VG2187-001-A-006_0

Total Sheet 17

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

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

Purchaser : JGCS Consortium

Responsible OC : GS Engineering & Construction Co.,Ltd.

Plant Location : Nghi Son, Vietnam

Project name : NSRP Complex Project

P / Order No. : 0-6495-PG2187-001-A101

Equipment/Material name : Cathodic Protection Materials

Item number : Common

Document title : Installation Procedure

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

DOCUMENT CLASS: OTHERS

ISSUE PURPOSE: FI

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

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

RESUBMISSION DATE: ( )

RESPONSIBLE DEPT./PERSON: ( )

Review Date: ( )

A: Approved without Comment; B: Approved with Minor CommentR: Not Approved; F: Not Subject to Review

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

PurchaserDOC. No.

ORIG. PURCHASE ORDER NO. SERIAL REV.

V G2187-001-A 006 0

0 21/Jan/2015 All For Imformation E.J.Song S.G.Kim D.J.KimRev Date Page Description Prep’d Chk’d App’d

A NA NA ELEC/W.S.Lee 26.Jan.2015

for Onshore Pipeline

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NSRP Complex Project Employer Doc. No.

Rev. 0

Title: Installation Procedure Contractor Doc. No.

VG2187-001-A-006 of 17

TABLE OF CONTENTS

No. Description Page

1. INTRODUCTION ................................................................................................................................... 3

2. CODES & STANDARDS ...................................................................................................................... 3

3. MATERIAL RECEIVING AND HANDLING .......................................................................................... 4

4. INSTALLATION PROCEDURE ............................................................................................................ 4

4.1. INSTALLATION OF DEEP WELL GROUND BED ............................................................................... 4

4.2. INSTALLATION FOR REFERENCE ELECTRODE(Cu/CuSo4) .......................................................... 5

4.3. INSTALLATION FOR CP COUPON ..................................................................................................... 5

4.4. INSTALLATION OF CABLE LAYING ................................................................................................... 5

4.5. INSTALLATION OF BACKFILLING ..................................................................................................... 5

4.6. CABLE TO PIPE CONNECTION .......................................................................................................... 5

4.7. INSTALLATION OF JUNCTION BOXES ............................................................................................. 6

4.8. INSTALLATION OF BIG FINK TYPE STATIONS ................................................................................ 6

4.9. INSTALLATION OF TRANSFORMER RECTIFIER ............................................................................. 6

5. PRE-COMMISSIONING TESTING & INSPECTION ............................................................................ 8

5.1. CHECK POINT OF TRANSFORMER RECTIFIER .............................................................................. 8

5.2. POTENTIAL TEST AT TEST STATION ................................................................................................ 8

5.3. JUNCTION BOXES .............................................................................................................................. 8

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1. INTRODUCTIONThe purpose of this procedure is to provide minimum requirements of cathodic protection system

installation works in accordance with IFC drawings, standards, codes and related specifications.

2. CODES & STANDARDSThis 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


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

RP0196


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


Title : Cathodic Protection of Buried Metallic Tanks and Related Piping

EN 13509


Title : Cathodic Protection Measurement Techniques

EN 14505


Title : Cathodic Protection of Complex Structures

EN 12499


Title: Internal Cathodic Protection of Metallic Structures

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3. MATERIAL RECEIVING AND HANDLING Materials and components shall be completely free of water, dry and shall be secured to prevent

damages during transition, lifting and unloading.

Materials and components shall be protected to safeguard against all adverse environmental effect

such as humidity, moisture, rain, dust, dirt, sand, mud, salt and sea water.

Store all materials in a dry and well ventilated place preferably in the original package covering.

All cables shall be handled and stored to avoid damage to the insulation.

During transportation, rubber or wood support/underpinning shall be used to avoid surface

scratching. Gloves shall be worn to avoid smudges from fingerprints.

4. INSTALLATION PROCEDURE

4.1. INSTALLATION OF DEEP WELL GROUND BED Anode location identified as per approved drawing.

The drilling of Deep Well Hole shall be witnessed to ensure the correct depth is achieved and well

casing is installed as per approved drawing.

The well casing shall be bare steel to a depth and elevation as per approved drawing.

The non-active part of the deep ground bed casing shall be insulated from the outer soil as per

approved drawing.

The anode installation will be witnessed to ensure freedom of movement and the correct anode

depth is achieved.

All welding (centralizers, anodes shoe and plate) shall be carried out before the installation of the

anodes to avoid any damages to anodes or the cables.

Weld centralizers to support pipe to ensure that the anode is located vertically and centrally in the

casing. Continue to install anodes, support pipe and vent tubing until all the anodes are in place and

assembly lowered to the bottom of the cased hole.

Carbonaceous backfill shall be fluidized with water to form slurry and pumped into the ground bed.

The procedure will be checked to ensure the bed is pumped from the bottom and no airlocks occur.

The carbonaceous backfill shall be pre-mixed in 50kg batches with 24 to 30 liters of water. The

slurry shall be continuously stirred during pumping operations. Potable water shall be used in the

installation process.

Rough sand or gravel shall complete the fill over the carbonaceous backfill up to 1m below grade

level as per the approved drawing.

Install anode junction box and terminate each anode cable after that each cable shall be labeled

correctly.

The following inspection and tests shall be performed for deep well ground bed and related

accessories as per the approved drawing:

- Location of Deep Ground Bed.

- Depth of borehole to the required length.

- Anode quantity.

- Anode spacing.

- Anode center in steel casing.

- Casing, vent pipe, PVC pipe and support pipe length.

- Coke breeze backfill.

- Anode bed sealed as per approved drawing.

- Visual check of deep well system accessories.

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4.2. INSTALLATION FOR REFERENCE ELECTRODE(Cu/CuSo4) Install the permanent reference electrode at location required as per approved drawings (prior to

installation, polyethylene bag to be removed from the reference electrodes and to be soaked in a

water container for 30 minutes minimum).

Connect to the test station as per the approved drawing.

The following inspection and tests shall be performed for the installation of permanent reference

electrode.

- Installed Electrodes shall be inspected to ensure the functional capability, their location and

level is as per the detail drawing.

- Check the reference cell soaked in water.

- The measured potential of the electrodes to standard electrode (Potable reference electrode)

shall be as follow:

* Cu/CuSO4 Reference electrode : ±50mVThe inspection will be recorded on attached inspection and test sheet.

4.3. INSTALLATION FOR CP COUPON Location of coupons coincides with the location of permanent reference electrodes.

A coupon shall be installed together with permanent type reference electrode as a monitoring facility

and location of the coupon will be the zero to 1/3 diameter of buried piping and the permanent type

reference electrode as per approved drawing.

Coupons shall be backfilled with native soil and wetted with potable water to provide better soil

contact and compaction.

The following inspection and tests shall be performed for the installation of coupons.

- Location of coupons.

- Termination status of lead cables

4.4. INSTALLATION OF CABLE LAYING Buried cables should laid at a depth that will protect them from disturbance by plough or other

excavations.

Cable tiles or cable warning tape should be used to warn of the presence of the cable during any

subsequent excavation.(Cable tiles and warning tape shall be supplied by contractor)

The cable shall immediately be tagged with its unique ID as per approved drawing.

The cable lengths shall be checked against the cable schedule lengths or approved drawing in order

that wastage is minimized.

The inspection will be recorded on attached inspection and test sheet.

4.5. INSTALLATION OF BACKFILLING Before Backfilling, Be attention to avoid damages to anode, cables & etc.

If any damage to C.P materials is detected (cable cutting, welding damage etc), backfilling shall be

stopped and promptly repaired or replacement actions shall undertaken.


4.6. CABLE TO PIPE CONNECTION Cable to pipe connections shall be performed by the welding plate for bolt fastened method, the

welding plate shall be welded directly to the pipe as detailed below:

The pipe coating shall be removed over an area of approximately 50 x 50 mm either using a scraper

or hot knife.

The area shall be thoroughly cleaned to bright metal using a coarse file. If necessary, the exposed

area is then pre-heated using a flame torch to relieve area of moisture.

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The completed welding shall be checked visually and mechanically tested with a 1 KG copper

headed hammer. Negative & test cable shall be connected to welding plate by bolt fastened method

with double nut.

The completed connection point and pipe shall be cleanly washed. The cable connection and the

exposed pipe shall be coated with approved coating material (Epoxy, AR-16). The repair material

shall overlap existing coating at least by 20mm.

- Welding plate for cable connection shall be as same material as cooling water piping to

avoid galvanic corrosion and shall not be coated for electrical continuity.


4.7. INSTALLATION OF JUNCTION BOXES Install the junction box at location as per approved drawing.

It is highly recommended to install the anodes cables first and then select the anode terminal box

location where all associated anode cables tails can reach, because cable joint in anode cable is not

allowed. Therefore, select the anode terminal box location very carefully to avoid any problem

related to short cable length one more time.

Install the pre-cast foundation with frame for mounting of the box. Mount the box on the frame.

Identification the box with Tag No plate.

A minimum suitable length of cable shall be left in the trench at points of termination/connection to

above ground boxes.

The following inspection and tests shall be performed for the installation of boxes.

- Equipment supports will be inspected to ensure they are fabricated as per the approved

detail drawing.

- Base plates, fixings, concrete foundations etc. will be checked for locations and level and

the fixings.

- Cables to boxes will be checked against the approved drawing for correct routing and

termination.

- Visual and connection check.


4.8. INSTALLATION OF BIG FINK TYPE STATIONS Install Flush Fink Type Stations as per approved drawing.

A minimum suitable length of slack cable shall be left in the trench at points of

termination/connection to above ground apparatus.

The following inspection and tests shall be performed for the installation of Flush Fink Type Stations.

- Equipment supports shall be inspected to ensure they are fabricated as per the approved

detail drawing.

- Concrete pit, etc. shall be checked for locations and level and the fixings.

- Cables to the stations shall be checked in accordance with the approved drawing for correct

routing and termination.

4.9. INSTALLATION OF TRANSFORMER RECTIFIER Location of TR/Rectifier shall be decided at site as per approval drawings.

Prior to the installation, the foundations will be checked for level and civil clearance.

Fix transformer rectifier on a concrete foundation by utilizing anchors and the fixing holes provided.

Great care shall be taken in identification of polarity of all cables ensuring they match the polarity of

the marked terminals.

The installation of TR/Rectifier will be witnessed to ensure correct orientation alignment for cabling

in accordance with approved drawings. Secure fasten of termination.

Final check of cable termination with approved drawings.

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On completion of the cable connections, all glands shall be tightened with sufficient slack in the

cables to permit cables to be removed from the terminals. The opening where the cables exit the

duct for buried cables shall be sealed properly.

Earthing shall be provided according to electrical specification. (Earthing shall be supplied by

contractor)

The following inspection and tests shall be performed for the installation of TR/Rectifier.

- Prior to removal to site the TR/rectifier will be inspected for mechanical damage at enclosure

of TR/Rectifier.

- Particular attention for safety risk will be paid to control panel measuring instruments and

control devices.

- Oil filling will be completed in vendor ’s factory before delivery at site.

- Prior to installation, the foundations will be checked for level and civil clearance will be

obtained.

- The installation of TR/Rectifier will be witnessed to ensure correct orientation and alignment

for cabling, including termination and earthing as per approved drawing.


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5. PRE-COMMISSIONING TESTING & INSPECTION

5.1. CHECK POINT OF TRANSFORMER RECTIFIER Check the input/output switch (MCCB) position. It should be at "Off" position.

Check the input voltage. It should be fit to rating of rectifier.

Before energizing the TR/rectifier, adjust output volume to minimum position. And then check the

potential at test station (Natural potential).

Energizing the rectifier step by step as follows.

- Input MCCB “ON”

- Output MCCB “ON”

Check the polarity at output terminal by multi-tester

- The cable to anode terminal box or positive junction box shall be connected on positive (+)

terminal of TR/Rectifier. Cable tag & continuity shall be checked before termination.

- The cable to structure or negative junction box shall be connected on negative (-) terminal of

TR/Rectifier. Cable tag & continuity shall be checked before termination.

- Check the polarity at output terminal by multi-tester

Check the value of DC ampere, DC voltage and record it on the form.

- Adjust the volume for control with slowly until it reaches the protective potential


5.2. POTENTIAL TEST AT TEST STATION At test station, the potentials of structure to electrolyte should be recorded with respect to a

reference electrode(Cu/CuSO4).

The structure lead wire shall be connected to the (+) terminal of a multi-meter(DC Volts mode)

The reference electrode lead wire shall be connected to the (-) terminal of the multi-meter and the

electrode placed upon moist soil immediately above the structure under test station.

Check the natural potential before TR/Rectifier energizing.

Check the protective potential after TR/Rectifier energizing.

This potential shall be measured with respect to a Cu/CuSO4 reference electrode contacting the

electrolyte.

- The protective (Instant off) potential of pipe for this project should be more negative than

(-)0.85V vs Cu/CuSO4 Reference cell.

- A minimum of 100mV of cathodic polarization between the structure surface and a stable

reference electrode contacting the electrolyte. The formation or decay of polarization can be

measured to satisfy this criterion.

All potential measurements shall be taken with meters having a minimum input impedance of 100m

ohm.


5.3. JUNCTION BOXES Check the internal connection with approved drawing.

Check the anode current of feed cable.


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Appendix

INS -01 Inspection and Test Sheet : MMO-Ti Tubular Anode

INS -02 Inspection and Test Sheet : Mg Anode

INS -03 Inspection and Test Sheet : Reference Electrode Function Test

INS -04 Inspection and Test Sheet : Boxes

INS -05 Inspection and Test Sheet : Coating

INS -06 Inspection and Test Sheet : Cable Installation

INS -07 Inspection and Test Sheet : TR/Rectifier

INS -08 Pre-commissioning check list : TR/Rectifier

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INSPECTION AND TEST SHEET (For Construction)MMO-Ti Tubular Anode(For U/G Onshore Pipeline)

PIPE No: Date:

No Description Results Remark

1 Location and length of anode as per drawing

2 Cable identification

3 Depth of excavation to the required length

Results

Acceptance :

Rejection : X

Note :

Title

Name

Signature

Date

Form no. INS-01

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INSPECTION AND TEST SHEET (For Construction)Mg Anode (For Temporary)

PIPE No: Date:


1 Location of anode

2 Termination of anode lead cables

3 Cable tags

Results

Acceptance :

Rejection : X

Note :

Title

Name

Signature

Date

Form no. INS-02

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INSPECTION AND TEST SHEET (For Construction)Reference Electrode Function Test (For U/G Onshore Pipeline)

Item No: Date:

No Reference Electrode

No.

Potential

(Portable Reference

Electrode)

(△mV)

Results Remark

1

2

3

4

5

6

7

8

9

10

Results

Acceptance :

Rejection : X

Criteria : ±50mV

Note :

Title

Name

Signature

Date

Form no. INS-03

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INSPECTION AND TEST SHEET (For Construction)Boxes(For U/G Onshore Pipeline)

Box No : Date :


1 Support as per approved drawings

2 Foundation location and direction

3Cable connections as per connectiondiagram.

4 All cable clearly identified with tags.

Results

Acceptance :

Rejection : X

Note :

Title

Name

Signature

Date

Form no. INS-04

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INSPECTION AND TEST SHEET (For Construction)Coating(For U/G Onshore Pipeline)

Pipe No: Date:

No Description Results Location Remark

1 Check the welding condition

2 Check the cable connection to welding plate

3 Check the coating condition

Results

Acceptance :

Rejection : X

Note :

Title

Name

Signature

Date

Form no. INS-05

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INSPECTION AND TEST SHEET (For Construction)Cable Installation(For U/G Onshore Pipeline)

Item No: Date:


1 Sufficient slack

2 Buried depth

3 Backfilling

Results

Acceptance :

Rejection : X

Note :

Title

Name

Signature

Date

Form no. INS-06

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INSPECTION AND TEST SHEET (For Construction)TR/Rectifier(For U/G Onshore Pipeline)

TR/Rectifier No : Date :


1 Equipment Undamaged

2 Orientation and Alignment Correct

3 Accessories Installing

4 Earth as per detail drawing

5 Oil filling complete and no leakage

Results

Acceptance :

Rejection : X

Note :

Title

Name

Signature

Date

Form no. INS-07

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INSPECTION AND TEST SHEET (For Pre-commissioning)TR/Rectifier(For U/G Onshore Pipeline)

Item No: Date:


1 Before energizing the TR/Rectifier

ACheck if all anodes cable are terminated and labeledin the junction box.

BCheck if the negative cable (from structure) isterminated in the junction box.

C Check if all JBs and test boxes are labeled outside.

D Check if all shunt and resistor in the box are installedas per drawing.

E Check if all TR/Rectifier capacity, location, labeling,oil level, silica gel are installed as per specification.

F Check if all the TR/Rectifier’s positive cable is

connected to PJB and negative cable is connected toNJB

G Check if all reference electrode are installed as perdrawings.

H Witness potential natural reading for all test boxes before energizing the TR/Rectifiers.

2 After energizing the TR/Rectifiers

A Verify if TR/Rectifiers meters are functioning.

B Witness if potential “On/Off” readings are meetingthe protection criterion for all test boxes.

Results

Acceptance :

Rejection : X

Note :

Title

Name

Signature

Date

Form no. INS-08

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VG2187-001-A-006_0

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