JOB PROCEDURE FOR

TGPL-AD-TSS02-PRO-
TEMPORARY CATHODIC
039
PROTECTION SYSTEM

TORRENT GAS PRIVATE LIMITED.

CITY GAS DISTRIBUTIONPROJECT

JOB PROCEDURE FOR TEMPORARY

CATHODIC PROTECTIONSYSTEM

DOC NO. : TGPL-AD-TSS02-PRO-039

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TABLE OFCONTENTS

1 PROCEDURE FORCABLELAYING.............................................................................................................3
2 PROCEDURE FOR SACRIFICIAL MAGNESIUMANODEINSTALLATION.......................................................5
3 PROCEDURE FOR SACRIFICIAL ZINCANODEINSTALLATION....................................................................8
4 PROCEDURE FOR TESTSTATION INSTALLATION...................................................................................11
5 PROCEDURE FOR SURGEDIVERTERINSTALLATION...............................................................................14
6 PROCEDURE FOR CABLE TO PIPE CONNECTIONBYPINBRAZING...........................................................16
7 PROCEDURE FOR POLARIZATIONCOUPON INSTALLATION..................................................................19
8 PROCEDURE FOR PERMANENT REFERENCECELLINSTALLATION...........................................................21
9 PROCEDURE FOR TCPSYSTEMCOMMISSIONING..................................................................................23

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1 PROCEDURE FORCABLELAYING PROC. NO-001

1.1 PURPOSE

To describe the procedure for installation of cable laying& termination of all type of cables
and provide adequate quality assurance/control of workmanship and inspection at site.

1.2 SCOPE

This procedure covers the cable laying and termination of al ltypeof cables related to the
Cathodic Protection System as per TGPL technical specifications.

1.3 MATERIAL &EQUIPMENTS

Equipments : Crimping Tool kit,etc.
Materials :Cables,Sands,Normal Bricks,CableLugs&warningmats,etc.

1.4 REFERENCEDOCUMENTS

Specification forCathodic Protection

1.5 PROCEDURE

Before Starting the work check material against datasheet & test certificate.

Cables shall be laid in accordance with standard specification/approved layout drawings.

Check IR value before and after laying.

No joint shall be permitted in a single run of anode and a cathode cable. Cable route shall
be carefully measured and cables to be cut for required length including required loops at
either end. Minimum half meter slack/loop shall be provided near anodes, pipeline and
test stations to account for any adjustment.

Obtain the cable route approved prior installation /excavation in plant area.

All cables inside station/plant area shall be laid at a depth of min 0.75 mtr and Cable outside
plant/ station area shall be laid at the depth of 1.5 mtr. Cables shall be laid in sand under brick
cover backfield with normal soil and in rocky terrain area cable shall be laid at min 0.5m depth.
Outer or inside plant the route shall be marked with polythene cable warning mats placed at a
depth of 0.4/0.9m from the finished grade for 0.75 & 1.5mtr installations.

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In case of Cable laying for BType current measurement test station, Reference cell cables
and other lengthy cables shall be carried out along side of the pipe by securely strapping it
with adhesive tape / nylon rope or equivalent as required.

In case of above ground cables installation, all unarmoured cables forming part of permanent
C.P.System shall be laid in G.I.conduit of sufficiently size up to accessible height for
protecting against the mechanical damage with all fittings, fixtures and accessories.

RCC or GI pipes of proper size shall be provided for all underground unarmoured cables at
road crossings.

Cables shall be neatly arranged in trenches in such a manner that criss-crossing is avoided
and final take-off to equipment is facilitated.

All underground cables shall be route through GI pipe/PVC pipes of proper size while passing
through road/rail crossings.

The armour of all the cables from pipeline to test station (potential measurement, reference
cell cables, cathode cables ,etc.)and test station to ground bed (anode cable)shall be clipped
at both end of the cable to avoid armour carrying CP current. The cable armour shall be
insulated by cutting and taping with insulation tape.

Cable termination should be by means of correctly sized crimped Tinned copper lugs.
Crimping shall be by means of proper Crimping tools only.

Installation shall be recorded in Installation formats.

1.6 PRECAUTIONS

Cables are to be of sufficient length so a store achthe termination point without any joint
with sufficient loop for further maintenance purpose.

All cables are to be appropriately tagged.

Prior to unloading/installation cable shall be checked for mechanical Damage.

One set of drawings/documents should be kept by site supervisor at workplace.

Proper Personnel Protective Equipment (PPE) shall be used during works at site.

1.7 ITP AND INSTALLATION REPORT

RecordandDocumentallinspectionresultsobtainedinthestandardinspectionreport formats
attached inAnnexure-A.

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2 PROCEDURE FOR SACRIFICIAL MAGNESIUMANODEINSTALLATION PROC. NO-002

2.1 PURPOSE

To describe the procedure for installation of sacrificial Magnesium anode to ensuring its
best result in protecting pipeline under Cathodic Protection and provide adequate quality
assurance / control of workmanship and inspection at site.

2.2 SCOPE

This procedure covers the installation of sacrificial Magnesium anode related to Cathodic
Protection System as per standard drawing and technical specifications.

2.3 MATERIAL &EQUIPMENTS

Equipments :Calibrated portable multimeter, Copper-Copper Sulphate

Reference Cell and Tool kit etc.
Materials :Pre-packaged Magnesium Anode, Epoxy & Hardener, M–seal, PVC
funnel/pipe, cables, cable lugs, Measuring tape and Tool box, etc.

2.4 REFERENCEDOCUMENTS
Specification for Cathodic Protection-Document No- P.013753 D 11077 124

2.5 PROCEDURE

Before Starting the work check material against datasheet & test certificate.

Measure 5m distance from pipeline to left side(or)right side of ROU based on the land
availability and mark anode location.

The Prepacked galvanic anode, top of the anode shall be installed at min depth equal to
bottom level of the pipeline or 1.5m depth whichever is deeper.

Excavate the pit up to1.5m and Width as requires vertical or horizontal. The Top of the
anode shall be at the bottom of the pipeline.

Anodes shall be placed in a cotton bag as per design and approved drawings. The cotton
bag shall be filled with the backfill mixture of Gypsum (75%), Bentonite (20%) and Sodium
Sulphate(5%).

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Install the prepackaged sacrificial anode in the excavated pit. The anodes shall be installed
either horizontally or vertically as per design with the top of the anode at a minimum1.5mtr.
The anodes shall be installed perpendicularly to the pipeline. Sufficients lack shall be
provided in anode cable to avoid mechanical strain.

Backfill the excavated soil and soil shall be tamped down.

Measure and record open circuit potential of anode after installation.

Al some a sure and record the pipe to soil potential before and after connecting the anode to
pipeline.

At any location if rock is found than anode shall be installed at 0.5m depth or equal to
depth of pipeline whichever is higher in horizontal configuration, this is to avoid current
shielding because of rock; however it should be ensured that the pipeline is protected
cathodically.

The anodes shall be installed ina manner as above to avoid interference problem son
the existing pipeline in a common ROW.(i.e.) anodes hall not be installed on existing
pipeline side.

Excavateatrenchof0.3mx1.5mdeepfromexcavatedlocationtoteststationlocationfor cable
laying. Lay the anode tail cable up to test station and terminate if single anode is installed.

If more than three anodes is to be installed at a particular location than each anode tail
cable shall be individually terminated into the buried junction box and one cable from
buried junction box shall be terminated into the test station at the particular location as per
the approved drawing.

If more than One anode is to be installed at particular location, the centre to centre spacing
between consecutive anodes shall be 3m.

Terminate cable in test station as per connection scheme.

The anode open circuit potential shall be measured after install at ion w.r.t. a portable copper-
copper sulphate reference cell.

The anode shall be soaked in water before installation for minimum one day.

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2.6 PRECAUTIONS

Install pre-packaged anode carefully. While lowering, the anode should not be suspended or
lowered by its lead wire.

Anode shall be soaked in water before installation for min one day.

The backfilling soil shall be with out stones and garbage etc. and well compacted to avoid
voids later on.

If native soil is dry than watering may be done for proper moisture and reduce resistance.

Anode Tail Cable should be of sufficient length so that it reaches TLP without any Joint.

All cables are to be properly tagged. All cable connections should be checked for proper
tightening.

Epoxy Hardener should be solid and no air gap holes before backfill.

One set of Drawing/Document should be kept by site supervisor at workplace.

Proper Personnel Protective Equipment (PPE) shall be used during works at site.

2.7 ITP AND INSTALLATION REPORT

Record and Document all Inspection results obtained in the standard inspection report
formats attached in Annexure-A.

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3 PROCEDURE FOR SACRIFICIAL ZINCANODEINSTALLATION PROC. NO-003

3.1 PURPOSE

To describe the procedure for installation of sacrificial Zinc anode to ensuring its best result in
grounding the surges and where as the installation of zinc anode is required and provide
adequatequalityassurance/controlofworkmanshipandinspectionatsite.

3.2 SCOPE

This procedure covers the installation of sacrificial Zinc anode related to Cathodic
Protection System as per technical specifications.

3.3 MATERIAL &EQUIPMENTS

Equipments :Calibrated portable multi meter, Standard Copper-Copper
Sulphate Reference Cell and Tool kit etc.
Materials :Pre-packaged Zinc Anode, Epoxy &Hardener, M–seal, PVC pipe/funnel
Cables, Cable lugs, Measuring tape and Tool box, etc.

3.4 REFERENCEDOCUMENTS
Specification for Cathodic Protection-Document No- P.013753 D 11077 124

3.5 PROCEDURE

Before Starting the work check material against datasheet & test certificate.

Measure 2m distance from pipeline to left side (or)right side of ROU based on the land
availability and mark anode location.

Excavate the pit upto1.5m and Width as requires vertical or horizontal. The top of the
anode shall be at the bottom of the pipeline.

Anodes shall be placed in a cotton bag as per design and approved drawings. The cotton
bag shall be filled with the low resistivity chemical backfill mixture of Gypsum(75%),
Bentonite (20%) and Sodium Sulphate(5%).

Install the prepackaged sacrificial Zn anode in the excavated pit. The anodes shall be
installed either horizontally or vertically as per design with the top of the anode at a
minimum 1.5mtr.

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The Prepacked galvanic anode, top of the anode shall be installed at min depth equal to
bottom level of the pipeline or 1.5m depth whichever is deeper.

The anodes shall be installed perpendicularly to the pipe line.

Backfill the excavated soil and soil shall be tamped down.

Measure and record open circuit potential of anode after installation.

At any location if rock is found than anode shall be installed at 0.5m depth or equal to
depth of pipeline whichever is higher in horizontal configuration, this is to avoid current
shielding because of rock; however it should be ensured that the pipeline is protected
cathodically.

The anodes shall be installed in a manner as above to avoid interference problems on the
existing pipeline in a common ROW.(i.e.)anode shall not be installed on existing pipeline
side

Excavate a trench of 0.3mx1.5m deep from excavated location to test station location for
cable laying.

If more than One anode is to be installed at particular location, the centre to centre spacing
between consecutive anodes shall be 2m.

Terminate cable in test station as per connection scheme.

The anode open circuit potential shall be measured after installation w.r.t. a portable copper-
copper sulphate reference cell.

The Anode shall be soaked in water before installation for minimum one day.

3.6 PRECAUTIONS

Install pre-packaged anode carefully. While lowering, the anode should not be suspended or
lowered by its lead wire.

Anode shall be soaked in water before installation for minimum one day.

The backfilling soil shall be with out stones and garbage etc. and well compacted to a void
voids lateron.

If native soil is dry than watering may be done for proper moisture and reduce resistance.

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All cables are to be properly tagged. All cable connections should be checked for proper
tightening. Anode Tail Cable should be of sufficient length so that it reaches TLP without
any Joint. Epoxy Hardener should be solid and no air gap holes be for e backfill.

One set of Drawing/Document should be kept by site supervisor at workplace.

Proper Personnel Protective Equipment (PPE) shall be used during works at site.

3.7 ITP AND INSTALLATION REPORT

Record and Documental in section results obtained in the standard inspection report
formats attached in Annexure-A.

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4 PROCEDURE FOR TEST STATION INSTALLATION PROC. NO-004

4.1 PURPOSE

To describe the procedure for installation of Test Station to monitor the performance of
CP system along pipeline route at specified distances as in design document and provide
adequate quality assurance/control of workmanship and inspection at site.

4.2 SCOPE

This procedure covers the installation of Test Station related to Cathodic Protection
System as per TGPL technical specifications.

4.3 MATERIAL &EQUIPMENTS

Equipments :Calibrated portable multimeter, Standard Copper–Copper Sulphate
Reference Cell and Tool kit etc.
Materials :Test Station Box &Bend ,shuttering plates, Cables, Lugs,
Ferrules, Sand, Cement, etc.

4.4 REFERENCEDOCUMENTS
Specification for Cathodic Protection-Document No- P.013753 D 11077 124

4.5 PROCEDURE

Before Starting the work check material against datasheet & test certificate.

The location of the teststation shall be marked on right of use as per approve document
with their connection scheme and other related information on alignment sheet.

Make a pit of dimension 0.8mx0.8mx0.8m. The distance of pipe line center to foundation
pit center shall be 2 m on the Right or left hand side.TLP shall not be installed at the Space
between parallel pipelines.

Fix shuttering plates. Place the reinforcement and pipe bend and level it to ensure that
cable entry point be faced towards the pipeline.

Bonding provision at test station shall be provided at every 5km interval for Existing
Pipeline.

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Place a PVC ring/bushing on the rim of the M.S pipe protruding out of the foundation block
to avoid damage to cable insulation while pulling the cables in to the enclosure.

Foundation should be cast either at site location. The overall dimensions of foundations
shall be 600 mm x 600 mm x 800 mm as per drawing. The concrete mix should be of RCC M
20 Grade & ensure about compactness of foundation. The foundation cast should be
properly watered and cured appropriate. 150mm PCC shall be done on top of the
foundation after installation of test station.

Pull the cables upto the top of foundation and then drive them through the support pipe
into the enclosure. The cable entry shall be sealed properly after laying of cable to avoid
entry of water into test station.

The M.S. support pipe along with enclosure should be erected on top of foundation block by
matching the base plate bolt welded with baseplate.

Test station shall be sealed at both side of cable entry.

The orientation of the terminal enclosure should be such that its door faces the pipeline.

Mount the necessary hardware within the enclosures and terminate the cable on to the
respective terminals. No of terminal and different scheme of wiring shall be as per the
Test Station connection Scheme. Minimum 20% spare terminals shall be provided in each
test station. Refer to respective connection scheme drawing as per approved Test station
schedule.

Test station No. shall be painted on test station along with arrow showing direction of
productflowby40mmstencilblockletterinblackalongwithchainagedetailandTLPNo.

The name plate of test station shall in minimum carry following information which is to
be fitted during commissioning of PCP system.

150mm PCC shall be done on top of the foundation after installation of test station.

 Test station number

 Chainage In Km
 Test station connection scheme type (Permanently Fixed)
 Distance from pipeline in meters.
 Direction of product flow

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Installation shall be recorded in installation formats.

4.6 PRECAUTIONS

Cables used shall be of sufficient length so as to reach termination point without any joint
provide sufficient care for feature maintenance purpose.

Test station at HT line crossing shall be installed minimum100-500m away from HT line
crossing.

Test station for bonding shall be provided with shunt and Resistors as means to monitor and
control current.

Test station should be straight & level to check before final setting.

All cables are to be appropriately tagged & all the connection should be checked for proper
tightening.

Cable core ferrules are to be provided at end before final termination & cable should be
neatly dressed inside the trench and to be terminated inside test station.

Test station used for sacrificial anodes shall have shunt for measurement of anode
current and provision for variable resistance insertion to limit the anode current outputs.

All necessary civil work should be done to protect the Test Station.

One set of Drawing/Document should be kept by site supervisor at workplace.

Proper Personnel Protective Equipment (PPE) shall be used during works at site.

4.7 ITP AND INSTALLATION REPORT

Record and Documental in section results obtained in the standard inspection report
formats attached in Annexure-A.

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5 PROCEDURE FOR SURGEDIVERTERINSTALLATION PROC. NO-005

5.1 PURPOSE

To describe the procedure or installation of surge diverters across the insulating joint to
protect it from high voltages urges and provide adequate quality assurance/control of
workmanship and inspection at site.

5.2 SCOPE

This procedure covers the installation of Surge Diverter across the insulating joint to
protect it from surges as per TGPL technical specifications.

5.3 MATERIAL &EQUIPMENTS

Equipments : Tool kit,etc.

Materials :Surge Diverter, Cable, Copper strip, Epoxy & Hardener, Cable
Lugs, Bolts &Nuts, etc.

5.4 REFERENCEDOCUMENTS
Specification for Cathodic Protection-Document No- P.013753 D 11077 124

5.5 PROCEDURE

Surge diverter shall be installed to avoid the damage to the isolation joints from excessive
over voltage across the joint due to lightning or overhead AC power line failure.

Check the location of the Isolating Joints and check the insulation of the joint.

Measure the Copper Strip & cut for required length. Connect the strip by clit welded with
pipeline and tight the bolt (Brass nut and bolt).

Connect the Surge diverter across the Insulation Joint in the copper strip and tight the bolt.

All the exposed connection parts with the pipe line shall be covered by means of Epoxy-
Hardener.

Measure the PSP readings at both sides of the IJ/Surge Diverter.

Connect all the cables as per F-Type test station.

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5.6 PRECAUTIONS

Visually inspect the surge diverter before mounting/connecting it.

Polarity to be checked as per manufacturer instructions.

All the cable connection should be checked for proper tightening & tagging.

One set of Drawing/Document should be kept by site supervisor at workplace.

Proper Personnel Protective Equipment (PPE) shall be used during works at

site.

5.7 ITP AND INSTALLATION REPORT

Record and Documentall inspection results obtained in the standard inspection report
formats attached in Annexure-A.

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6 PROCEDURE FOR CABLE TO PIPE CONNECTION BYPINBRAZING PROC. NO-006

6.1 PURPOSE

To describe the procedure for cable to pipe connection by Pin Brazing for foreign/charged
pipe line and provide adequate quality assurance/control of workmanship and inspection
at site.

6.2 SCOPE

This procedure covers the cable to pipe connection by Pin Brazing for foreign / charged
pipeline for all type of cables related to Cathodic protection system as per TGPL
technical specifications.

6.3 MATERIAL &EQUIPMENTS

Equipments : Pin Brazing Set including pin studs, Brazing gun, Holiday detector,
Calibrated portable multimeter, Crimping tool, etc.

Materials : Cable lugs, Epoxy & Hardener, M–seal, PVC funnel /pipe, etc.

6.4 REFERENCEDOCUMENTS
Specification for Cathodic Protection-Document No- P.013753 D 11077 124

6.5 PROCEDURE

Before Starting the work check material against datasheet & test certificate.

Pin Brazing is used to ensure a safe electrical connection to different types of steel
structures. This Method is preferred usually because of its minimum thermal effects on the
steel because of low melting of solder(650°For345°C), short heating time, fast Installation,
performance, and versatility by the Portable nature of the equipment.

Brazing pins shall be of M8 size..

The ferrule insulates the pin from the gun body; shields the molten braze metal from the
air and protect the operator against spatter.

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Excavate a pit over the pipe line to expose the pipe line top surface at Pin Brazing
location where cable to Pipe connection is to be carrying out as per design. Care should
be taken to avoid coating damage of the buried pipeline.

Mark the point where connection has to be carried out. If there is more than one
connection at a location as per design, the consecutive marking shall be minimum 300 mm
apart. The location for cable to pipe connection shall be selected such that the pipe joints
and field coated areas are avoided. Care shall be taken that cable to pipe joint is not made
upon the long seam or circumferential weld.

Cut and open the coating of the pipe line with care and without damaging the pipe for a
size of Approximately 50 mm x 50 mm. Clean the surface of the pipeline to white metal
finish using sandpaper.

Braze the pin over the exposed pipeline using the brazing equipment and leave for 2
minutes. Place a Plastic funnel(70mm) around the exposed area such that about 5mm wide
coating remains inside the plastic funnel/PVC Cap. Place M-seal around the plastic funnel
to prevent leakage of encapsulation materials.

Check the mechanical integrity of the of the weld by use brass hammer (0.5 kg).

Fill up the conical mould from the top by pouring mix of Epoxy – Dobefill – 60 and hardener
–758at1:10ratio.3/4th of the PVC Cap/Funnel have to be filled with mix and cut the
remaining plastic cone after Setting of the hardener.

Verify battery for holiday test is good charged condition.

Qualification of pin brazing procedure to be carried out be fore taking up field work/field
joint.

6.6 PRECAUTIONS

Excavation to be done without damaging the coating. For that only manual excavation
shall be carried out over the pipeline.

Pipeline material shall not be damaged while be removing the coating.

The pin brazing gun shall be used as per manufacturer instruction if

any.

The pipe line surface of the weld area shall be prepared to white metal finish without any
dust or grease.

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Take precaution & ensure that the cable to pipe joint is not made upon the seam on
circumferential weld of pipe.

If one connection fails, wait for approx. 5minutes for pipeline cooling and then repeat the
procedure as above.

Any damage to coating/ pipe metal should be brought to the notice engineer to requisite
actions.

Check hardness of encapsulation before holiday test by applying pressure with thumb.

Coating repair and Holiday test should be completed before backfilling.

One set of Drawing/Document should be kept by site supervisor at workplace.

Proper Personnel Protective Equipment(PPE) shall be used during works at site.

6.7 ITP AND INSTALLATION REPORT

Record and Documentall inspection results obtained in the standard inspection report
formats attached inAnnexure-A.

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7 PROCEDURE FOR POLARIZATIONCOUPONINSTALLATION PROC. NO-007

7.1 PURPOSE

To describe the procedure for installation of Polarization Coupon needed for measurement
of “off” potential and thereby assessing an IR drop in the PSP measurement and provide
adequate quality assurance/control of workmanship and inspection at site.

7.2 SCOPE

This procedure covers installation of Polarization Coupon related to cathodic protection as

per TGPL technical specifications.

7.3 MATERIAL &EQUIPMENTS

Equipments: Calibrated portable multimeter, Standard Copper–Copper Sulphate

Reference Cell and Tool kit, etc.

Materials: Polarization coupon material (same as pipe line material provided by TGPL at
site), Epoxy & Hardener, Cables, Cable lugs and Toolbox, etc.

7.4 REFERENCEDOCUMENTS
Specification for Cathodic Protection-Document No- P.013753 D 11077 124

7.5 PROCEDURE

Buried polarization coupon shall be fabricated from the same material as that of the
pipeline & shall be provided by M/s. TGPL at site.

Mark the location of polarization coupon. This shall be in line with approved design and
tender specification.

Polarization coupon shall be totally insulated with pipe line coating material except one
side area of 50 mm x 50 mm and coupon size is 100 mm x 100 mm & the same remain
bare exposed to soil. And it shall be square housing.

Two cables (10sq.mm and 06sq.mm armd) connections shall be provided for each coupon
(i.e.) one connection to pipeline for protection & other for potential measurement. Cables

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Shall be connected on the insulated side of the coupon and the connection shall be
insulated by encapsulation with epoxy and hardener and with square housing.

Connection of coupon to pipe line shall be through a magnetic reed switch housed inside
the test station. The magnetic reed switch shall be rated to carry and break minimum 50mA
at 50 VDC.

The coupon protection cable shall be connected to pipe line through a magnetic reed
switch inside the test station to enable measurement of coupon ‘OFF’ potential.

The coupons shall be installed at bottom of pipe line and approx.200mm away from the
pipeline with insulated surface towards pipe line.

One permanent reference cell shall be installed approx.200mm away from coupon & faces
towards exposed surface area of coupon to sense the coupon potential only.

7.6 PRECAUTIONS

Ensure that the polarization coupons required for a particular location are available at site.

Install the polarization coupon carefully. While lowering , the coupon should not be
suspended or lowered by its lead wire.

Care should be taken on that the test coupon and pipeline not to be shorted.

The coupon cable shall be terminated with sufficients lack to avoid mechanical strain on
the cable inside the test station box.

One set of Drawing/Document should be kept by site supervisor at work place.

Proper Personnel Protective Equipment (PPE) shall be used during works at site.

7.7 ITP AND INSTALLATION REPORT

Record and Document all inspection results obtained in the standard inspection report
formats attached in Annexure-A.

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8 PROCEDURE FOR PERMANENT REFERENCE CELL INSTALLATION PROC. NO-008

8.1 PURPOSE

To describe the procedure for installation of Permanent Reference Cell needed for
measurement of Pipe to Soil Potential in Permanent Cathodic Protection provide
adequate quality assurance/control of workmanship and inspection at site.

8.2 SCOPE

This procedure covers the installation of permanent reference cell related to the Cathodic
Protection System as per standard TGPL technical specifications.

8.3 MATERIAL &EQUIPMENTS

Equipments : Calibrated portable multimeter, Portable Copper / Copper Sulphate

reference cell, Electrician tool kit, etc.

Materials :Permanent Copper/Copper Sulphate reference cell, Cotton Bag, Cables,

Cable lugs, Cable joint tool kit, Backfill material (Gypsum, Bentonite&
Sodium Sulphate), Epoxy & Hardener, Ferrules, etc.

8.4 REFERENCEDOCUMENTS
Specification for Cathodic Protection-Document No- P.013753 D 11077 124

8.5 PROCEDURE

Before Starting the work check material against datasheet & test certificate.

Check serial number of permanent reference cell and verify with manufacture test
certificate. Record serial no. of reference cell on inspection report. Check cable
connection and permanent Reference cell for any damage prior to installation.

Keep portable reference cell and permanent reference cell on ground above the buried
pipelinecloseToeachothernearteststation.Measurepipetosoilpotentialwithreference to
portable as well as permanent reference cell and record it.

Mark location of reference cell. This shall be in line with approved CP equipment layout for
appropriate location & system design.

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PROTECTION SYSTEM

Check cable connection and cotton bag filled with backfill material (Gypsum-75%,
Bentonite - 20%, Sodium Sulphate-5%) and permanent reference cell for any damage prior
to installation.

Excavate and install the permanent reference cell on either sides of the pipeline at the
bottom level of the pipe line and approx.200mm away from the pipe line where to sense
the pipeline potential.

Terminate the permanent reference cell cables in to the test station and proper
identification tag shall be provided.

If more than one reference cell installed at one location than distance between two
consecutive reference cells is to be minimum as per approve drawings or 5m.

8.6 PRECAUTIONS

Ensure that the reference cells required for a particular location are available at site.

While lowering, the reference cell should not be suspended or lowered by its lead wire. The
reference cell tail cable shall be terminated with sufficient care to avoid mechanical strain on
the cable inside the test lead point.

All cables to be appropriated tagged. All the cable connection should be checked for proper
tightening. The backfillingg operation shall be completed to finished grade level using Excavated
material.

One set of Drawing/Document should be kept by site supervisor at workplace.

Proper Personnel Protective Equipment (PPE) shall be used during works at site.

8.7 ITP AND INSTALLATION REPORT

Record and Document all inspection results obtained in the standard inspection report formats
attached in Annexure-A.

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9 PROCEDURE FOR TCPSYSTEMCOMMISSIONING PROC. NO-009

9.1 PURPOSE

The intent of the document is to describe the standard procedure to be adopted for
commissioning of a Temporary Cathodic Protection installation (TCP) System and
provide adequate quality assurance/control of workmanship and inspection at site.

9.2 SCOPE

A Temporary C.P. system shall be installed to protect the pipeline during construction
period. The testing and commissioning of temporary C.P. system shall be carried out to
make sure that the pipe line is being protected against the corrosion till the permanent
C.P. system is commissioned.

TCP commissioning shall be in parts along with pipeline lowering. It shall be considered final
commissioning, on commissioning of all items for particular location and upon providing
protection to the pipeline under that location.

9.3 INSTRUMENT &EQUIPMENTS

We shall provide all necessary instruments, equipment and labour to perform all the
required checks and test. For this purpose, the following instruments shall be deployed at
site:

 Copper/Copper sulfate reference half cells (Portable).

 Digital Multimeter.
 Electrician’s Tools Kit.

9.4 REFERENCEDOCUMENTS
Specification for Cathodic Protection-Document No- P.013753 D 11077 124

9.5 PROCEDURE

 The Following tests shall be carried out and recorded.

The Natural pipe-to-soil potential shall be measured before energizing C.P. system using
portablecopper-coppersulfatehalfcellasreferenceandaportabledigitalMultimeter.The

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PROTECTION SYSTEM

Pipe to soil potential shall be measured between pipeline and reference cell in contact
with earth directly over the pipe line. All results shall be recorded on the approved
formats.

The natural pipe to soil potential shall be measured before connecting the anode to
pipeline & recorded in the approved format.

Measure anode open circuit potential with respect to Cu-CuSO4 reference electrode and
record the reading in the given approved format.

Connect the anode with the pipeline thorough the test station.

Measure the pipe to soil potential and anode current output immediately /after24hours
and record the readings in the given approved format.

After connecting all the anodes to pipeline, measurement of pipe to soil potentials shall
be taken at each testpost to ensure conformity to protection criteria.

Also measure AC voltage (with & without Zn anode) and Zinc anode open circuit potential
at HT line crossing.

 TCP system should meet the following criteria for acceptance:

The pipe to soil potential measurements shall be between–0.95VONand–1.5VONwith

respect To a Copper/Copper Sulphate Reference Electrode. If the potentials are below the
(-)0.95V, install additional anode/anodes as required till the desired potential level is
achieved.

If the pipe to soil potentials are above (-)1.5V, install a suitable resister in the anode
Circuit to control the anode output current. Each anode installed location shall be come
individually operation as above.

In case of insufficient protection as per the CP design criteria, on any portion of the
pipeline then necessary additions/modifications shall be carried out to provide adequate
protection in consultation with engineer in charge at site.

The above procedure shall be followed for all the Galvanic Anode ground bed as well as
for the anodes Installed for the casing pipe protection (if any).

The TCP System provided shall be monitored at all test station once in a month of
healthiness/adequacy of protection till commissioning of PCP system or design life of TCP
system whichever is less.

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PROTECTION SYSTEM

The monitoring report shall be submitted every month to client for review / information.

9.6 PRECAUTIONS

Investigation shall be made for stray current electrolysis of the pipeline, AC induction on
Pipeline due to overhead high voltage line, interference due to high voltage DC lines,
electric traction etc.

Incase of fluctuating stray currents, investigations shall be made continuously over a Period
of time.

One set of Drawing / Document should be kept by site supervisor at work place.

Proper Personnel Protective Equipment (PPE) shall be used during works at site if required.

9.7 ITP AND INSTALLATION REPORT

Record and Documental inspection results obtained in the standard inspection report
formats approved by TGPL

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