ZUBAIR OIL FIELD DEVELOPMENT PROJECT

CATHODIC PROTECTION COMMISSIONING

PROCEDURE

EPC for Water Injection Network Installation

EX-DE 01 12/05/2019 Final Issue Hareesh Mercelito H. Hammami M. Shaker M. Borriello

EX-DE 00 8/02/2017 Issue for Approval Hareesh Mercelito H. Hammami M. Shaker R.Dellacecca
Validity Rev.
Status number Prepared Checked Approved Contractor Company
Date Description
by by by Approval Approval
Revision Index
Company logo and business name Project name Company Identification

ZUBAIR OIL FIELD 250600DWQRD0087

DEVELOPMENT
eni iraq b.v. Job N.
Contractor logo and business name Contractor Identification

OGI002-QA-0034-01
Drake & Scull International PJSC
Contract N. 5000008451
Vendor logo and business name Vendor Identification

Order N.
Facility Name Location Scale Sheet of Sheets
ZUBAIR WATER INJECTION NETWORK ONSHORE N.A 1 of 11
INSTALLATION
Document Title Supersedes N.

CATHODIC PROTECTION COMMISSIONING PROCEDURE Superseded by N.

Plant Area Plant Unit
N.A N.A
Software: Microsoft Word 97-2003 File N° 250600DWQRD0087_EXDE01_11.doc

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EX-DE 01

REVISION HISTORY

Rev. Date Nr. of sheets Description

EX-DE00 08/02/2017 11 Issue for Approval

EX-DE00 12/05/2019 11 Final Issue

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INDEX

1 General ........................................................................................................................................... 4
1.1 Scope of work .......................................................................................................................... 4
1.2 Acronyms and abbreviations ................................................................................................... 4
2 Reference documents ................................................................................................................... 5
2.1 Project documents .................................................................................................................. 5
2.2 Company Standards ................................................................................................................ 5
2.3 International rules, codes and standards ................................................................................ 5
2.4 Mechanical Completion ........................................................................................................... 6
3 Safety requirements ...................................................................................................................... 6

4 Equipment’s list on Testing Area................................................................................................. 7

4.1 Utility List on Testing Area. ...................................................................................................... 7
5 Preliminary Checks ....................................................................................................................... 7

6 Pre – commissioning and commissioning Sequences. ............................................................ 8

7 Risk Assissment .......................................................................................................................... 10

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1 General

1.1 Scope of work

This scope of this procedures is to detail all the activities related to

commissioning of cathodic protection under the scope of work for water injection
network installation.

1.2 Acronyms and abbreviations

AC Alternating Current
CB Circuit Braker
CSE Copper Sulphate reference Electrode
DC Direct Current
GB Groundbed
JB Junction Box
OTL Oil Transfer Line
T/R Transformer / Rectifier
TP Test Point
ZOFD Zubair Oil Field Development
ZSE Zinc Sulphate reference Electrode.
CPS Cathodic Protection Station
ETP Equi-potential Test Point
SIJ Shunt Insulating Joint
SGP Saftey Ground Point
NDB Negative Distribution Box
PJB Positive Junction Box
CPSx-ELCy Cathodic Protection Station n.x-Cu/CuSO4 reference electrode n.y
CPSx-ELZy Cathodic Protection Station n.x-Zn/ZnSO4 reference electrode n.y
AAA-ELCx Pipeline AAA-Cu/CuSO4 refernce electrode n.x
AAA-ELZx Pipeline AAA-Zn/ZnSO4 refernce electrode n.x

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2 Reference documents

2.1 Project documents

00250600DEDQD0133 CP TEST POINTS INSTALLATION DRAWING FOR

WATER INJECTION

00250600DEEBD0138 CP MTO FOR WATER INJECTION FLOWLINES

00250600DERBD0135 CP 8 SINGLE LINE DIAGRAM

00250600DERBD0136 CP 9 SINGLE LINE DIAGRAM

00250600DERBD0137 CP 10&11 SINGLE LINE DIAGRAM.

00250600DESTD0139 CP MATERIAL SPECIFICATION FOR WATER

INJECTION

250600DEQRD0198 CP inspection Test Plan.

2.2 Company Standards

27589.VAR.COR.PRG Guidelines for design and construction of cathodic

protection systems.

2.3 International rules, codes and standards

EN 12954 Cathodic protection of buried or immersed metallic

structures – General principles and application for
pipelines.
EN 50122-2 Railway applications – Fixed installations – Part 2:
Protective provisions against the effect of stray currents
caused by DC traction systems.
EN 50162 Protection against corrosion by stray current from DC
systems.
ISO 8501 Preparation of steel substrates before application of
paints and related products – Visual assessment of
surface cleanliness.
ISO 15589-1 (2001) Petroleum and natural gas industries – Cathodic
protection of pipeline transportation.
NACE SP0169 Control of external corrosion on underground or
submerged metallic piping systems.
NACE SP0177 Mitigation of alternating current and lightning effects on
metallic structures and corrosion control systems.

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EX-DE 01

2.4 Mechanical Completion

Mechanical Completion is defined as that point in the project when work to install,
erect and fit out the facilities has been completed, and that fitting out work has
been tested. In addition, mechanical completion for each component of the
facility is defined by completion and signs off of the corresponding Mechanical
Completion “A” check sheet.

Detailed inspection check sheets (defined as “A” check sheet) are employed to
confirm that particular type and activity, if applicable, has been addressed
specific to a particular discipline summarized below; all discrepancies, damages,
malfunctions or missing documents results from the check and tests being
performed are incorporated in the “punch list”.

Contractor shall develop Handover certificate for all equipment and System within
its scope of work as defined by Company. The aim is to standardize documentary
evidence throughout the project endorsed by Company representatives, for
verification of compliances to Company contractual requirements, including
inspection and testing during fabrication and Mechanical Completion. The
Handover shall be endorsed /approved by Contractor and Company
representative.

3 Safety requirements
It is the policy of the Contractor to provide a safe and healthy workplace for all its
employees.
For the execution of the Commissioning activities, all necessary safety and
environmental precautions shall be taken to avoid any risk for personnel injury
and equipment’s damage. All instructions regarding safety aspects indicated on
Vendors documentation shall also be taken into account.
For safety recommendations, refer to:
Project HSE Plan, Doc. No. 00250600DFPD0002.

A Power extinguisher is usable inside a closed space (without people inside), this
kind of extinguisher can be used outside.

Risk assessment and PTW shall be followed during activity, and must be
available on site for the entire duration of the tests.

Caution notices shall be posted adjacent to, and at all access way to the test area.

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4 Equipment’s list on Testing Area.

The testing area is a delimitated area where the tests have been performed.
In that area will be all items involved for the pre-commissioning as listed below:

 Cu/CuSo4 half-cell portable reference Cell.

 Multi Meter
 Clamp on meter
 Pipe, Cable & Short Locators
 Test Lead Reels & Wire
In that area only authorized people can be access, in order to avoid any injury, the
people authorized for the access are listed below:

 Commissioning team;
 ENI Representative;
 ZFOD Representative;
 HSE team

4.1 Utility List on Testing Area.

The following duties must be provide for the entire duration of the Tests:

 Temporary generator (230 Vac 50 Hz).

 Multi Meter device with 4-20 mA Signal Generator.
 Earth Megger Tester.
 5 off Radio VHF.
 Cu/CuSo4 half-cell.

5 Preliminary Checks
The following activities must be close:

 The Mechanical completion will be completed, all identify “TYPE A” of punch

items must be cleared;

 All identified “TYPE B” of punch items can’t involve any functionality aspect
of each device, equipment or switchgear;

 All final dossier of each involved equipment, device, switchgear must be

available on field for the entire period of the pre-commissioning tests;

 All test report of each device, equipment must be available and reviewed by
Company;

 All instruments must be calibrated;

 All cables must be tested.

 Contractor and the Company representatives shall be perform a visual

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EX-DE 01

Check of each equipment, device, switchgear in order to check if the items

are free from damage, to check the installation, and to verify the safety
status;

 All energized CB must be locked and not accessible by not authorized

people;

 Verify the Work to Permits have been compiled and signed;

 HSE Design/Review Analysis Check Sheet has been verified;

 HSE toolbox has been performed.

 All Approved drawing in red mark (If any) should be available on field.

All mentioned checks must be verified before to start the pre-commissioning

program.

6 Pre – commissioning and commissioning Sequences.

The installed cathodec protection system shall be commissioned as per following

general procedure and the same shall be modified as per the system design
parameters.
 Check correct termination of all cable at junction boxes, drain points .

 Natural pipe-to-soil potential values shall be measured with respect to Cu/CuSo4

half-cell.

 All the insulating joints shall be individually checked for intended electrical
isolation.

 Grounding and polarization cells shall be less than 1 ohm checked for their
expected performance.

 Bonding between individual pipes in common ROW/ pipe trench shall be ensured.

 For each CP system, one of the T/R units at one CP station end shall be
energized to an output regulated manually so as to achieve a -1500 mv maximum
structure-to-electrolyte potential of with respect to Cu/CuSo4.

 Install the current interrupter in the DC output circuit and set 4:1 interrupter cycle.

 Measure and record the On and Off readings at all test station facilities with
respect to permanent or reference cell.
 Potential at both sides of the insulating joint shall be checked to 0 mv to observe
any potential charge in the unprotected side.

 Perform interference testing on all pipelines which are not bonded and in close
proximity to the new pipelines (10m circumference of the new line) and vice versa.
Where all or any part of a foreign structure is found to undergo a positive potential
charge greater than 20 mv and the potential is more positive than – 850 mv when
the CP system is switch on, further action to mitigate stray current effects shall be
under taken. Interference testing shall also be carried at the foreign pipeline
crossing /parallelism locations.

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EX-DE 01

 Thereafter the existing T/R unit at the other CP station end shall be energized
after switching off the CP station which was tested. The same procedure as shall
be adopted and Pipe to Soil Potential values recorded. This T/R station shall then
be switched off. After ensuring that both T/R units are in order, both shall be
switched on simultaneously and Pipe to Soil Potectial values shall be recorded
along the entire pipelines at each test station.

 Sufficient time must be allowed to elapse between switching on the CP station

and recording of pipe to soil potential values.

 As result of these tests, if any deficiencies are found in the system, the same shall
be rectified by the vendor to the satisfaction of Project Engineer. Such
deficiencies shall include mitigation of interaction problems that may be found
existing in the course of testing and commissioning. This shall also include a set
of observations taken during the peak of first dry season in the area after
commissioning the system into regular operation.

 Protection of each line under this system shall be taken for structure to
electrotype potential at each of the installed test station till a value of (–) 1.12 volts
with respect to CU/CuSo4 is reached. Also the pipe line current values across the
cross section of the pipeline shall be determined at all the intended test stations
influenced by this station. Operating parameters of the T/R unit shall also be
recorded.

 CP system shall provide all buried surfaces of pipe a polarized protective potential
ranging between -0.85 V ad -1.12 V vs. CSE (instant “off” measurement
condition).

 Where the structures shall be installed in anaerobic soils (clay) the polarized
protective potential shall be more negative than -0.95 V vs. CSE (instant “off”
measurement condition).

 According to ISO 15589-1 where the structures shall be installed in soils

with very high resistivity, the polarized protective potential (instant “off”
measurement condition) shall be more negative than

 -0.75 V vs. CSE for soil resistivity ranging between 100 and 1000 m
and -0.65 V vs. CSE for soil resistivity over 1000 m.

 CP system shall be sized to ensure a pipe-to-soil potential ranging

between -0.85 & -1.12 V (versus saturated Cu/CuSO4 reference
electrode).
Where pipelines shall be installed in soils with high resistivity range, the
protective potential shall be more negative than -0.75 V (versus saturated
Cu/CuSO4 reference electrode).Eventually, at irregular instances, a
minimum of 100 mV of Cathodic polarization may be accepted.

Potential measurements of the pipelines shall be performed in areas free

from oil leakages, because oil presence in the soil can false potential
values or make measurements impossible to perform in any case,
rectified potential value and the Off Potential of the CP system shall not
exceed the design value with respect to Cu/CuSo4 cell.

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EX-DE 01

The upper limit of pre-set reference SEP value at transformer rectifier unit
at which it should operate at permanent half-cell failure should then be
adjusted according to rectified maximum protective potential value.

7 Risk Assissment

RA014 - Electrical Services

SAFETY STATEMENT
Date
Revision Number: 5 Assessed by:

Task/operation and location [including any tools/equipment in use]

Installation of temporary/ permanent electrical supplies

Hazards Risk ratings

Without controls With controls

Electrocution High Low

Fire Medium Low
Other:

Harm
Burns or fatalities may arise from contact with live conductors or hot components
Other:

Persons in danger Number of persons in danger

Workers involved in the activity
Other workers in the area
Other:

Control measures
Surveys carried out before work begins to assess the risk of any underground cables or overhead lines present
A safe unit distribution system in place
Electrical supplies installed in hazardous situations, e.g. excavations, may require the advice of an electrical engineer with appropriate
qualifications and/or experience
Any metal work that could be made live by any leakage of electricity earthed
Permit to Work systems used for work on live systems, and on any equipment which has been made dead
A suitably qualified person appointed to control Permit to Work systems and records
Only competent electrical tradesmen/contractors employed to install electrical systems
Systems tested and certified prior to use
All temporary switch rooms, distribution cabinets, etc locked
Warning notices ["Electrical hazard"] placed on all live distribution equipment
Fire extinguishers [CO2] placed by distribution units
Cable routes planned to minimise tripping hazards
Any cables used on site sheathed and their routes recorded if buried
Offices, canteens, drying rooms and stores regarded as permanent installations
When it is necessary to work outside of daylight hours, tower lights or other means to ensure proper vision for operators and banks man to
be in place.
Portable Appliance Testing carried out on all electrical appliances as necessary.
Other:

Personal protective equipment

PPE, particularly rubber gloves to BS 697 is required for all live work
Other:
Additional assessments required
Manual handling
PPE
HSA Guide to Legislation listed below
Other:

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Method statement required? Yes No

Is the task adequately controlled? Yes No

HSA and other guidance

Other:

Information, instruction and training

Electricians fully informed of the requirements for cable routing, etc
Electricians fully conversant with Permit to Work systems
Proof of training obtained for all electricians and supervisors
Site based training on the operation and use of the Permit to Work systems
Other:

Emergency procedures
First aid facilities as required generally for the site
Competent first aiders
Basic medical treatment for electrical shock in place around the site
All persons must know how to raise the alarm in an emergency
Other:

Monitoring procedures
Checks to ensure the strict enforcement of permit and key control systems on site
Checks regarding misuse of equipment, e.g. step up transformers, powering radios
Records kept of the Permits to Work issued, the training of the workers involved, the inspection, testing and maintenance of the system,
and all relevant diagrams and background information
Maintenance and compatibility of equipment checked
Temporary electrical systems formally inspected and tested every 6 - 12 months and new certification issued (PAT)
Other:

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