineering drawings
and details for installation work wherever applicable or required by the CLIENT/ Consultant and
submit to the CLIENT/ Consultant for approval.
All CP document shall be prepared and vetted by a NACE certified CP level 3 personnel on the
roles of the CP contractor company and for installation, testing and commissioning activities
shall be performed by a NACE certified CP Level 2 engineer. CV of the personnel shall be
submitted by the contractor to the Client/Consultant for review and approval prior to Engineering
& Construction activities.
Major documents and activities requiring pre-approval from Client/Consultant shall include but
not to limited to the following:
 Methodology of soil resistivity survey, site data collection & soil resistivity report.
 Detail engineering document with equipment selection and sizing calculations, construction
drawings with Bill of material (with supplier name)
 Quality Assurance Plan (QAP) for FAT & Inspection Test Plan (ITP).
 Procedure for field-testing, Installations, commissioning and post commissioning surveys with
formats for SAT (Site acceptance test).
 Electrical connection schemes, cable schedule, cable layout drawings etc.
 Interference study procedures duly vetted from the NACE –IV certified person.
All design and calculation reports/documents including formulas shall be submitted for
review/approval to Client/Consultant in editable & PDF copies.
10.0 SCOPE OF WORK (SUPPLY, INSTALLATION, TESTING & COMMISSIONING)
General
Contractor shall execute TCP work simultaneously in coordination with laying contractor when
lowering of the -pipeline is going on. Activities like- Cable to pipe connection, installation of ER
probe, Polarisation cell, Polarisation coupon etc should be completed before the backfilling of the
trench.
10.1 TEMPORARY CATHODIC PROTECTION SYSTEM
Corrosion survey, design, detail engineering, fabrication, supply, installation, testing and
commissioning of the temporary cathodic protection system using Mg/ Zn galvanic anodes to
protect the external surface of 3LPE coated pipeline against corrosion for design life of minimum
2 years or till the commissioning of PCP system, whichever is later. The detailed length of
pipeline is as under-
Location Approx.
From To (Km)
SECTION-II

WORK (TCP+PCP)
106.8 km
approx.
Maintaining and keeping of PSP value as specified and monitoring at monthly basis of PSP
voltage & AC voltage of the temporary cathodic protection system (As per format Enclosed in
Annexure-B) till commissioning of the permanent cathodic protection system. All work shall be
carried out conforming to the Scope of work, Design Basis, Data Sheets, national & international
standard & as per standard specification No.- MEC/TS/05/E9/016A for temporary cathodic
protection system. Scope shall also include but not limited to the following for completion of
jobs:-
a) Temporary CP system shall be installed immediately of the any lowered section but not
later than 15 days from the time of lowering of pipeline segments. If TCP system is not
provided for any of the lowered section in the specified time, necessary deduction shall be
carried out from the contractor’s head as non-compliance of work. The deduction shall be
1000 rs per day per lowered section in each spread, example_ 1000x nos of days TCP
unprotected x lowered sections.
b) Measurement of soil resistivity along the right of way of the main pipeline (At 500mtr Interval) &
collection of soil & water samples along ROW at depth of 1M, 2M & 3M at every 10km interval (Min
03 sample at each location) for its chemical & microbial analysis along the pipeline route as per
specification for corrosion survey MEC/TS/05/21/016C & NACE Standard TM0106-2006 for
detection of SRB, ARB, TDS, pH, Rx, Moisture & Total dissolved H2S etc. These sampled shall be
stored in sealed container and stored in the dark place.
c) Collection of additional data related to cathodic protection along the right of way of pipeline as per
standard specifications during the survey along with GPS coordinates. Site survey report shall
include detailed layout drawings of pipeline / facilities, reflecting all foreign pipeline / Overhead
power transmission lines crossings & parallelism, Power cables, river, railway traction
(electrified/non-electrified), Substations (HVAC/HVDC), fabrication yard, existing CP facilities
(such as transformer rectifiers, anode ground beds, test facilities etc.), soil resistivity survey
locations, road crossing locations, etc. Site survey includes details of all AC, DC interfering
elements all along pipeline ROW.
Site survey shall be carried out along the pipeline route to identify the HVAC crossing locations
and/or HVAC line parallelisms. Site survey report shall include a comprehensive list which includes
the HVAC line rating in KV, distance of HVAC line / tower footings from pipelines and length of
parallelism. Survey shall also include AC potential measurements of existing pipelines in the same
corridor.
d) Design, Detailed Engineering, Preparation of Design Document, Preparation of Test station

schedule & Bill of Material as per the corrosion survey & Chemical analysis of Soil / Water samples
for Temporary Cathodic Protection system.
e) Total number of anode shall be calculated as per total anode weight requirement & total protection
current required.
f) Supply, Installation, Testing & commissioning of Test stations (Big Size & Normal Size) weather
SECTION-II

WORK (TCP+PCP)
proof (IP-55) as per specification & enclosed drawings. Selection of TLP size will be as per the nos.
of cables terminating at the station. TLP shall be sealed at both ends by means of foam
sealing/solid sealing. Termination plate inside the TLP should have high insulation level (FRP or
higher grade) to avoid drainage of CP current due to insulation leakage.
All the test-stations and junction boxes shall be provided with shrouded allen screws to avoid
vandalism.
g) Supply, installation, testing & commissioning of Mg (Min 5.0 Kg)/ Zn Galvanic anodes/ Mg ribbon
anodes with backfill as per the standard specification- MEC/TS/05/E9/016A. The weight of the Mg
Anode & the total nos. of anodes shall be calculated as per the corrosion survey, soil chemical
analysis, total weight and current requirement of the pipeline section. However, Min one anode is
to be installed at every one KM with test station.
h) Supply, installation, testing and commissioning of 10kg Mg anodes at both side of River
crossings/ HDD, and Road/ Railway/ Nallah crossing (for casing pipe).
i) Cable to pipe connection by thermit welding/Pin brazing (for charged pipeline) for 35, 25, 10, 6
sq.mm copper cable including excavation and exposing piping, recoating with epoxy, testing etc.
j) Supply, laying of HDPE sheets (1200mm wide, 6mm thick) between the HPCL pipeline and
the other CP protected foreign pipelines at the crossing locations for providing electrical
isolation and discharge of the CP System current between the pipelines.
k) Earthing of above ground catholically unprotected pipeline at consumer station/DRS

station/Metering skid etc, the earth electrode shall be 65 mm dia, 4.5 mm thickness & 3000mm
long. Total grounding resistance shall be limited to 2 Ohm max.
l) Earthing of MOV’s at DS/RS/SV stations shall be carried out by SSD (Solis state de-
coupler/Polarisation cell) Zn anodes with min installation of 02 nos. Of electrode or by Zn ribbon
anodes. Grounding resistance shall be limited to the min 02 Ohm.
m) Supply, installation, testing & commissioning of one set of Explosion proof type spark gap arrestor
(100 kA@ 10/350 uS rating for lighting protection and 8/20 uS 100kA for surge protection) across
each insulating joint provided at dispatch terminal, receiving terminal, tap-off, SV & various
consumer terminals as per P&ID / specification.
All the monolithic insulating joints (MIJs) on the main line, on the tappings for the instruments viz.
pressure transmitter, densitometers etc. shall be provided with explosion proof surge divertors.
Note 1-Surge diverter cable needs to be terminated without any joints across the IJ. Surge diverter
with its pre‐wired connecting cables with suitable length & size should be provided and installed at
the Isolating joint.
n) CP AT CASED CROSSINGS
i) Casing should be avoided as far as possible. If cased crossing is unavoidable, Bare casing is
always recommended with selecting higher thickness allowance as per API 1102.
ii) No sacrificial anodes (ribbon anodes) shall be used inside casing & carrier annular space.
iii) Casing filler bentonite shall be filled between annular space of casing and carrier.
SECTION-II

WORK (TCP+PCP)
o) Where high voltage (66 KV and above) transmission line runs in parallel or crosses the pipeline,
the pipeline shall be grounded through polarisation cells of suitable rating (solid state) & Grounding
(a continuous length of Zn Ribbon Anodes/Copper conductors with back fill material shall be laid
along the pipeline) shall be done at regular intervals of maximum 1 km where transmission lines
run parallel within 1km of the pipeline and have separation distance of 50 mtr on both side of the
pipeline.
The rating of the cell shall depend upon anticipated fault current & ground bed resistance at the
location of installation and the calculation of the same shall be furnished to MECON for review &
selection of rating of the Polarisation Cell. However, the rating of polarisation cell shall not be less
than 3.7 KA @ 30 Cycle & number of 20 kg net weight zinc anode shall not be less than two. Zn
Ribbon anode (Dia min. 12x14 mm with back fill in trench)/ pre-packed AC mitigator wire of
MATCOR make or equivalent also be used for the grounding purpose to get lower grounding
resistance (for soil resistivity higher than 25 Ohm-Cm) as per the direction of engineer in-charge.
The resistance of grounding shall be limited to 2 ohms max.
At any location of HT line crossing, max 2 (two) nos. zinc anodes shall be provided to limit the
grounding resistance to 02 ohms max for not achieved Zn Ribbon anode (Dia 15mm with back fill
trench) or Cu conductor with backfill shall be used for the grounding purpose. Calculation for
grounding resistance shall be submitted along with design document.
If any proposed additional line of voltage rating 66kV & above is envisaged during construction, the
same shall also be considered in the design document. Contractor shall supply polarization cell
along with necessary grounding system for the same.
If it is observed during the monthly monitoring that the source of the AC interference is due to the
HT lines less than 66kV or LT line, Contractor shall provide the grounding the pipeline through SSD
to lower impact of the AC interference on the pipeline.
p) Supply, installation, testing & commissioning of external electrical resistance Probe (02 nos. probe
per laying section for all sections) utilizing the electrical resistance technique shall be provided
along the pipeline at marshy / vulnerable locations to monitor the external corrosion activity on the
pipeline. Location of external ER probe shall be decided during detail engineering.
Care shall be taken during installation of ER probes so that probe element is opposite to pipe (Not
facing the pipeline).
q) Supply, installation, testing & commissioning of Polarisation coupons (01 every 10Km of pipeline)
having total area of 100mm x 100mm having one side exposed area of 25 mm x 25 mm without
permanent reference cell shall be provided along the pipeline and at additional vulnerable locations
(River crossings, Marshy locations, Interference prone area, stray current source locations, foreign
pipeline crossings/parallel (at every KM in case of parallel), at CP stations) to monitor the external
corrosion activity on the pipeline as per enclosed standard specification. Location of external
Polarisation coupons & Number of magnetic devices for operation of magnetic switch shall be
decided during detail engineering in consultation with HPCL/MECON.
Permanent Reference cell shall be manufactured & constructed in line with drawing no.
MEC/SD/05/E9/E/CP/1610 Rev-0.
Care shall be taken during installation of polarization coupon that bare face of polarisation coupon
is opposite to pipe & polarisation coupon shall not be installed between TLP & Pipeline.
SECTION-II

WORK (TCP+PCP)
The works related to collection of approximately 2-5 m of pipeline material (In pieces of 300 to
1000mm length) for fabrication of Polarisation coupons is in the scope of the Contractor and shall
be supplied by the Owner.
r) Bonding in between pipelines running parallel or crossing as required including taking of

permission from the owner of the foreign pipeline (Permission shall taken by the Pipeline Owner
and any fee required for the same shall be paid by the Owner, however contractor shall assist in all
respect to get such permissions from foreign pipeline owner).
i) Bonding of pipelines shall be carried out through bonding stations (variable resistance of
suitable value + shunt + diode, if required). Polarization coupons shall be installed at every test
station in the parallel section and at crossings.
ii) The Contractor shall supply and install bonding stations as provision to bond the pipelines. For
the new pipeline as a provision for interference mitigation Bonding Junction box (BJB) shall be
installed as a minimum at the following locations-
iii) Where the new pipeline runs parallel to the existing pipelines, at start and end of parallelism
and at every five (5) km intervals. As a minimum, all existing parallel pipelines laid with a
separation distance of 10 m shall be provided with bonding provision.
iv) Where the pipeline crosses or intersects the existing buried pipelines or buried section of
pipelines / Piping.
v) BJB shall have provision to terminate 25/35 mm2 bonding cables and a 6 mm2 potential
monitoring cables connected to each foreign pipelines as well as new pipelines. BJB shall be
provided with appropriately rated shunts and resistors for each circuit. Rating of the resistors
shall be calculated based on the mitigation requirement.
s) Supplying, laying, termination, Glanding, ferruling & testing of all the cables of TCP system, Cu-
Conductor, XLPE insulated, PVC sheathed, Armd/Unrmd (1Cx6 mm2, 1Cx10 mm2, 1Cx25 mm2,
1Cx35mm2) as required.
t) Cable coming from 60 Mtr for Current measurement test stations (Type_B) & cables for foreign
pipeline crossing shall be provided with black sleeves for the identification purpose.
u) Calibration factor of similar thickness pipeline section shall be carried out by the Bidder at each
B_Type test stations by arranging separate power source. Bidder shall refer pipe book for the
same.
v) PSP Monitoring on monthly basis of the TCP system till commissioning of the permanent cathodic
protection system including the coupon OFF psp.
w) All civil/ structural & other miscellaneous works related to TCP system including supply of bricks,
cement & steel etc. required for completion of the system.
x) Coating Integrity test of HDD section of the pipeline shall be conducted immediately after the
completion of the HDD of each HDD section by separate temporary power source and anode bed.
Bidder shall submit the procedure as per the NACE requirements for approval along with the
design document.
SECTION-II

WORK (TCP+PCP)
Note for TCP-
Note-2 Additional protection of carrier pipe (By Zn ribbon anodes) inside the bare casing is
not required.
Note-3 5 kg Mg anodes shall be provided for protection of Casing pipe (external side)
wherever required.
Note-4 Connection scheme of CP system in TLP boxes shall be permanently fixed inside
the test station box (TLP Box).
Note-5 At saline soil Ag/Agcl Permanent Reference electrode shall be used.
Note-6 Vendor list of Make of CP Materials is enclosed with the tender as appendix-I all CP
material shall be as per the make mentioned in the vendor list.
Note-6 For chainages refer Pipeline Schematic Route Diagram
Note-7 Localized soil resistivity at 1.5Mtr depth shall be considered for calculation of
number of Anodes.
10.2 PERMANENT CATHODIC PROTECTION SYSTEM
General
Contractor shall execute PCP work simultaneously in coordination with other contractor when
Lowering, Electrical & Civil of the -pipeline is going on. Activities like- AGB land acquisition, Cable
to pipe connection, installation of ER probe, Polarisation cell, Polarisation coupon etc shall be
coordinated with other contractors.
Execution Methodology
Successful bidder shall start acquisition of land for AGB immediately & execute interference study
work (site data collection and software modelling) simultaneously with TCP work after award of the
contract and all other post commissioning activities shall be commenced after completion of the
Interfere study work and PCP supply, installation, testing and commissioning work.
Training
Successful bidder will provide classroom training as well as field training to the Owner’s personnel
for at least of 2 Man days at each spread covering TCP, PCP & Interference detection and
Mitigation (1 day classroom and 1 day field). The training will broadly consist of system basics,
installation, operation & function of CP system and interference detection & mitigation and post
commissioning surveys its data analysis & assessment and experience sharing etc The trainer will
have vast experience in cathodic protection field and corrosion data analysis and have NACE-IV
certification.
10.3 Permanent Cathodic Protection System
Survey, Design, Detailed Engineering, Manufacturing, Inspection/FAT (Factory acceptance test),

SECTION-II

WORK (TCP+PCP)
Supply, packing, transportation to site, installation, testing and commissioning of the permanent
cathodic protection system by impressed current method using MMO coated Titanium anodes to
protect the external surface of 3LPE Coated pipeline against corrosion for a service life of 35
years, as per Standard Specification No. MEC/TS/05/21/016B for Permanent Cathodic
Protection system. The detailed length of pipeline is as under-
Location Approx.
From To (Km)
106.8 km
approx.
The scope shall include complete Permanent Cathodic Protection system, including carrying out
the soil resistivity measurement for anode ground beds, design of anode ground beds
considering size / rating of anode bed not less than the minimum requirements of the anode
ground bed specified, AC/DC Interference detection and mitigation, AC/DC interference on
pipeline and CP System due to proximity of foreign AC/DC source, detection and mitigation of
high induced voltage at pipeline due to proximity of HT lines, substations etc, close interval
potential logging survey for entire length of 18” dia pipelines and additional surveys (as per
OISD and PNGRB)i.e. Pearson & CAT survey (Full length), CAT with frame ‘A’ /DCVG etc at
selected locations which shall be decided from the abnormal areas of close interval potential
logging survey results & CAT survey result to identify coating defects/holiday, conducting
pipeline line current & coating resistance test at selected locations where current measurement
test stations installed, preparation of commissioning report and as built drawings etc. All work
shall be carried out conforming to the Scope of work, Design Basis, Data Sheets, standard
specifications enclosed with this tender & other standards as applicable.
Scope shall also include disconnection of TCP system which does not form part of PCP system.
Equipments coming under TCP system if useful & required in PCP system shall be used
effectively in designing of PCP system. If any inadequacy present in these equipments at the
time of commissioning of PCP, in such case all work associated with supply, installation, testing
and commissioning shall be in scope of CP contractor with no extra cost.
The Scope shall also include but not limited to the following for completion of jobs:-
a) Selection of plot for shallow type anode groundbed/ Deepwell anode groundbed at CP station at
following proposed locations of CP stations given below (Min. three plots nearby each location shall
be selected for the survey out of which the most favorable plot shall be considered for installation of
anode ground bed).
Section-I:
i- DT (Ch 00.00 km)

ii- SV-01(Ch 36.80 km)
iii- SV-02 (Ch 76.35 km)
iv- IP-01 (Ch 106.822 km)
SECTION-II

WORK (TCP+PCP)
Section-II:
v- SV-03 (Ch 148.124 km)

vi- SV-04 (Ch 178.20 km)
vii- RT-Palanpur (Ch 216.36 km)
The above selected plot for the anode ground bed will be truly remote with respect to the proposed
pipeline’s & other nearby foreign structure/pipeline. For calculating the remoteness of the
groundbed from cathodically protected pipeline and nearby foreign structure/pipeline location
(NACE latest recommendation shall be utilized & remoteness from both cathodically protected
pipeline & nearby foreign structure/pipeline shall be calculated). However the distance of anode
bed from cathodically protected pipeline and other nearby foreign structure/pipeline shall not be
less that 100 mtr.
b) Carrying out the soil resistivity survey for design of anode ground bed at the selected CP station
locations. (Min. at three locations shall be selected for the soil resistivity survey & necessary data
shall be collected to determine the most suitable anodebed location) as per specification for
corrosion survey MEC/TS/05/21/016C.
c) Preparation & submission of design document as per the results of surveys, specification & data
sheet for procurement of CP System equipment/materials, drawing/document to the Engineer-
incharge for review & approval, preparation of site engineering & installation drawings for
installation work wherever applicable or required by the Engineer-in-charge, and submit the same
for approval and comments. All documents of PCP system including survey, Design, review of
collected survey data, installation procedures, post commissioning surveys and complete PCP
system of pipeline shall be designed & signed by NACE certified CP specialist having valid CP
specialist certificate.
d) Development of topo sheets which should be suitable for use in land acquisition for anode ground
bed, Anode Junction box, ROU for laying at CP stations.
e) Acquisition of land & ROU of land for anode header cable for anode ground bed (Land size Min
46mx3m for shallow and Min. 5mx5m, for deepwell type), ROU for laying of cables (1mtr wide)
from AJB to CPTR. Transferring the title of the acquired land in favour of HPCL at the following CP
station locations.
Section-I:
SV-01(Ch 36.80 km) - By Contractor

SV-02 (Ch 76.35 km)- By Contractor
Section-II:

AGB land at following stations shall be provided by the M/s HPCL-
DT (Ch 00.00 km)- AGB land shall be provided by HPCL Inside the Despatch terminal
SECTION-II

WORK (TCP+PCP)
IP-01 (Ch 106.822 km)- AGB land shall be provided by HPCL inside the IP terminal
RT-Palanpur (Ch 216.36 km)- AGB land shall be provided by HPCL inside RT-Palanpur.
Note- Deduction for land in case of not acquired by Bidder at location in the Bidder scope shall be
DLC rate*4 times plus 20%.
The item scope includes acquiring land and Change of land ownership to the name of HPCL
including NA conversion (where required), area grading / levelling to a suitable grade level to avoid
water logging, supply and fixing of chain-link fencing and gate. The item scope also includes
acquiring ROU (where required) for cable laying between CPTRU and Anode bed.
Note: PCP/Land for anode bed for the complete Pipeline is in the scope of contractor. Contractors
Scope:
The Contractors scope of job includes, but is not limited to, the following:
a) Identification of plot in close vicinity to the chainages of the respective Sectionalising Valve
Stations along the pipeline route and acceptance by HPCL.
b) Taking consent from the land owners.
c) Collection of revenue records, establishing correctness of ownership by search/ revenue
records, nil encumbrances etc.
d) Obtain the required documents from revenue department and get it verified from an Advocate
from HPCLs approved lawyers.
e) Submit cleared documents with Legal certification to HPCL for final Legal clearance from HPCLs
Legal department.
f) Contractor shall carry out the survey of the land from RDO or Dy Inspector of Surveyor or other
designated authority and mark the four corners of land. The report shall be part of deliverables of
contractor before agreement.
j) Only such legally and technically cleared lands will be considered and given clearance to the
contractor for purchase of such lands.
l) The legally cleared agreement shall be given by HPCL.
m) Expediting subsequent formalities including signing of agreements or sale deed if any, to
facilitate possession of land by HPCL.
n) Obtaining all required approvals/ no objection certificates from concerned authorities like village
panchayats or municipalities etc. under whose jurisdiction each plot of land falls, for constructing
and setting up the Sectionalising Valve Stations.
o) Obtaining approvals from concerned for laying cables to the Sectionalising Valve Stations from
the anode bed.
p) Registering the land in HPCLs name.
q) Entry of HPCLs name in original Land Records on the acquired plot no. and obtaining copy of
the same in support.
r) Getting Non Agricultural conversion of the land if required.
HPCLs scope In above context shall be limited to:

a) Obtaining Legal Clearance from HPCLs Legal department.
f) Design of shallow/deep-well anode beds for construction at selected locations as per national/
international standard & specification. The type of the anode bed i.e. shallow type or deep well type
will depend upon the soil resistivity of the anode bed plot location. CP contractor will submit
necessary data for the type of anode bed considered & shall be decided during detail engineering.
Bidder shall take specific approval for Installation of Deep-Well anode groundbed from
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WORK (TCP+PCP)
HPCL/MECON.
g) Design, Supply, installation, testing & commissioning of anode ground bed (Shallow bed size Min.
46x3 mtr or size may increase as per the design calculation), consisting of minimum ten (10)
numbers Mixed Metal Oxide Coated Titanium Hollow Tubular Anodes of 25mm dia. / 1000mm long
size and 8A Rating along with tail cable of 1C x 10mm2 Annealed Stranded Copper conductor,
PVDF insulated, HMWPE sheathed/Jacket (Kynar Cable) shall be terminated at AJB at the CP
station locations, with anode canister in normal resistivity area (0-100 Ohm-m). Actual numbers of
anodes shall be finalized during the approval of design calculation submitted by the Contractor.
In high resistivity area (where resistivity ≥100) anodes shall be installed without canister & anode
bed trench of cross-section 300mmx300mm for horizontal type of anode bed shall be backfill by
Coke breeze (In slurry form) for its full length.
Anode Ground Bed resistance should be maintained less than 1 Ohms (Max.).
MMO anodes shall be as per ASTM B861 GR-I.
h) Incase of deep-well anode bed, supply, installation, testing & commissioning of individual anodes in
vertical installation, consisting of minimum ten (10) numbers of Mixed Metal Oxide Coated Titanium
Tubular Anodes of 25mm dia./ 1000mm long size and 8A Rating with tail cable of 1C x 10mm2
Annealed Stranded Copper conductor, PVDF insulated, HMWPE sheathed/Jacket (Kynar Cable)
shall be terminated at AJB. Actual numbers of anodes shall be finalized during the approval of
design calculation submitted by the Contractor. Design of deep anode-bed shall be as per
NACE:0572:2007 requirements.
Anode Ground Bed resistance should be maintained less than 1 Ohms.
Minimum depth of anode bed shall be 48m (As per drawing) & it may increase as per the survey
data. The bore hole shall be filled by coke breeze in slurry form.
i) Anode bed backfill material bulk density and other requirements shall be as per NACE:0572:2007.
j) Disconnection of temporary cathodic protection system which does not form part of permanent
cathodic protection system, prices for disconnection of temporary cathodic protection system is
integral part of bid & deemed to be inclusive in prices quoted by the Bidder.
k) Supply & Installation of Chainlink Fencing for Anodebed & AJB as per instruction of Engineer-In-
Charge & approved drawings.
l) Supply, laying, termination, glanding and ferruling of all the cables of CP system, including all
incoming power cable and outgoing CP cables of CPTR/ CPPSM units.
m) Minimum nos. of CP stations considered are mentioned in cl no. a), however actual numbers of CP
stations shall be finalized during the approval of design documents submitted by the Contractor,
but it won’t less than the minimum mentioned. The nos. of CP stations may increase during the
detailed engineering, Bidder shall supply, Install & commission the increased CP stations without
any extra cost implication to protect the pipeline. PCP system shall be designed in such a manner
that TR/CPPSM units comes at Intermediate SV/IP station locations. The proposed locations of CP
stations may also change during the detail engineering.
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WORK (TCP+PCP)
n) Supply, installation & commissioning of Min 3 Nos. permanent references cell (Zn type) each at the
proposed locations for CP stations locations. (Design criteria for Zn type ref electrode is given in
design basis) The installation locations of reference cell shall be decided during detail engineering.
Bidder to note that at D/T, R/T, TOP/TOT, IP stations min 02 additional ref cells shall be installed at
each pipeline terminating/originating from the stations & all measurement /Ref cable shall be
terminated to the CP stations. CP unit shall have selector switches for required no. of inputs of ref
available as per the nos. of ref cells of pipeline terminating/originating at station and provision to
select the ref PSP of any of pipeline in CP unit. Separate local monitoring meter shall also be
provided in CP units. Multi-core signal cable of suitable pair shall be considered for the
measurement cable & reference cell cable from CJB to TR unit. (For this bidder may consider 8/12
pair, Multi-core, FRLS, 2.5 Sqmm, 8/12 pair, twisted pair, shielded, armoured, signal cables as per
IS/BS).
One permanent reference cell shall also be installed on the unprotected side of the pipelines at IP,
DT & RT and wired upto the CPTR unit and to SCADA by 4-20mA signal to the SCADA for remote
monitoring and accessing integrity of the IJ.
o) Separate drainage connections are to be made with separate junction box (having provision to
control the current) to each pipeline at IP station location feeding from the common CPPSM/CPTR
unit.
p) Supply, installation, testing & commissioning of Computerized Test Stations (CTSU) @ 4 Nos. (02
no for each section) with Permanent Zn/Cu-CuSo4 ref electrode & portable data readers 2 nos. (1
no. for each section, ) along with permanent reference cell (Zn/Cu ref cell) and central Monitoring
server with PC (Min. specification Intel 5th Generation Processor, Core i7, and 19” LED Monitor) at
one maintenance base for automatically monitoring through GPS and recording the pipe to soil
potential, pipe current etc of the pipeline. Locations of CTSU shall be decided during detailed
engineering. Central monitoring server shall have facility to interface the CP unit signals available in
SCADA system and the work related to interfacing the signals is in the scope of the bidder,
including supply & installation of all items.
Notes-2-
All hardware & software required for the central Monitoring of the system shall be supplied for
automatically monitoring of the CTSU from central server.
CTSU shall be able to record Simultaneous recording of 3 No. analogue channels, generate +ve &
-ve sign for recorded PSP values, Battery Low alarm. Spare Battery Pack shall be supplied with
each CTSU.
The test stations shall be designed for installing and mounting portable data logger inside with theft
proof design.
q) Supply including design, manufacturing, shop testing, inspection, packing, forwarding, delivery
erection/ installation, civil/ structural support, earthing, testing & commissioning of Min. 50V/50A or
75V/50A or higher rating output CPTR unit each at CP station locations confirming to standard
specification No. MEC/05/S/26/82A, data sheet & Drawing. The CP units shall be installed inside
the control room. All the CP units shall have SCADA monitoring facility, current interruption facility
with timer (GPS Synchronized) etc as per specification including commissioning spares as
required. Current shall start/stop/reset from local as well as from remote thru SCADA. Current
interrupter shall be configurable from 0.1 sec to 999 sec. Minimum 30 mtr GPS cable shall be
provided with each CP unit.
SECTION-II

WORK (TCP+PCP)
r) Bonding in between pipelines running parallel or crossing as required. Taking of permission from
the owner (By Owner) of the foreign pipeline wherever required for effective PCP protection and to
reduce the anodic interference among them. Interference surveys and mitigation shall be carried
out for both the pipelines i.e. proposed and existing. Other CP related surveys for existing pipeline
is not applicable. For proposed new pipeline all CP related survey to be carried out and DC
interference mitigation measures shall be implemented for both the pipelines.
Bonding with existing/new CP system of parallel pipelines hook-up methodology shall be designed
by the NACE CP specialist after conducting all required field surveys including details study of
existing PCP system & previous PCP system problems of existing pipeline in common ROU and its
mitigations.
s) In case, anode groundbed of foreign pipeline existing within the ROW of proposed pipeline & is
source of interference to the proposed pipeline, the contractor shall relocate the anode ground bed
in consultation with Owner of foreign pipeline without any extra cost.
t) The contractor shall carry out interference detection and mitigation measures for all the pipelines
including detection of AC and DC interference on pipeline’s and its mitigation due to proximity of
foreign AC and DC source i.e. HT line (Parallel, Crossing), Underground HT Cables in proximity,
substation, railway traction, welding yard, existing pipeline running parallel or crosses & other
foreign pipeline/structure/utilities, HVDC Interference. For the interference detection & mitigations
(AC & DC interference study & mitigation) the contractor shall include the services of specialist
agencies having proven track records & experience on software modelling & recommendation for
its mitigation.
Pipeline AC Interference studies & Mitigations measures including measurement of AC pick-up due
to long term (Induced, conducting due to transformer neutral, fault) & short term interference
(Ground Fault, Lightning, conducting etc) as per field data collected, AC corrosion study (As per BS
EN 15280:2013 - Evaluation of A.C. corrosion likelihood of buried pipelines applicable to
cathodically protected pipelines), Effect of HT line/ Cables running parallel/crossing the pipeline
and discharge of current from nearest HT tower/Substations due to fault or lightning etc.
Implementations of interference mitigative measures on pipeline’s bring down these voltages
(touch & step potentials) to safe limits as per the National/International standards & other mitigation
measures to reduce the AC corrosion densities. Mitigation measures suggested by the bidder shall
be submitted for review and approval to Engineer-In-Charge.
As a part of AC interference detection, the following AC modeling shall be done by the contractor
through an expert agency/contractor itself should have experience as mentioned in BEC clause as
approved by MECON/HPCL. (Expert agency/Bidder shall be in the field of interference study and
mitigation work for minimum 05 years.) :
 The software suggested for AC modelling shall be of SES’s Right-of-Way Pro software/ (Elsyca)
or equivalent approved which can models complex arrangements of buried and aboveground
conductors and computes currents and voltages resulting on every utility modelled, including
conductors associated with the power line, for normal (load) and fault conditions.
 Software package for the analysis of electromagnetic interference between electric power lines
and adjacent installations such as pipelines, communication lines and railways and able to
model a large network including multiple power lines and pipelines in one model and have Large
Conductor database to choose from including most transmission line conductors and mitigation
SECTION-II

WORK (TCP+PCP)
devices like Zinc ribbon, Diodes, SSPC and copper wire Mitigator, etc. Copper wire Mitigator
shall have Outer wrapping (Sealed, porous, non-degrading acid reducing fabric) and braiding
with carbon backfill with copper corrosion inhibitors for long life. Dia and installation length of the
mitigator shall be as derived by the software modelling.
 Software package have ability to model transformers, transmission system (AC/DC), sub
stations, Faults Modelling etc.
 Provide results on Touch and coating stress output, GPR, CSV (Coating stress voltage) & AC
corrosion output (AC corrosion densities) on whole modelled pipeline.
 Have Multi-layer Soil Resistivity Model.
The software shall be capable to:
 Analyses electromagnetic interference effects, currents and voltages in every span of a multi-
conductor, multi-phase power network and in any neighbouring victim circuits sharing the same
corridor with pipeline.
- Capable of modelling a total interference scenario consisting of inductive, conductive and

capacitive interference and generating outputs based on different current loading conditions in
different seasons.
- Capable to calculate mitigating measures with sizing the SSD's (Solid State Decoupler devices),
earthing devices & earthing system to reduce the AC interference.
- Able to generate outputs for true Touch Potential, and 1 cm2 coating holiday current density
output in amperes per square meter to analyse the effects of AC Corrosion on a pipeline.
- All required data of pipeline, soil resistivity; HT lines, sub-station and other interfering sources as
suggested by interference specialist shall be collected CP contractor/Expert agency and
reviewed by the NACE CP specialist.
- Mitigations of Interference as per the results of software modelling are in the scope of the
Bidder.
- Mitigation measure location details with detailed BOM
- Post mitigation verifying the induced voltage/ current density
 The agency proposed by CP contractor shall be subject to acceptance as per sole discretion of
MECON / HPCL.
Pipeline DC Interference studies & Mitigations measures shall also be carried out due to proximity
of DC interference source. GPS coordinates of all HT tower locations, distribution transformers,
Foreign Pipeline crossings & other interfering source shall be taken during field data collection.
For the interference detection & mitigations (AC & DC Interference study & Mitigation) the
contractor shall include the services of specialist agency or will carry out the same on their own as
per the BEC requirement as mentioned in the BEC clause of this document.
SECTION-II

WORK (TCP+PCP)
Interference detection & mitigation due to DC sources (i.e. HVDC transmission lines. DC traction
etc.) shall be carried out as per DIN 57150/VDE 0150:Protection against corrosion due to stray
currents from DC installations.
The contractor shall handover interference free CP system to M/s HPCL. If HPCL/MECON desires,
contractor have to take opinion from specialist other than the hired agency for the Detection/
Mitigation of interference, recommendations, if any is in the scope of the contractor with no
additional cost.
CRITERIA FOR AC INTERFERENCE –Refer standards specification no.

MEC/TS/05/E9/016B cl no. 12
CRITERIA FOR DC INTERFERENCE –Refer standards specification no.
MEC/TS/05/E9/016B cl no. 7.0/Design Basis.
DATA COLLECTION FOR INTERFERENCE STUDY
Contractor shall carry out field survey for collecting data required for the Interference survey
from various authorities like Power Authorities/ Foreign facility Owners (Pipeline, substations,
welding shops, HVDC line and its convertor stations etc as required for the interference
simulation which includes following.
 Existing or proposed (33 kV & above) EHV/HV AC/ DC overhead power lines along with details
of voltage, AC/DC type etc, crossing or parallel to the pipeline, phase configuration, number of
circuits and other line parameters.
 Voltage rating, phases, sheathing details of underground power cables along ROW or in its
vicinity.
 Substations (33kV and above) in the vicinity of the pipeline and pole mounted (11kV)
substations.
 Tower footing, earthing distance from tentative ROU to be recorded for ascertaining safe
distance.
 Fault current rating of each HT line, Designed load current ,operating load current Location of
grounding of tower and substation location etc. to be obtained from powercompanies.
 Multi-layer soil resistivity near the area of AC tower parallel or crossing.
REPORT
Recommendation shall be for both operating load and design load of the pipeline.
AC/DCinterference mitigation report shall have the following:
 Mitigation measure location details with detailed BOM

 Type of grounding: distributed vertical zinc ground anodes, horizontal zinc ribbon anode,multiple
zinc ribbon anodes, independent deep ground beds. The grounding system shall bede-coupled
with the ICCP system using suitably located and rated solid statedecouplers.
 Location of TLP’s where AC corrosion coupons/ Polarization coupons shall be installed for
monitoring the induced potentials and AC current densities for safe operation of the pipeline.
 Locations of additional TLP’s for interference mitigation
SECTION-II

WORK (TCP+PCP)
Post commissioning, the values of current density and AC induced voltages shall be measured
at site and the same cross checked with the modelled values, the overall profile of the site data
andthe modelled data as seen over a segment shall be in similar.
Specialist agency shall also verify the induced voltage/ current density after the mitigation
aretaken care & installed at the site.
u) The contractor shall carry out following post commissioning surveys (As per OISD/PNGRB)-
1) Close interval potential logging survey for entire length of 18” pipeline,
2) CAT survey (entire length of 18” pipeline) including measurement of depth of the buried
pipeline,
3) Pearson Survey
4) Specific Coating resistance/conductance test at current measurement test location and pipeline
current mapping with direction of the current (After PCP system commissioning), including
calibration factor of same thickness pipelines.
5) Current drainage test at bonding locations.
6) CAT with frame ‘A’ and DCVG survey (Both) at selected locations which shall be decided from
the abnormal areas of CPL and CAT survey results to identify coating defects/holiday and
implement mitigation measures for the same.
Note-DCVG survey (where CAT survey cannot be conducted) shall be carried out after
commissioning of PCP.
v) The TR/CPPSM units shall be provided with facilities for sending and receiving digital and
analogue input/output signals for remote SCADA monitoring.
w) Supply and installation of the power supply cable from switch fuse unit/ MCC /PDB of OWNER’S
Electrical substation to CPPSM/CPTR Units shall be CP Contractor’s scope of work.
x) Supply of Two Years O&M Spares as described in Appendix-II at Two locations.
y) Monitoring & maintenance (as a whole) of PCP System of entire length of 18” 3LPE Coated
pipelines for 6 months (Monthly Basis) including collection of data from data loggers after
commissioning of PCP works simultaneously with post commissioning survey work.
z) Supply, Installation, Testing & commissioning of AC corrosion coupons (exposed area 1cm2) for
monitoring of AC corrosion densities at HT line crossings and AC interference prone area along
with high accuracy AC shunt (Additional 10% quantity of coupons shall be also be considered).
aa) The material shall be checked as per the packing list of the vendor without opening of the boxes for
physical verification jointly verified by Purchaser/Consultant.
bb) Interconnection PVC water pipeline of 1.5” between AGB & Terminal water supply system to
maintain the lower grounding bed resistance, including supply, installation & all connection at all CP
station locations.
cc) All civil/ structural & other miscellaneous works related to PCP system including supply of bricks,
cement & steel etc. required for completion of the system.
Note-
Note-1:-The distance between the anode bed & Pipeline shall be as per the remoteness
SECTION-II

WORK (TCP+PCP)
calculation between pipeline & anodebed, successful CP contractor will submit the
remoteness calculation of the anodebed based on actual site data collected.
Note-2:- It may be noted that the size of plot/land for anode-bed mentioned above may
increased from the minimum specified (As per the design) Accordingly, the suitable size
land for anodebed shall be acquired.
Note-3:- At saline soil Ag/Agcl Permanent Reference electrode shall be used.
Note-4:- Vendor list of Make of CP Materials is enclosed with the tender as appendix-I all CP
material shall be as per the make mentioned in the vendor list.
Note-5:- The CP contractor/s shall handover interference free CP protected pipeline to the
owner.
Note-6: - TR/CPPSM unit shall be designed and manufactured as per the design criteria
mentioned for the Zn type permanent ref cell.
Note-7: - For chainages refer Pipeline Schematic Route Diagram
Note-8:- Permanent reference shall be provided with back fill.
10.4 Tentative Bill of Material
Tentative bill of material of TCP shall be prepared by the successful contractor for each section as
per the approved design and the same shall be submitted with the detail engineering package for
review.
10.5 Other Miscellaneous Works
i) The job includes all civil works including supply of bricks, cements steel etc. connected with
grouting of equipment to be installed. The job includes repairing of all civil works damaged during
installation of electrical and other facilities.
ii) Preparation of buried cable trenches including excavation, back filling, compacting, providing of
brick protection by second-class bricks, spreading of fine river sand, including all supplies.
iii) CP contractor shall provide Colour code identification for the various CP System cables used in the
system with design document for approval.
iv) The scope of work under this contract shall be inclusive of breaking of walls and floors, and
chipping of concrete foundations necessary for the installation of equipment, materials, and making
good of the same. Minor modifications wherever required to be done in the owner free supplied
equipments or devices to enable cable entry, termination, etc.
v) Checking of all connections, i.e. power, control, earthing and testing and commissioning of all
equipment erected and/or connected under this contract as per testing procedures and instructions
of Engineer-in-Charge.
vi) Armour of the cables of MOV or other cables which creates leakage of the CP currents shall be cut
to prevent the leakage of CP current.
SECTION-II

WORK (TCP+PCP)
vii) All electrical equipments are to be doubly earthed by connecting two earth wires from the frame of
the equipment to be earth grid. The cable armours will be earthed thro’cable glands.
The following shall be earthed:
 All non-current carrying metallic parts of electrical equipments such as lighting and power
panels, push button stations, cable trays etc.
viii) Supply and installation of all other accessories not specifically mentioned herein but nevertheless
necessary for completion of job.
ix) Engineering and preparation of specifications, data sheets, procedures and drawings etc required
for procurement & installation of CP System wherever applicable/required by Owner/ MECON and
submit to Owner/ MECON for approval/comments.
x) Supply and installation of all other accessories not specifically mentioned herein, but nevertheless,
necessary for completion of the job including any other material required as per tender terms and
conditions for successful commissioning of TCP and PCP.
xi) Correction and submission of all owners’ drawings for as-built status.
xii) Obtaining clearance for energising the complete electrical facilities covered under this tender and
approval of installation/drawings from Govt. authority if required.
xiii) Test certificates, catalogues, vendor drawings, installation, operation and maintenance manuals for
all equipment/materials in contractor’s scope of supply.
xiv) All civil work related to the CP work is in scope of the CP contractor.
xv) Co-ordination with other Contractors/Pipeline contractor.
10.6 WORK CONTRACT
The entire work as per Scope of Work covered under this contract shall be treated as “Works
Contract”.
All works included in the scope of CP work will be done simultaneously with main pipeline
construction by main pipeline Contractor. Bidder will supply all the materials required for completing
the system and organise manpower & equipments accordingly to meet the requirement of Cathodic
Protection work in time as per completion schedule given in Volume - I.
10.7 SCOPE OF SUPPLY
10.7.1 Owner’s Supply – NIL
Supply, testing, Packing, Forwarding, Delivery, Installation and commissioning of all the equipment
covered in this package are included in the scope of the contractor. No equipment will be free
issued by the owner to the contractor.
10.7.2 Contractor’s scope of supply shall be as mentioned in Cl. No. 9.1 & 9.3.
SECTION-II

WORK (TCP+PCP)
10.7.3 Bidder shall submit list of two year operational & maintenance spares along with offer.
O&M CP Spares/ Tool / Tackles for CP system like Multimeter, Clamp meter, Portable reference
cell, UT meter, Tool box Complete for each maintenance base etc.
List of O&M spares is enclosed with appendix-II.
All commissioning & start up spares are in bidder’s scope (Included in this package). Any
commissioning & startup spare consumed during the start up & commissioning is included in the
supply of this package, for which no extra payment is made.
1. Contractor to note that the exact cable routing shall be decided at site based on actual site
conditions. Exact cable quantities/sizes shall be based on actual measured route lengths at site by
Contractor in coordination with Engineer-in-Charge/Client. Contractor shall ensure that there is no
surplus or shortage of cables at site and procure cables accordingly.
2. Contractor to note that all cabling (including supply & laying) & other electrics for the CP System
shall be supplied along with the package and no separate payment shall be admissible for the
same. Owner shall provide only single point power supply for the same.
3. Job is lump-sump basis, price breakup shall be submitted to the Engineer-In-Charger &
HPCL for approval for payment purpose for TCP & PCP work, however the work to be
carried out & material to be supplied for this project which is not covered under this
contract the payment shall be done as per unit price on submission of the back invoices
documents & GST bill.
11.0 STATUTORY APPROVAL OF WORKS
The submission of application on behalf of the Owner to Govt. Authority/ Central Electricity
Authority/State authority/Private bodies, if required along with copies of required certificates
complete in all respects, shall be done by the contractor well ahead of time so that the actual
commissioning is not delayed for want of approval from respective authority. The actual inspection
of work by the above mentioned authority inspector shall be arranged by the Contractor and
necessary coordination and liaison work in this respect shall be the responsibility of the contractor.
However any fee paid to these Authorities in this regard shall be reimbursed by the Owner on
submission of bills with documentary evidence.
The Inspection and acceptance of the work as above shall not absolve the Contractor from any of
responsibilities under this contract.
The necessary permissions required for the bonding etc for the interference mitigation
(From SEB’s, Water works Departments/ Boards, Railways & Other pipeline owners) shall
be obtain before taking mitigation measures in the scope of contractor & the same will be
hand over to HPCL after commissioning of CP system.
12.0 QUALITY ASSURANCE, INSPECTION AND TESTING
All the equipment supplied by the contractor shall be inspected by the Owner/MECON and/or their
approved inspection agency (TPI) at the manufacturer’s works prior to despatch. The equipment
will be inspected as per the tests pre-identified in the approved QAP to ensure conformity of the
SECTION-II

WORK (TCP+PCP)
same with relevant approved drawings, data sheets, specifications, National/International
standards. The TPI shall be arranged by the CP contractor for the testing of the
material/equipments at the vendor works.
12.1 Performance tests of any equipments which cannot be conducted/demonstrated either partially
of wholly at the manufacturer’s work, shall be conducted after erection at site in the presence of
Owner & their inspection agency. In all the cases, prior approval of the approval shall be
obtained.
12.2 In case of waiver category of items, the same shall be pre identified. For such items, the
contractor shall furnish necessary certificates, test reports etc for Review/Approval to
Owner/Inspection agency. The issue of Inspection Certificate/Waiver Certificate for any
equipment or component there of does absolve the contractor from his contractual obligations
towards subsequent satisfactory performance of the equipment at site. Should any equipment
be found defective, In whole or part thereof after receipt at site or during erection/commissioning
and testing shall be Rectified/Changed by contractor free of cost.
12.3 Contractor shall submit test plan for the equipments with four week advance notice.
12.4 The following equipment/items shall be tested and inspected by MECON/ owner at manufacturer’s
works before dispatch. Test certificates duly signed by MECON/ Owner shall be issued by the
contractor as part of the final document.
- Hazardous area equipment

- CP TR/ CPPSM units
13.0 TESTING & COMMISSIONING
13.1 The successful bidder shall submit detailed installation, site testing & commission procedure
with time schedules for Review/Approval to Owner/MECON.
13.2 The successful tenderer shall provide adequate supervisory/ skilled personnel and all tools and
tackles, testing equipment and instruments required for complete checking of installations and
testing and commissioning of all equipment and accessories.
13.3 All the tests shall be conducted in the presence of Owner/ MECON/Engineer-in/charge or his
authorized representative unless he waives this requirement in writing.
13.4 The testing and commissioning of all equipment under the scope of the bidder & shall be carried
out in accordance with the latest edition of relevant Indian Standards, International Standard
NACE standards and IE Rules.
13.5 Test reports shall be submitted in required number of copies duly signed by the Bidder to
MECON and OWNER.
13.6 On successful completion of erection of each item /equipment, a final inspection will be carried
out at site by Owner / MECON, for correctness and completeness of erection.
13.7 After the completion of all tests and rectification of all defects pointed out during final inspection,
start-up trials would be commenced. During the start-up trials contractor shall provide skilled /
unskilled personnel and supervision round the clock at his cost. The number and category of
SECTION-II

WORK (TCP+PCP)
workmen and duration up to which required, will be decided by the Engineer-in-charge. Any
defects noticed during the start-up trial relating to the equipment supplied and work carried out
by the Contractor, will be rectified by the contractor at his own cost.
13.8 Any work not conforming to the execution drawings, specifications or codes shall be rejected
forthwith and the contractor shall carry out the rectification at his own cost.
13.9 After the operating conditions are fully achieved for CP system and the other requirements as
stated in the General Conditions of Contract are fulfilled, the contractor would be eligible for
applying for a completion certificate.
14.0 DRAWINGS, STANDARD SPECIFICATION AND INSTALLATION STANDARDS
14.1 The drawings accompanying the tender document are indicative of the nature of work and issued
for tendering purposes only. Construction shall be as per drawings/specifications issued/ approved
by the Owner/ MECON during the course of execution of work.
After the job completion, contractor shall prepare ‘AS-BUILT’ drawings, final certified as built
drawings vendor drawings for bought out equipments shall be submitted by the contractor to owner
in bound volume with one set of reproducible original sepia plus five sets of prints & one set to
MECON.
The equipments/ materials to be supplied by the contractor shall conform to the requirements of
the applicable standard specifications. Also the installation of various material/ equipment shall
also conform to the standard specification.
The purpose of the pipeline alignment drawings, P&IDs & Plot Plan drawings enclosed with the
tender is to enable the tenderer to make an offer in line with the requirements of the Owner.
These are indicative of the nature of work and issued for tendering purposes only. The bidders,
however, shall visit the site before bidding for proper information of site conditions. Construction
shall be as per drawings/ specifications issued/ approved by the Owner/ Consultant during the
course of execution of work and no additional payment shall be made for any changes made
and bidder shall supply the package at no additional cost and time to Owner.
A) SPECIFICATION
1. Specification for TCP system MEC/TS/05/E9/016A

2. Specification for PCP system MEC/TS/05/E9/016B
2. Specification for Corrosion Survey MEC/TS/05/21/016C
B) DATA SHEETS & QAP
1. Quality Assurance Plan MEC/05/E9/23VE/QAP/082

2. Data- sheet for Cathodic Protection TR Units MEC/DS/05/E9/082A
3. Data- sheet for Cathodic Protection CPPSM Units MEC/DS/05/E9/082
C) STANDARD DRAWINGS
1.0 Prepacked Zinc Anode MEC/SD/05/E9/E/CP/1601

SECTION-II

WORK (TCP+PCP)
2.0 Prepacked Mg Anode MEC/SD/05/E9/E/CP/1602

3.0 Mg Ribbon anode for Grounding MEC/SD/05/E9/E/CP/1603
4.0 Details of Test Station for TCP MEC/SD/05/E9/E/CP/1604
5.0 Test Station Connection Schemes MEC/SD/05/E9/E/CP/1605
6.0 Galvanic Anode Installation MEC/SD/05/E9/E/CP/1606
7.0 Zinc Ribbon Anode for Cased Crossings with MEC/SD/05/E9/E/CP/1607
Coated Casings
8.0 Pipeline Grounding Through Polarisation Cell and MEC/SD/05/E9/E/CP/1608
Galvanic Anodes
9.0 Details of Zinc Grounding Cell MEC/SD/05/E9/E/CP/1609
10.0 Permanent Copper – Copper Sulphate Reference MEC/SD/05/E9/E/CP/1610
Cell & Installation Details
11.0 Shallow Anode Ground Bed (PCP) MEC/SD/05/E9/E/CP/1611
12.0 Anode Lead Junction Box MEC/SD/05/E9/E/CP/1612
13.0 Casing Pipe Detail MEC/SD/05/E9/E/CP/1613
14.0 Test station for polarization cell MEC/SD/05/E9/E/CP/1614
15.0 Deep well anode bed MEC/SD/05/E9/E/CP/1615
16.0 Connection scheme for hooking through MEC/SD/05/E9/E/CP/1616
CJB/TLP
17.0 Details of thermit weld for cable to pipe joint MEC/SD/05/E9/E/CP/1618
18.0 Installation details of Polarization coupons MEC/SD/05/E9/E/CP/1619
19.0 Electrode for earthing system MEC/SD/05/26/23/01
20.0 Earth Electrode in Test Pit MEC/SD/05/26/23/02
14.2 Drawings for Tender purpose enclosed with construction tender
Schematic Route Diagram

P&ID
Plot Plan
14.3 Survey Drawings/ Details
a) Overall Schematic Route Diagram
15.0 RESOURCES FACILITIES
15.1 Recruitment of Personnel by Contractor

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WORK (TCP+PCP)
The Contractor shall not recruit personnel of any category from among those who are already
employed by the other agencies working at the sites but shall make maximum use of local
labour available.
15.2 Construction Water and Power Supply
No water and power will be provided by the owner. It should be the responsibilities of the contractor
to arrange water and power at his own cost.
15.3 Land for Residential Accommodation
Owner shall not provide any land for residential accommodation of contractor’s staff and labour.
Space for storage of material is included in contractors scope. Contractor shall be responsible for
safety and security of his equipment, supplied material, etc.
16.0 PROJECT SCHEDULING & MONITORING
The following schedules/documents/reports shall be prepared and submitted by the

Bidder/Contractor for review/approval at various stages of the contract.
16.1 Along with Bid
b) Time Schedule
The Completion Time Schedule for the work (including mobilization period) as given in VOL-I of in
all respect, from the date of issue of letter/Fax of Intent.
The Bidder is required to submit a Project Time Schedule in Bar Chart Form, along with the Bid.
The Schedule shall cover all aspects like sub-ordering, manufacturing and delivery, indicated in the
Bid Document. The Owner interface activities shall be clearly identified with their latest required
dates. Owner reserves the right to disqualify the Bidder if the above Schedule submitted by the
Bidder is not in line with the over all Project requirement.
c) Scheduling & Monitoring System
The Bidders should describe their system of Project Scheduling and monitoring, the extent of
computerization, level of detailing, tracing methodology etc. with the name of computer package
and sample outputs.
16.2 After the Award of Contract
a) Overall Project Schedule
The Contractor shall submit within 2 week of Fax of Intent, a sufficiently detailed over all Project
Schedule in the activity network form, clearly indicating the major milestones, interrelationship/
interdependence between various activities together with analysis of critical path and floats.
The network will be reviewed and approved by Engineer- in-Charge and the comments if any shall
be incorporated in the network before issuing the same for implementation. The network thus
finalised shall form part of the contract document and the same shall not be revised without the
prior permission from Engineer-in- Charge during the entire period of contract.
SECTION-II

WORK (TCP+PCP)
b) Progress Measurement Methodology
The contractor is required to submit within 2 week of award of WORK, the methodology of progress
measurement of sub-ordering, manufacturing/ delivery, sub- contracting construction and
commissioning works and the basis of computation of overall services/physical progress informed.
Owner reserves the right to modify the methodology in part or in full.
c) Functional Schedules
The contractor should prepare detailed functional schedules in line with network for functional
monitoring and control and submit scheduled progress covers for each function viz. ordering,
delivery and construction.
16.3 Project Review Meetings
The Contractor shall present the programme and status at various review meetings as required.
Weekly Review Meeting
Level of : Contractor’s/Consultant’s RCM/

Participation Site In-charge & Job Engineers.
Agenda : a) Weekly programme v/s actual achieved in the past week &
programme for next week.
b) Remedial Actions and hold up analysis.
c) Client query/ approval.
Venue : Site Office
Monthly Review Meeting
Level of : Senior Officers of HPCL/MECON and Participating

Contractors.
Agenda : a) Progress Status/ Statistics

b) Completion Outlook
c) Major hold ups/slippages
d) Assistance required
e) Critical issues
f) Client query/ approval
Venue : HPCL/MECON Office/ Site Office
16.4 Progress Reporting Proforma
A) Monthly Progress Report
This report shall be submitted on a monthly basis within 10 (ten) calendar days from cut-off date,
as agreed upon covering overall scenarios of the work. The report shall include, but not limited to
the following:
SECTION-II

WORK (TCP+PCP)
 Brief Introduction of the work.

 Activities executed/ achievements during the month.
 Schedule versus actual percentage progress and progress curves for Detail Engg. Sub-
ordering, Manufacturing/ Delivery, Sub-contracting, Construction, Commissioning and
Overall and quantum wise status & purchase orders against schedule.
 Area of concern/ problem/ hold-ups, impacts and action plans.
 Resources deployment status.
 Annexures giving status summary for drawings, MRs, deliveries, sub-contracting and
construction.
 Procurement status for items to be supplied by Contractor.
B) Weekly Reports
The report will be prepared and submitted by the Contractor on weekly basis and will cover
following items :
 Activities programmed and completed during the week.

 Resource deployed men and machines.
 Quantities achieved against target in construction
 Record of Mandays lost.
 Construction percentage progress schedule and actual.
C) Daily Repots
 Activity programme for the day

 Progress of the previous day and commutative progress.
 Manpower & machinery deployed.
Successful bidder shall submit DPR (Daily progress report) & Monthly Monitoring Report to
the owner/MECON as per the format in Annexure-A & B.
16.5 Progress Reports
16.5.1 CONTRACTOR shall make every effort to keep the OWNER adequately informed as to the
progress of the WORK throughout the CONTRACT period.
CONTRACTOR shall keep the OWNER informed well in advance of the construction schedule so
as to permit the OWNER to arrange for requisite inspection to be carried out in such a manner as
to minimize interference with progress of WORK. It is imperative that close coordination be
maintained with the OWNER during all phases of WORK.
16.5.2 By the 10th (tenth) of each month, CONTRACTOR shall furnish the OWNER a detailed report
covering the progress as of the last day of the previous month. These reports will indicate actual
and scheduled percentage of completion of construction as well as general comments of interest or
the progress of various phases of the WORK. The frequency of progress reporting by the
CONTRACTOR shall be weekly.
16.5.3 Once a week, CONTRACTOR shall submit a summary of the WORK accomplished during the
preceding week in form of percentage completion of the various phases of the WORK, to the
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WORK (TCP+PCP)
OWNER.
16.5.4 Progress reports shall be supplied by CONTRACTOR with documents such as chart, networks,
photographs, test certificate etc. Such progress reports shall be in the form and size as may be
required by the OWNER and shall be submitted in at least 3 (three) copies.
16.5.5 Contractor shall prepare daily progress report (DPR) in the desired format and submit it to
Engineer-in-charge alongwith schedule of next day to Engineer-in-charge.
17.0 CONSTRUCTION
OWNER reserves the right to inspect all phases of CONTRACTOR's operations to ensure
conformity to the SPECIFICATIONS. Owner will have Engineers, Inspectors or other duly
authorised representatives, made known to the CONTRCTOR present during progress of the
WORK and such representatives shall have free access to the WORK at all times. The presence
or absence of a OWNER's representative does not relieve the CONTRACTOR of the responsibility
for quality control in all phases of the WORK. In the event that any of the WORK being done by
the CONTRACTOR or any SUB-CONTRACTOR is found by OWNER's representatives to be
unsatisfactory or not in accordance with the DRAWINGS, procedures and SPECIFICATIONS, the
CONTRACTOR shall, upon verbal notice of such, revise the work in a manner to conform to the
relevant DRAWINGS, procedures and SPECIFICATIONS.
17.1 Rules & Regulations
CONTRACTOR shall observe in addition to Codes specified in respective specification, all National
and Local Laws, Ordinances, Rules and Regulations and requirements pertaining to the WORK
and shall be responsible for extra costs arising from violations of the same.
17.2 Procedures
Various procedures and method statements to be adopted by CONTRACTOR during the

construction as required in the respective specifications shall be submitted to OWNER in due time
for APPROVAL. No such construction activity shall commence unless approved by OWNER in
writing.
17.3 Field Inspection
CONTRACTOR shall have at all times during the performance of the WORK, a Competent
Superintendent on the premises. Any instruction given to such superintendent shall be construed
as having been given to the CONTRACTOR.
17.4 Erection and Installation
The CONTRACTOR shall carry out required supervision and inspection as per quality
Assurance plan and furnish all assistance required by the OWNER in carrying out inspection work
during this phase. The OWNER will have engineers, inspectors or other authorised representatives
present who are to have free access to the WORK at all times. If an Owner’s representative notifies
the Contractor’s authorised representative not lower than a Foreman of any deficiency, or
recommends action regarding compliance with the SPECIFICATIONS, the CONTRACTOR shall
make every effort to carry out such instructions to complete the WORK conforming to the
SPECIFICATIONS and approved DRAWINGS in the fullest degree consistent with best industry
SECTION-II

WORK (TCP+PCP)
practice.
17.5 Construction Aids, Equipment, Tools & Tackles
CONTRACTOR shall be solely responsible for making available for executing the work, all requisite
Construction Equipments, Special Aids, Cranes, Tools, Tackles and testing equipments and
appliances. Such construction equipments etc. shall be subject to examination by owner and
approval for the same being in first class operating condition. Any discrepancies pointed out by
OWNER shall be immediately got rectified, repaired or the equipment replaced altogether, by
CONTRACTOR. OWNER shall not in any way be responsible for providing any such equipment,
machinery, tools and tackles.
The OWNER reserves the right to rearrange such deployment depending upon the progress and
priority of work in various sections.
Tie-end between main line and starting point of terminal is included in the scope of contract, as and
when main line section is available for Tie-ins.
17.6 ORDER OF WORKS/PERMISSIONS/RIGHT OF ENTRY/CARE OF EXISTING SERVICES
The order in which the WORK shall be carried out shall be subject to the approval of the
Engineer-in-charge and shall be so as to suit the detailed method of construction adopted by the
CONTRACTOR, as well as the agreed joint programme. The WORK shall be carried out in a
manner so as to enable the other contractors, if any, to work concurrently.
OWNER reserves right to fix up priorities which will be conveyed by Engineer-in-Charge and the
CONTRACTOR shall plan and execute work accordingly.
Existing Service
Drains, pipes, cables, overhead wires and similar services encountered in course of the works shall
be guarded from injury by the CONTRACTOR at his own cost, so that they may continue in full and
uninterrupted use to the satisfaction of the Owners thereof, or otherwise occupy any part of the
SITE in a manner likely to hinder the operation of such services.
Should any damage be done by the CONTRACTOR to any mains, pipes, cables or lines (whether
above or below ground etc.), whether or not shown on the drawings the CONTRACTOR must
make good or bear the cost of making good the same without delay to the satisfaction of the
Engineer-in-Charge.
18.0 DOCUMENTATION
18.1 Drawings and design documents
18.1.1 The following documents shall be submitted along with the offer:
a) Filled up data sheets & Check lists

b) HSE Policy
c) QAP
d) Bar Charts & Project completion schedule
e) Bidder’s Compliance Report (Annexure-AA)
f) Un-priced List of two years operation and maintenance spare
SECTION-II

WORK (TCP+PCP)
18.1.2 The following drawings (in three sets) & documents shall be submitted for approval within 3
weeks of award of contract.
a) Various Procedures of CP system Installation Like- Soil survey (PCP), Thermit weld, Pin
Brazing, Sacrificial anode (Zn/Mg/Ribbon) installations, Test stations & Junction Boxes
installation, Cable laying, Installation of polarization cell, External ER probe, Surge diverter
& grounding cell, connection & sealing of sacrificial anode, Earthing of above ground
pipeline, AGB installation, CP unit installation, Installation of polarization cell, CTSU,
Earthing of above ground pipeline etc.
b) Soil survey report with marked location vulnerable area.
c) QA & QC Procedures.
d) Basis of system design and design calculations, equipment selection criteria and sizing
calculations, formulae used
e) Detailed design calculations of TCP & PCP system (Complete Design Package).
f) Equipment layout, Cable layout & schedule.
g) Colour code identification for the various CP System cables used in the system
h) Procedures for Various Post commissioning surveys (CPL, CAT, CAT Frame ‘A’ DCVG &
coating conductance etc).
i) Procedure for AC & DC interference detection & mitigation.
j) Construction drawing for fencing of anode bed & AJB.
k) Procedure for field testing, pre-commissioning & commissioning of TCP & PCP.
l) Procedure for Monitoring & maintenance of CP system.
m) Equipment layout, Cable layout & schedule.
n) TLP’s & junction boxes installation & erection details drawings.
o) Procedure for Monitoring & maintenance of CP system.
p) Incorporation of Anode bed, Polarisation cell, surge arrester, TLP, Junction boxes & other
relevant feature in CP system design in Alignment sheet, pipeline route diagram & Plot
plan.
q) Tentative Bill of Material
18.1.3 After the job completion, contractor shall prepare AS-BUILT drawings/data sheets and
documents, submit catalogues/manuals (O&M) of major brought out items. Final certified as
built drawings, documents and manuals etc shall be submitted by the contractor to owner in
bound volume with one set in soft copy (CD) plus five sets of prints to owner & one set to
MECON..
Other drawings and documents shall be submitted by contractor along with AS-BUILT
Drawings/Datasheets-
a) Test documents & drawings for bought out items.

b) Detailed commissioning report of pipeline CP system (TCP & PCP).
c) Warranty certificates as per DLP (defect liability period).
d) Original deed OR Lease agreement for acquired/leased land (In favour of M/s
HPCL) for Anode Bed, ROU for cable laying etc shall be handed over to M/s HPCL.
e) As all permissions for interference detection and mitigation is in scope of Owner,
After completion of the work contractor shall take NOC from the owner of the
foreign pipeline owner and refund the security deposit (if any).
19.0 MAKE OF MATERIAL/BOUGHT OUT ITEMS

SECTION-II

WORK (TCP+PCP)
An Appendix-I of approved vendors for various major items is enclosed with this tender
specification. The bidder shall consider such names only as indicated in the aforesaid list and
clearly indicate in the bid the name(s) as selected against these items. For any other item not
covered in the list enclosed with this tender document, prior approval shall be obtained by the
contractor for its make/ supplier’s name.
20.0 INSPECTION OF SUPPLY ITEMS
All inspections and tests shall be made as required by the specifications forming part of this
contract. Contractor shall advise Owner/ Consultant in writing at least 10 days in advance of the
date of final inspection/tests. Manufactures inspection or testing certificates for equipment and
materials supplied, may be considered for acceptance at the discretion of Owner/ Consultant. All
costs towards testing etc. shall be borne by the contractor within their quoted rates. All inspection
of various items shall be carried out based on Quality Assurance Plan, which will be submitted by
the Contractor and duly approved by Owner/ Consultant.
21.0 ESCALATION
The Rates quoted shall be kept firm till completion of work and no price Escalation shall be paid.
22.0 DOCUMENTS TO BE SUBMITTED/ PRODUCED ALONGWITH R.A. BILLS
a) Computerized R.A. Bill/ Manual Bill, with IT No./ ST No./ Labour License No. printed
thereon.
b) ESI/ EPF clearance certificates for the last month alongwith R.A. Bills.
c) Insurance Policy as per relevant clauses of Contract Agreement.
d) Attendance Register and Salary Records.
e) Photocopy of the measurement book to be attached with R.A. Bills.
f) Any other document required for the purpose of processing the bills.
g) Registration Certificate with Sales tax authorities of state concerned.
-x-x-x-
SECTION-II

WORK (TCP+PCP)
APPENDIX-I
Sheet 1 of 2
1.0 APPENDIX-I (LIST OF SUPPLIER/S OF MAJOR BOUGHT OUT ITEMS)
1) CABLES
i) Brooks Cables
ii) Nicco Corporation Ltd
iii) CMI Ltd
iv) Delton Cables Ltd
v) KEI Industries
vi) Torrent Cables
vii) Universal cables
viii) Victor Cables
ix) Associated Flexible & Wires Pvt Ltd
x) Asain Cables (RPG Cables)
xi) Fort Gloster (Gloster Cables Ltd)
xii) Finolex Cable
xiii) Rediant Cables
xiv) NETCO Cables Pvt Ltd
xv) Chandresh Cables Ltd
xvi) RR Kabel Ltd,Vadodara
2) JUNCTION BOX (FLP Type)
i) Exprotecta, Beroda
ii) Baliga
iii) Flexpro
iv) FFLP Control Gears
v) Sterling
vi) Sudhir
3) SACRIFICIAL ANODES
i) M/s Scientific Metals Engineers Pvt. Ltd., Karaikudi

ii) M/s Shakti Metals, Ahmedabad
iii) M/s PSL Holding Pvt. Ltd., Mumbai
iv) M/s BHEL, Bhopal
v) M/s Nippon Corrosion, Japan
vi) M/s AFIC, KSA
vii) M/s Platt Bros. and Company, USA
viii) M/s YUXI, CHINA
ix) M/s Wilson Walton International
x) M/s XIANG METAL, CHINA
xi) M/s SHUNRUI, CHINA
xii) M/s Impalloy International
xiii) M/s Corrpro International
xiv) M/s HOCKWAY, UK
xv) M/s NAKABOHTEC, Japan
xvi) Shakti Enterprise, Ahmedabad
SECTION-II

WORK (TCP+PCP)
APPENDIX-I
Sheet 2 of 2
4) Portable Reference Cell : M/s MC Miller (USA) or Equivalent
5) Permanent Reference Cell : M/s Borin Manufacturer USA, M/s MC Miller USA , M/s Corrtech
6) AC operated : M/s Canara Electric (M/s Raychem RPG Ltd), M/s

Automatic Transformer Kriston systems
Rectifier Unit/DC operated
Automatic CPPSM Unit
7) Thermit Weld : M/s Erico, USA, M/s Cad Weld

Pin Brazing : M/s Safe Track, M/s BAC UK
8) Surge diverter (Ex-d) : M/s Dhen, M/s OBO, M/s Corrpro system, USA, M/s Sohne
9) Digital Multimeter : MOTWANE, Rishabh, Fluke or Equivalent
10) CTSU : M/s Kriston systems or equivalent
11) Solid state polaristation cell : M/s Dairyland, M/s Corrpro systems, USA
12) Anode (MMO Type) : 1) Titanor Component Ltd., Goa, India

2) Denora Permelic S.P.A (Italy) Oronzio De Nora S.A. Ingano,
Switzerland
3) CER Anode Technologies International USA
4) ACTEL, UK
5) ELTECH System Corporation, Texas
6) MAGNETO-CHEMIE, Netherlands
7) M/S MATCOR (USA)
13) Anode Backfill Material : 1) M/S Goa Carbon (Goa)

2) M/S India Carbon (Calcutta),
3) M/S Petrocarbon & Chemical Company (Haldia)
14) Heat Shrink Cap For Anode : M/s RAYCHEM, M/s MATCOR (USA)
To Cable Joint
15) MCCB/MCB for Power : Siemens, Indo Asian, L&T, Hager, Merlin Gerin
Distribution Board Schneider Electric, AEG, HAVELL’S, ABB, MDS
16) ER- PROBE (External Corrosion : M/s Rose Corrosion Services UK, M/s Metal Samples, USA M/s
Monitoring) Roharbak Cosasco, USA M/s Caproco, UK
17) ER- PROBE & Corrosion Coupon : M/s Rose Corrosion Services UK, M/s Metal Samples, USA
Assembly M/s Roharbak Cosasco, USA, M/s Caproco, UK
18) Proposed CP Contractor : M/s Corrtech (I) Pvt Ltd, Ahmedabad, M/s CCS (B) Pvt ltd,
(Have to meet criteria in cl no.8) M/s Raychem RPG Pvt ltd, M/s Consultech, Baroda, M/s
UNDTS, Noida, M/s SARK EPC Pvt Ltd
Note-For any other brought out item(s) for which the vendor list is not provided in the tender , bidders can supply
those item(s) from vendors/ suppliers who have earlier supplied similar item(s) for the intended services in earlier
Oil and Gas projects and the item(s) offered is in their regular manufacturing/ supply range subject to submission
SECTION-II

WORK (TCP+PCP)
of following documents and their approval.
1) The vendor / supplier should not be in the Holiday list of HPCL/ MECON / other PSU
2) The bidder is not required to enclose documentary evidences (PO copies, Inspection Certificate etc.)
along with their offer, however in case of successful bidder, these documents shall required to be
submitted by them within 30 days from date of Placement of Order for approval to HPCL/ MECON.
SECTION-II

WORK (TCP+PCP)
Appendix-II
Sheet 1 of 1
2 Years Operational & Maintenance Spares for Temporary Cathodic protection

system (One Lot for each section, description of LOT is given below)
Sl. Description Unit Total

No. Qty.
1 Multimeter- Fluke 87V Digital Multimeter Nos. 1
2 Clamp Meter (AC&DC)-Fluke Nos. 1
3 Portable Cu/CuSO4 Reference Cell –Mc-Miller/Tinkar Razor Nos. 1 nos.
/SV
Station
4 UT (Ultrasonic Thickness Tester) Meter –Olympus model 27MG or Nos. 1
equivalent
5 Tool Box-Taparia Make (Consisting of Screw Driver Set, Electrical screw Set 1
driver set, Adjustable Spanner 12”, Flat File 12”, Round File 12”, Plyer,
Chiesel, Hexa Frame, Hexa Blade, Hammer, Nose Plyer, DE Spanner
set 6-32, Ring spanner set 6-32”, Allen key set etc.)
6 Lab Calibrated reference (Cu-CuSo4) cell to calibrate portable half Nos. 1
reference cell
7 Spare battery pack for CTSU Nos. 4
8 02 Year O&M CP Spares for TR / CPPSM units
8.1 TR/CPPSM Unit Spares
1 Set of control Card Consisting of 1 No. each Type Set 1
2 AC Circuit breaker(MCB) Nos. 2
3 DC Circuit breaker(MCB) Nos. 2
4 AC Voltmeter Nos. 2
5 AC Ammeter Nos. 2
6 DC Voltmeter Nos. 2
7 DC Ammeter Nos. 2
8 Set of fuse link consisting 1 No. of each Type (Input & Output) Set 1
9 HRC fuse for Diodes Nos. 5
10 O/p Filter circuit capacitor Nos. 1
11 Signal light assembly for annunciation Nos. 1
12 Input Surge diverter (8/20 uS) Nos. 1
13 Control transformer Nos. 1
14 Coarse voltage control switch Nos. 2
15 Coarse current control switch Nos. 2
16 Fine voltage control switch Nos. 2
17 Fine current control switch Nos. 2
18 Set of Indicator lamps consisting of two no. of each type Set 1
19 Diode Module Set 1
20 SCR Module Set 1
21 Output Lighting Arrestor (10/350 uS- 100kA) Set 1
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WORK (TCP+PCP)
22 Assorted Glass cartridge fuses Nos. 20
Set of Rotary Switches consisting of one no. of switch of each type Set 1
23 including Auto Manual Mode selector switch
24 Set of 4-20mA converter and digital relays (1 no. of each type Set 1
calibrated)
25 Toggle switches Nos. 10
Note-Price of these spares shall deemed to be considered in the total price of supply of CP system
quoted by the Bidder.

SECTION-II

WORK (TCP+PCP)
Annexure-A
Format for Daily Progress report
DAILY PROGRESS REPORT – TCP SYSTEM
CLIENT: DPR NO.
CONSULTANT: MECON Limited PROGRESS DATE:
CONTRACTOR: REPORT DATE:
PROJECT: PLACE:
PROGRESS (Spreads A, B……)
S.No. ACTIVITY UOM SCOPE Remarks
PREVIOUS TODAY CUMULATIVE
Soil Resistivity &
1
Chemical Analysis
Additional Data
2
Collection
TCP design
3
Document
4 P/L LENGTH KM
5 P/L LOWERED KM
6 TCP PROVIDED KM
7 PSP LEVEL (-V)
S.No. Material Work Description
1 Test station Nos.
2 Mg anode Nos.
3 Zn anode Nos.
5 No. of Thermit Nos.
5(a) No. of Pin Brazing Nos.
5 Surge Diverter Nos.
6 ER Probe Nos.
Polarisation
7 Nos.
Coupon
8 Polarisation Cell Nos.
9 Cased crossings Loc
10 TCP Cables
1Cx6 mm² Mtr.
10(a)
Armoured
1Cx6 mm² Un- Mtr.
10(b)
Armoured
10(c) 1Cx10 mm² Mtr.
10(d) 1CX25 mm² Mtr.

SECTION-II

WORK (TCP+PCP)
DAILY PROGRESS REPORT – PCP SYSTEM (Material Installation)
CLIENT: DPR NO.
CONSULTANT: MECON Limited PROGRESS DATE:
CONTRACTOR: REPORT DATE:
PROJECT: PLACE:
PROGRESS (Spreads I, II……)
S.No. ACTIVITY UOM SCOPE Remarks
PREVIOUS TODAY CUMULATIVE
Soil Resistivity of
1 Anodebed & Nos.
Chemical Analysis
PCP Design
2 Nos.
Document
Registration of
3 Nos.
Land of Anodebed
Installation of TR Nos.
4
Unit
Installation of Nos.
5
CPPSM Unit
6 Shallow Anode
bed
7 Deepwell Anode
bed
8 Anode Junction
Box
9 Cathode Junction
Box
10 Permanent Ref
cell for CJB
11 Permanent Ref
cell for CTSU
Installation of Zinc Nos.
12
Grounding anode
13
Polarization cell
14
CTSU Unit
Cable Laying -
15 Mtr
1Cx06 Sq mm
Cable Laying - Mtr
16
1Cx25 Sq mm
Cable Laying - Mtr
17
1Cx35 Sq mm
SECTION-II

WORK (TCP+PCP)
Cable Laying - Mtr
18
3Cx10 Sq mm
Cable to pipe Nos.
19
connection
Pre
20 Commissioning & Kms
Commissioning
AC Interference Kms
21
Survey
DC Interference Kms
22
Survey
23 CIPL Survey Kms
24 CAT Survey Kms

DCVG Survey or Kms
25 CAT with Frame
‘A’ survey
Coating Kms
26 Conductance
Survey
Annexure -B
Format for TCP system Commissioning

Sr. TS Chainage TS Natural Instant Polarised Anode Anode AC Other Remarks
No No Type PSP PSP PSP Voltage Current Voltage Readings
(24 Hrs.) (V) (mA) (V) (If Any)
Format for Monthly Monitoring Report of TCP system

Sr. TS Chainage TS PSP (-) Voltage Anode Anode AC Other P. Remarks
No No Type Voltage current Voltage Readings Coupon
(V) (mA) (mV) (If Any) OFF
PSP
Carrier Casing
Without Bonding
Bonding
Format for Monthly Monitoring Report of PCP system
Sr. TS Chainage TS PSP (-) Casing AGB CP unit CP unit AC Other Remarks
No No Type Voltage PSP Resistance O/P O/P Voltage Readings
Voltage Current (mV) (If Any)
(V) (A)
On OFF
SECTION-II

WORK (TCP+PCP)
Annexure-C
Organogram for the TCP work
PROJECT OFFICE
Name:
Address:
Ph No:
E-Mail:
OVERALL PROJECT INCHARGE

(NACE CP Level II)
SPREAD INCHARGE
(Each Section)
(NACE CP Level I/II)
01 TEAM /
SECTION
Note-
1. Overall Project In charge should have B.E. in (Electrical, Electronics and Metallurgical Engineering)
& atleast 10 year Experience in the Cathodic Protection (NACE CP Level II) Field.
2. Spread Incharge should have B.E. or Diploma in (Electrical, Electronics and Metallurgical
Engineering) & atleast 5 year Experience in the Cathodic Protection (NACE CP Level I/II) Field and
shall be available at site office for entire time schedule of the project.
3. CVs including Experience & Qualification shall be submitted by successful bidder.

SECTION-II

WORK (TCP+PCP)
Annexure-AA
Compliance to Technical Bid (CP System)
Sl Tender Clause No. Description Documents Required for Submitted in E- Reference In E-Bid
No. Qualification (Technical Part of Bid (Bidder to Document (Bidder
Bid)/ Bidder’s Compliance/Bidder’s Indicate Yes/No) to indicate Place,
Confirmation Page No. /Vol No.
In the Bid)
1 - Technical Compliance to Bidder shall furnish “No Deviation
the complete scope of Certificate”.
work Deviation if any, due to of
change/amendment/revision in design
code (vendor specific) shall not be
considered at this stage and subjected
to review/approval of Client/MECON.
(For the acceptance of the deviation in
the design code suitable justification is
required during detail engineering).
2 - Confirm No Deviation in Confirm (Offer may be rejected if there
Technical Bid. is any deviation).
3 Annexure Confirm No Deviation. Confirm (Offer may be rejected if there
is any deviation).
4 Installation, All the spares required Confirm.
Commissioning & for Installation,
Start-Up spares Commissioning & Start-
Up of the CP system
shall be included in the
scope of the bidder, any
spares required
permanently for the
Installation,
Commissioning & Start-
Up of the CP system the
same shall be supplied
free of cost.
5 16.1.1 All the required Confirm.
documents are enclosed
with the bid document as
per the clause.
6 Tentative BOQ/BOM Tentative BOQ/BOM Confirm.
shall be prepared by
bidder and shall be
reviewed & approved by
MECON during the detail
engineering stage. As
this is a Lump-Sump
contract for any change
in quantity mentioned in
the scope of work the
bidder’s compensation
for these changed
quantities shall remain
unchanged.
7 Confirmation on The qualification of the Confirmation, submission of valid
Interference Detection surveyor for these works certificate & association/employment
(AC & DC) and should be Min NACE proof with the Bidder along with
Mitigation & cl no. 9.1 Level IV (CP Specialist). consent letter along with Bid.
(c) (s) (v)
8 Interference Modelling Bidder/Back up agency Submission of relevant document
Software licence shall have valid along with Bid.
license/key for Operating
Interference Modelling
Software.
9 CV & Qualification Submission of relevant Submission of CV & relevant
documents as per Documents along with qualification document.
Organogram Bid.
-X-X-X-
REV. : 1
Edition : 1
DATA SHEET
FOR
CATHODIC PROTECTION
TRANSFORMER RECTIFIER (TR) UNIT
SPECIFICATION NO.- MEC/DS/05/E9/082A
(OIL & GAS SBU)

MECON LIMITED
MECON LIMITED STANDARD DATA SHEET
REGD. OFF: RANCHI
834002 ELECTRICAL SECTION, DELHI
DOCUMENT NO. Page 1 of 6

CATHODIC PROTECTION
TITLE TRANSFORMER RECTIFIER MEC/DS/05/E9/082A REVISION : 1
UNIT
EDITION : 1
ANNEXURE - I
PURCHASER'S DATA FOR CPTR UNIT
1 Type Floor mounted , Indoor – IP 42 AC Operated Transformer
Rectifier Unit for Impressed Current CP System
2 Cooling Natural Air cooling (AN)
3 Quantity As per Scope of work
4 Transformer Insulation Vacuum pressure Impregnated Insulation, Class-
F, FOS-125%
5 Factor of safety for Voltage 300% factor of safety, Current- 400% factor of
Diodes/SCRs: safety
6 Surge Diverters for Metal Oxide Varistors / Capacitors / R - C Networks

diodes/SCRs
7 Input Power Supply As per Scope of work/Design basis
8 Input Fault Level 10 KA (for 1 Second)
9 Number of output circuits One/Two As required
10 Modes of Operation (a) Auto Ref

(b) Manual mode
11 Control Element The DC output will be controlled using latest solid state
SCRs. These SCRs will be controlled by the commands
from the control circuits. All the Electronic circuits will be
assembled on plug-in type control cards.
12 Rated output Voltage (+ve As per Scope of work/As per design calculations
earthed)
13 DC Voltage Regulation Better than ± 0.25V
14 Rated Output Current As per Scope of work /As per design calculations
15 Filtering circuit L.C. Filter
16 Insulation Level 2KV for 1minute
17 Full load PF Better than 0.8 lag
18 Full load Efficiency More than 80%
19
20 DC Current Regulation ±0.5 Amp
21 PSP Voltage Regulation Better than ±15 mV
22 Pipe to Soil Potential Setting (-)0.700mV to (-) 2500 mV – (For Cu/CuSO4 Electrode)
range (Vps)
23 Minimum set potential (-)0.4 V to (-)1 V
range (Vrs)
24 Maximum pipeline potential (-)1.2 V to (-)2.5 V
range (Vpm)
REGD. OFF: RANCHI

CATHODIC PROTECTION
UNIT
EDITION : 1
25 Minimum pipeline potential (-)0.7 V to (-)1.0 V

range (Vpn)
26 Reference fail safe feature In the event of failure of all the reference electrodes, the
DC output voltage of the unit will get set to a preset
value. This preset voltage is adjustable from 0 to rated
value.
27 Number of reference cells Required (3 Nos.) & 01 on unprotected side of IJ.
for control
28 SCADA Interface and Required

Current Interruption facility
(Keypad and SACADA)
29 Inbuilt Current Interruption Required
Facility
Site conditions: As defined in scope of work/design basis, minimum

conditions are follows-
(i) Ambient Temperature
0°-50°C (max.)
(ii) Relative Humidity
94% (max.)
(iii) Altitude above mean
sea level.
Less than 1000m above MSL
(iv) Specific Environment
To withstand site condition

(Dry & Dust Storms during summer & low temp during
winter)
30 Shade for final paint RAL 7032
31 Earthing Inbuilt Copper Earth bar with suitable bolts

32 Lightning Arrestor At both Input & output side of the T/R unit
33 Lifting Hooks 4 Nos
34 Cable Entry Bottom

35 Commissioning at site By Vendor
REGD. OFF: RANCHI

CATHODIC PROTECTION
UNIT
EDITION : 1
36 Meters 1) Digital Meters (Three & Half Digits) for

a) Input Voltage
b) Input Current
c) DC output voltage
d) DC output current
e) Reference voltage (P.S.P.)
f) PSP on unprotected side of IJ
37 Alarm & Indication a) T/R UNIT ON/OFF (AC Supply ON) – Visible.
(Indication Lamp shall be b) Reference 1 lowest –Visual
Cluster LED type) Reference 2 lowest – Visual
Reference 3 lowest – Visual
c) Reference 1 Fail – Visual

Reference 2 Fail – Visual
Reference 3 Fail – Visual
d) Pipeline over protected – Visual & Remote
e) Pipeline under protected – Visual & Remote
f) Unit in Auto – Visual & Remote
Unit in Manual – Visual & Remote
g) DC output over current (Current Limit-Visual)
h) All Reference Fail – Visual & Remote
i) Current Interrupter
Power ON, ON time & OFF time
SCADA Monitoring Facility Signals / Contacts shall be provided for remote
monitoring & control as per cl. No. 6.6 of specification
MEC/TS/05/E9/082A.
Current interruption Facility Current interruption facility will be provided by means
of a built-in Electronic Interrupter logic & microprocessor
based digital timer with real time clock & ON/OFF time
display. The timer will have facility for adjusting the ON
time & OFF time from 0 to 999 Sec. by means of digital
setting facility. The timer will also have Start/stop facility
thru a single external potential free contact. The Timer
will have GPS Synchronisation facility.
Protection a) Lightning Arrestor on AC & DC Sides
b) HRC fuses in input AC supply lines and in each
DC leads
c) Surge suppressors on input, output and across
each diode and SCR (Power Transistors).
d) Adjustable current limit, overcurrent and short-
REGD. OFF: RANCHI

CATHODIC PROTECTION
UNIT
EDITION : 1
circuit protection.
e) HRC fuses outgoing DC +ve lead and the DC –ve
lead.
f) MCB/MCCB in AC I/P (2-Pole).
g) MCB/MCCM in DC O/P (2-Pole).
h) Fast acting electronic over current limit circuit.
i) Glass cartridge fuses in live line of all lamps,
auxiliary power line to control circuit.
Note-Electronic earthing for PLC/Modules shall be
provided separately (Other then equipment earthing)
REGD. OFF: RANCHI

CATHODIC PROTECTION
UNIT
EDITION : 1
ANNEXURE – I A
1 Guaranteed Technical Particulars

Efficiency:
At 10% Load
1.1
At 25% Load
At 50% Load
At 75% Load
At 100% Load
Voltage regulation (from zero

to 100% load variation and
1.2
throughout the output voltage
range) Better than ±0.25V
Manual mode
Auto mode
Output ripple at full load
current (less than 5% RMS)
1.3
At 10% output voltage
At 100% output voltage
16 hour heat run test & routine test shall be witnessed
by MECON/Owner at manufacturers work.
2 Inspection
Final integrated field testing shall be done at site.
3 Combined Combined load test at site.
Note- Various Settings of CP unit for Zn ref electrode will be differ from conventional Cu-
Cuso4 ref electrode, Bidder shall submit the data sheet of the CP unit for approval before
manufacturing of CP unit considering the Constant conversion factor of -1.1v to CuSO4.
REGD. OFF: RANCHI

CATHODIC PROTECTION
UNIT
EDITION : 1
ANNEXURE-II
ACCEPTABLE MAKES FOR COMPONENTS
S.No. Material Make
1 Contactors Siemens/ L&T/ BCH/ Telemechnique

2 Moulded Case Circuit Breaker GE/ Cromption/ L&T / Hager
3 Miniature circuit breaker MDS/ Indoasian/ Havell / Hager
4 Transformer Indcoil/ Kappa Electrical/ AE
5 Switches, Fuses, Fuse base Siemens/ L&T/ GE / Kaycee/Salzer
6 PB Elements/ Indication Lamps Siemens / L&T / Teknic / Concord/ BCH
7 Selector Switch EE/ Siemens/ Kaycee/ L&T
8 Terminals Elmex/ Connect Well/ Phoenix

9 Meters AEP/ Simco/ IMP/ GEC/ Rishab/Meco
10 Cable Glands Commet/ Baliga / Flexpro/ Sudhir
(List of suppliers for solid-state devices shall be furnished by the vendor for Owner’s approval).
(1) HRC Fuses (13) Lightning Arrestor

(2) Auxikary Fuses (14) Blade Resistance
(3) Interrupter Contractor (15) Potentio Meter
(4) DC – DC Converter Power Transistors (16) LED’s
(5) Volt Meter (Digital) 3 1/2 (17) Convertors (4 to 20 ma)
(6) Ammeter (Digital) 3 1/2 (18) Timer (Interrupter)
(7) Shunt (19) All electronic (AC DC)
(8) Filter Choke in DC Output (20) Display Board
(9) Filter Capacitor bank in DC Output (21) Filters
(10) Power Diode (22) Links
(11) Diode
(12) Search Suppressor Network
-x-x-x-
CONTRACTOR CLIENT: M/S HPCL
QUALITY ASSURANCE PLAN PROJECT: BARMER- PALANPUR
FOR PIPELINE PROJECT
CATHODIC PROTECTION (BPPL) SECTION-I &
(TCP & PCP SYSTEM) SECTION-II
ORDER NO. & DATE PACKAGE NO. 23VE

SUB-CONTRACTOR PACKAGE NAME TCP system
ORDER NO. & DATE
INSTRUCTIONS FOR FILLING UP : CODES FOR EXTENT OF INSPECTION, TESTS, TEST CERTIFICATES & DOCUMENTS:
1. QAP shall be submitted for each of the equipment separately with break up Code Description Code Description Code Description DOCUMENTS:
of assembly/sub-assembly & part/component or for group of equipment
having same specification. 1. Visual 12. Routine test as per relevant IS 23. Short time rating D1. Approved GA drawings
2. Use numerical codes as indicated for extent of inspection & tests and 2. Dimensional other standard 24. Operational & functional D2. Approved single line/
submission of test certificates & documents. Additional codes & description 3. Fitment & Alignment 13. Type test as per relevant IS/ check schematic diagram
for extent of inspection & tests may be added as applicable for the plant and 4. Physical Test (Sample) other standard 25. Over Speed Test D3. Approved
equipment 5. Chemical Test (Sample)
3. Separate identification number with quantity for equipment shall be (Review of test report only) 14. Impulse Test 26. Flame Proof Test data sheet
indicated wherever equipment having same specifications belonging to 6. Ultrasonic Test 15. Partial Discharge Test 27. Clearance and creepage D4. Approved bill of materials
different facilities are grouped together. 7. Magnetic Particle Test (MPT) 16. Heat run risc test\tempr. Distance D5. Unpriced P.O. copy
4. Weight in tonnes (T) must be indicated under column 5 for each item. 8. Radiography Test 17. Enclosure Protection Test 28. Acceptance Test D6. Calibration Certificate
Estimated weights may be indicated wherever actual weights are not 9. Dye Penetration Test 18. Calibration 29. Material test of all measuring
available. instruments and gauges
ABBREVIATIONS USED : 10. Measurement of IR Value 19. Noise & Vibration 30. Coating Thickness (MMO Anode), Resistivity (MMO
a) Before HV Test 20. Test certificates for bought out Anode) & comsumption rate (For Mg, Zn & Zn Ribbon
CONTR : CONTRACTOR b) After HV Test components Anode only review of Test report)
11. High Voltage test/Dielectric 21. Tank Pressure Test / Pressure 31. Contact Resistance anode to cable Joint
MFR : MANUFACTURER test Test 32. Destructive testing
22. Paint shade verification & 33. Test Station Connection Scheme check, Name plate
Thichness check and terminal check
34. Chemical Composition & Open Circuit Potential (For Zn
Ribbon Anode, Review of Test report only)
EQUIPMENT DETAILS INSPECTION AND TESTS Test Certificates Acceptance REMARKS /
Sl. Description (With equipment Indentificatuin Quantity Manufacturer’s Expected schedule of Raw Material and inprocess stage Final Inspection/Test by & documents to Criteria SAMPLING
No. heading, place of use, and No. Name and Address Final Inspection inspection be submitted to Standards /IS/ PLAN
Breif Specifications) No/M T MFR CONTR MECON/ MFR CONTR/ MECON/ MECON BS/ASME/
TPI TPI OWNER Norms and
Documents
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1. CP Cables (1Cx6Sqmm, IW Meters 1,2,29 - - 1,2,28 1,2,28 1,2,28 D1, D2, D3, D4, I.S., Approved
1Cx10 Sqmm, 1Cx25Sqmm D5, D6, 20, 13 Data Sheet &
& 1Cx35Sqmm) Specifications
2. Test Stations (Big & Small IW Nos. 1,2,29 - - 1,2,3,4, 1,2,3,4, 1,2,3,4, D1, D2, D3, D4, I.S., Approved
Type) 22,33 22,33 22,33 D5, D6, 20, 13 Data Sheet &
Specifications
3. Sacrificial Mg & Zn Anodes IW Nos. 1,2,29 - - 1,2,4, 5, 1,2,4, 5, 1,2,4, 5, D1, D2, D3, D4, I.S., Approved * on 1%
30, 32* 30, 32* 30, 32* D5, D6, 20, 13 Data Sheet &
Specifications of total
nos. of
anodes
4. Spark Gap Arrestor (100 IW Nos. 1,2,29 - - 1,2,12 - - Manufacturer Approved Data
kA) test certificates Sheet &
& Compliance Specifications
Report
5. Polarisation Cell (Solid IW Nos. 1,2,29 - - 1,2,12 - - Manufacturer Approved Data

State) test certificates Sheet &
Report
6. External ER Probe IW Set 1,2,29 - - 1,2,12 - - D1, D3, D4, D5, Approved Data
D6, 20,12,13 Sheet &
Specifications
7. CTSU (Computerised Test IW Nos. 1,2,29 - - 1,2,3,12 1,2,3,12 1,2,3,12 D1, D3, D4, D5, Approved Data
Station Unit) & CTSU 22,24 22,2 22,24 D6, 20,12,13 Sheet &
Reader Specifications
8. Permanent Reference Cell IW Nos. 1,2,29 - - - - - Manufacturer Approved Data

test certificates Sheet &
Report
9. TR/CPPSM UNIT I Set 1,2,3, 24, - - 1,2,3,12, 1,2,3,12, 1,2,3,12, D1, D2, D3, D4, I.S., Approved 16 Hr Heat
27,28 *16,22,23 *16, 22, *16, 22, D5, D6, 20 ,12,13 Data Sheet & Run Test on
one no of each
24,27,28 23,24,27 23,24,27 Specifications type unit
10. MMO Anodes I Nos. 1,2,4, 29, - - 1,2,4, 29, 1,2,4, 29, 1,2,4, 29, D1, D2, D3, D4, I.S., Approved
31 31 31 31 D5, D6, 20, 13 Data Sheet &
Specifications
11. CTSU (Computerised Test IW Nos. 1,2,3 - - 1,2,3, 1,2,3, 1,2,3, D1, D3, D4, D5, Approved Data
Station Unit), Central 22,24,33 22,24,33 22,24,33 D6, 20,12,13 Sheet &
Monitoring server & CTSU Specifications
Reader
12. Anode Junction Box & IW Nos. 1,2,3,4, - - 1,2,3,4, 1,2,3,4, 1,2,3,4, D1, D3, D4, D5, Approved Data *Type test-
Cathode Junction Box 22, 29 17*,22, 17*,22, 17*,22, 33 D6, 20,12,13 Sheet & Report
33 33 Specifications
review
only
IW- Inspection waiver on basis of TPI IRN. Q.A.P. NO.

I-Inspection by MECON/Owner. MEC/05/E9/23VE/ QAP/082
REV. 0
For MECON (Stamp & Signature) for CONTRACTOR SUB-CONTRACTOR SHEET 2 OF 2
(Stamp & Signature)

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BARMER- PALANPUR PIPELINE

OIL & GAS SBU

MECON LTD, DELHI

TITLE DOCUMENT NO. Page 1 of 2

Sl No. Description Document No./ Drawing Rev. No. Pages

MECON LTD, DELHI

TITLE DOCUMENT NO. Page 2 of 2

30 Schematic route diagram

DESIGN BASIS FOR CATHODIC PROTECTION

BARMER- PALANPUR PIPELINE PROJECT (BPPL)

MECON LIMITED DELHI

Document No. Revision No. Date

Sl. No. DESCRIIPTION

HPPCL proposses to lay crross countryy POL pipeline from ne

En g Terminal : Existing Palanpur POL

Crross-countryy PL (18” x 216.3 km approx.)

Suurvey, Design, detailed engineerring, supply y, packing, transportaation to site

II) NACE Publication

VI) NACE Publication

XIII) IS: 1554

XIV) IS: 8062

XXI) NACE TM0101

XXII) ASTM B418

XXIII)) ASTM B843

XXVI)) BS EN 15280: Eva aluation of AC corrosion likelihoo

XXVIII) IS 2148: Specificattion for Flam

XXVIIII) IS 3043: Code of practice

- PNGRBB Guideline for Cross country

3.2 In case of imp

4.0 SITE CONDITIONS

Thhe equipment offered and

a) Area Classsification : Zone-1 & Zone 2

All electrical equipment

All the electrrical equipm

i) 230V AC+/- 10%

the requiremen nts of India

* Acctual curreent density to be ad dopted sha

b) Intterval for data

* CP sttations sho ould be deecided in such

8.0 ENCE STU

Intterference detection & mitigatioon due to DC source es (i.e. HV

9.0 P AT CASED CROSSINGS

10.1 athodic Prrotection Design

he pipe to soil potenttial measurements shall

c) Ass such therre is no lim

10.2 ATHODIC PROTECTIO

Noote 2: - Forr computerized test sttation: Inte

CPPTR unit shall

6 PIPE TO SOIL POTTENTIAL M AI (4-20mA)

8 REFERENNCE 1, 2, 3 FAIL M DI (4 nos.)

AI-- Analogue input to SC CADA/RTU

TCCP Cables shall be an nnealed higgh conductiv

Annode & Catthode Head der Cable shall be 1C

iii) TR nput Power Supply Cab

TRR/CPPSM Innput Power Supply Cable shall be

Meeasurement cable & Permanent

vi) Thhe cables fo ng various transducerrs from TR unit/ CPPS

Thhe submissiion of application on behalf

13.1 he following documentss shall be su

h) Construction drawin ng for fencin ng of anode bed & AJB..

13.3 Aftter the job

Other drawings and doocuments shall

HINDUSTAN PETROLEUM CORPORATION LTD