Total Sheet 14

Vendor’s name : Dong Yang Corrosion Engineering Co., Ltd.

Company’s name : Nghi son Refinery and Petrochemical LLC.

Purchaser : JGCS Consortium

Responsible OC : JVD

Plant Location : Nghi Son, Vietnam

Project name : NSRP Complex Project

P / Order No. : BV2187-001-A

Equipment/Material name : Cathodic Protection Materials

Item number : Common

Document title : Operating and Maintenance Manual

PROJECT (JOB No.: 0-6495-20)

DOCUMENT CLASS: OTHERS

ISSUE PURPOSE: AB

RESULT CODE: A, B, R, F (A )

NEXT STATUS: FA, FR, FI, FC, AB (- )

RESUBMISSION DATE: (- )

RESPONSIBLE DEPT./PERSON: ( ELEC/W.S.LEE )

Review Date: ( 27th-Mar-2017 )

A: Approved without Comment; B: Approved with Minor Comment

R: Not Approved; F: Not Subject to Review

Approval or review hereunder shall not be construed to relieve Vendor/ Subcontractor of his
responsibilities and liability under the Contract

ORIG. PURCHASE ORDER NO. SERIAL REV.

Purchaser
DOC. No.
V V2187-001-A 600 2

2 27/Mar/2017 14 As-Built E.J.Song S.G.Kim D.J.Kim

1 07/Dec/2015 14 For Construction E.J.Song S.G.Kim D.J.Kim
0 10/Apr/2015 15 For Information E.J.Song S.G.Kim D.J.Kim
Rev Date Page Description Prep’d Chk’d App’d

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TABLE OF CONTENTS

No. Description Page

1 SCOPE ……………………………………………………… 3

………………………………………………………
2 CODE&STANDARDS 3

………………………………………………………
3 OPERATION 4

………………………………………………………
3.1. SAFETY PRECAUTIONS 4

………………………………………………………
3.2. PRE-OPERATING PRECAUTIONS 4

………………………………………………………
3.3. ENERGIZING 4

………………………………………………………
3.4. SHUT-DOWN 5

………………………………………………………
3.5. FUNCTIONAL CHECKS 5

………………………………………………………
3.6. FREQUENCY OF THE CONTROL 6

………………………………………………………
ATTACHMENT_TR/RECTIFIER MANUAL 7

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1. SCOPE

This document defines the requirements of system design, equipment / materials of an impressed
current system for NSRP complex project..

2. CODES AND STANDARDS

This cathodic protection design shall be in accordance with; but not be limited by the following codes
and standards:

 SP0169

National Association of Corrosion Engineers (NACE)

Title : Control of external corrosion on underground or submerged metallic piping systems

 SP0286

National Association of Corrosion Engineers Stands (N.A.C.E)

Title : Electrical Isolation of Cathodically Protected Pipelines

 SP0193

National Association of Corrosion Engineers Stands (N.A.C.E)

Title : External cathodic protection of on-grade carbon steel storage tank bottoms

 RP0196

National Association of Corrosion Engineers Stands (N.A.C.E)

Title : Galvanic Anode Cathodic Protetion of Internal Submerged Surfaces of Carbon Steel Water

Storage Tanks

 EN 12954

British Standards Institution (U.K)

Title : Cathodic Protection of Buried or Immersed Metallic Structures - General Principles and

Application for Pipelines

 EN 13636

British Standards Institution (U.K)

Title : Cathodic Protection of Buried Metallic Tanks and Related Piping

 EN 13509

British Standards Institution (U.K)

Title : Cathodic Protection Measurement Techniques

 EN 14505

British Standards Institution (U.K)

Title : Cathodic Protection of Complex Structures

 EN 12499

British Standards Institution (U.K)

Title: Internal Cathodic Protection of Metallic Structures

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3. OPERATION

3.1 Safety Precautions

3.1.1. Beware of the AC line voltage inside of rectifier cabinet. Turn the AC power “OFF” before starting
inside work.
3.1.2. Do not exceed the AC or DC rating.
3.1.3. Correct any overload that may activates a circuit breaker or fuse. Do not bypass these protective
devices.
3.1.4. To prevent severe corrosion, always check the potential of protected structure after energizing a
rectifier. Be sure that potential value shifts toward the negative when the rectifier is turned ON.

3.2 Pre-operating Precautions

3.2.1. Check and repair installation damages.

3.2.2. Be certain the rectifier is connected to proper rate AC line voltage, phase and frequency.
3.2.3. Connect the positive rectifier output terminal to anodes. And connect the negative one to the metal
structure that will be protected.
3.2.4. Connect the rectifier reference electrode terminal to the Cu/CuSO4 Reference electrode or Ag/AgCl
Reference electrode. And connect the negative one to the structure that will be protected.
3.2.5. Check it continuity between main negative (-) cable and negative cable of reference cell with
Cu/CuSO4 Reference electrode or Ag/AgCl Reference electrode (up to 1 ohm)
3.2.6. Make certain that all electrical connections are snug
3.2.7. The natural structure-to-electrolyte potential values shall be particularly checked and recorded in
order to obtain reading to be compared to the next periodical ones.
3.2.8. Furthermore it is necessary to inspect the TR/rectifiers checking :
① Oil level for the TR/rectifiers
② All adjustable volumes are set to the minimum setting.

3.3 Energizing

3.3.1. After pre-operating, cathodic protection system can be started up.

3.3.2. Protection potential will be obtained by adjusting current supplied by the system.
3.3.3. Ag/AgCl reference should be used for screen, stop gate in lintake & tank internal. Cu/CuSO4
reference should be used for buried piping.
3.3.4. The structure lead wire is connected to the (+) terminal of a multi-meter set to D.C. Volts.
3.3.5. The reference electrode lead wire is connected to the (-) terminal of the multi-meter and the
electrode placed upon moist soil immediately above the structure under test box.
3.3.6. A negative potential(instant off) of at least –850 mV with cathodic protection applied. This voltage is
measured with respect to a Cu/CuSO4 reference electrode contacting the electrolyte.
3.3.7. A negative potential(instant off) of at least –800 mV with cathodic protection applied. This voltage is
measured with respect to a Ag/AgCl reference electrode contacting the electrolyte.
3.3.8. A minimum of 100mV of cathodic polarization between the structure surface and a stable reference
electrode contacting the electrolyte.

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3.4 Shut-down

All the electric components and the system are designed and built for a continuous operation ; therefore,
do not switch-off the power units, unless for extreme necessity or safety precaution, in order to avoid
the depolarization of the structures.
If the system is out of commission, break the circuit through the main switch.
Ampere meter and volt meter gets down to zero while the millivolt meter(potential meter) goes gradually
to the natural potential value.

3.5 Functional Checks

When functional checks, use forms in pre-commissioning and commissioning procedure.

3.5.1. TR/rectifier
TR/rectifier must be checked following the instructions of the operating manual supplied by the
manufacturer.
The following main controls shall be performed :
① Integrity of switch and fuses on DC circuit and on AC circuit
② Setting values of maximum voltage and current output
③ Correct indication of the instruments
④ Tightness of cable connection
⑤ Tightness of earth connections
⑥ Lubrication of cabinet locks and turning handles
⑦ Presence of sand or mist inside the cabinet

3.5.2. Test station and Junction box

1) Enclosure
It is sufficient to carry out a visual inspection and eliminate possible oxide deposits from the
terminals and clean from any extraneous body the terminal block.
2) Permanent reference electrodes
At the location of reference permanent electrodes, structure-to-electrolyte potential measurements
shall be carried out utilizing permanent and portable.

3.5.3. Status Checks

To determine the status of the cathodic protection system and to check its variations over the time, the
following periodic electrical measurement shall be performed.
1) Structure-to-electrolyte potential measurement
Once the CPS have been energized and set at the max design values for at least 24 hours, the
structure-to-electrolyte potentials shall be measured and recorded at test station including either
side of insulating flanges.
These measurement shall be performed in a similar way to the ON potentials except that the
output current from the feeder shall be interrupted by placing a switching device in the DC feeder
circuit.
The voltmeter shall be observed and the “OFF” potential recorded when the reading on the
voltmeter moves to a more positive value. The ON potential is recorded when the reading
becomes more negative.

The check will be carried out utilizing the following instruments

① Copper/copper sulphate(Cu/CuSO4) reference half cells
② Silver/Silver chloride(Ag/AgCl) reference half cells

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③ Digital multimeter shall have an input resistance of 100 megaohms

④ Synchronisable current interrupters
⑤ Clip on DC ammeter
⑥ Cable, etc

2) Structure-to-electrolyte potential measurement by monitoring tube

For measuring the structure-to-electrolyte potentials, use monitoring tube, voltmeter and
retractable reference electrode. First tied rope that is installed in monitoring tube to retractable
reference electrode. Second, measure potentials during pulling the rope at other side of monitoring
tube. The interval is 1(one) ~ 5(five) meters.

3.5.4. Current measurement

Current measurement shall be carried out at each anode terminal box by means the suitable
shunts connected with the output cable.
The check will be performed utilizing the following instruments
① Digital multi meter shall have an input resistance of 100 megaohms
② Clip on DC ammeter
The measurement shall be arranged as follows :

Step 1 : Measure by shunt

The most suitable scale being selected on the millivoltmeter. The cables of millivoltmeter
must be placed on the shunt edges and the tension drop measured is in value the same of
the total current flow.
Step 2 : Measure by clamp meter

3.6 Frequency of the control

In general, all components of Cathodic Protection System shall be checked annually.

Individual component must be controlled as schedule hereafter :

3.6.1. TR/rectifier
Once a month
3.6.2. Anode groundbeds
Every year or whenever great reduction of current output are found at the same output voltage
3.6.3. Insulating device
Every six months
Whenever losses of protection of the structure are found.
3.6.4. Test station
General check at each test station during potential survey
3.6.5. Potential survey
Every six months
3.6.6. Reference electrode
Every six months

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Attachment_Tr/Rectifier Manual

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1. OPERATION OF TR/RECTIFIER(HARDWARE)

1.1. Description of Operation Module

This LCD display of TR/Rectifier provides three(3) kinds of operation mode. All meter and
control/setting devices are assemble in a compact module. It divided as three(3) part as below

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1) LCD DISPLAY : Left side of module(Red color)

③ Operation Mode and Operation Value in LCD display

Show kinds of operation mode and

limit value of max. output

Show present operating DC output

voltage, current

2) VARIABLE VOLUME : Right-middle side of module(Blue color)

① Control volume to adjust DC output for local operation.

② The output voltage can be controlled/adjusted by two(2) volume, coarse and fine.

③ It is impossible to setting the value over the rated value.

3) PUSH BOTTON : Right-top side & right- bottom side of module(Orange color)

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1.2. How to Change of Operation Mode

1) Push and hold the “Display Mode” button for 5 second. Then, the LCD will be changed as following
display.
2) To move next stage, push the “Display.MODE” button. The mode will be changed in turn as below
at every push.
① Remote monitoring system
② Constant voltage
③ Constant current
④ Constant reference(potential)
⑤ Under protection alarm value setting
⑥ Interrupter “On-time” setting
⑦ Interrupter “Off-time” setting
⑧ Alarm On-Off setting

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1.2.1 Operation type selection

This is the mode to operate in constant voltage. In this mode, the

output voltage is controlled as per setting value.

This mode is saved by push the “Enter.SET” button .

If you want to constant current type, push the “UP” or “DOWN” button to select

This is the mode to operation in constant current. In this mode, the

output current is controlled as per setting value.

This mode is saved by push the “Enter.SET” button.

1.2.2 Under protection alarm value setting

This is the mode to setting the alarm level to announce in case of low
protection value is continued.

The alarm value is changed by up-down button and saved by push

the “Enter.SET” button.

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1.2.3 Alarm On-Off select mode

This is the mode to select the alarm On-Off . The alarm ringing in
case of abnormal condition, like as fuse open, MCCB trip condition.

The value is changed by up-down button and saved by push the

“Enter.SET” button.

The alarm function is provided as an option

1.2.4 GPS interrupt setting

This is GPS sync interrupt control module. The procedure for interrupt setting is below.

1) Push button “ M” for five(5) seconds.

2) Display will be changed then can set time for “ON” and “OFF”.

3) First, “ON” flicker on and off then can set time for “ON” by up/down button. Push button
“SET”.
4) Second , “OFF” flicker on and off then can set time for “OFF” by up/down button.
Push button “SET”.

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5) “GPS LOCK” and “CALCULATION” is displayed on the screen.

6) After calculation, the setting time is displayed. In case continuously changing value is
bigger than fixed value, interrupt function is activated.

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7) Push the button “ interrupt” then the Tr/rectifier is starting interrupt.

8) Caution
If the alphabet “A” is changed to any other alphabet, GPS lock is unactivated.
Then you have to re-setting.

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