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ILF-SPC-SRT-EL-810-0
07.11.2013
REVISION
7.11.2013 Approved
V.S.
P.B.
S. B.
V.S.
P.B.
S. B.
V.S.
P.B.
S. B.
Prepared
Checked
Approved
Rev.
Date
Issue, Modification
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TABLE OF CONTENTS
1
GENERAL
1.1
2.1
Definition
2.2
Abbreviations
STANDARDS
ENVIRONMENTAL CONDITIONS
GENERAL REQUIREMENTS
5.1
5.2
Tagging
5.3
Description of Operation
5.4
Design requirements
5.5
Survey
EQUIPMENT
6.1
Rectifiers
6.2
6.3
Test Stations
6.4
Reference Electrodes
6.5
Coupons
6.6
Distribution Boxes
10
REMOTE MONITORING
10
WIRING
10
11
10
PAINTING
11
11
PRE-COMMISSIONING
11
12
COMMISSIONING
12
13
TESTS
13
14
ADDITIONAL INFORMATION
13
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GENERAL
1.1
ILF-SPC-SRT-EL-810-0
07.11.2013
This specification defines the minimum requirements for the design, manufacturing, construction, installation, testing and commissioning of the terminal cathodic protection system for the new Amman Strategic Reserve Terminal for Petroleum Products.
2.1
Definition
In the present document the following definitions were used. Their meaning is explained
in the table below.
2.2
Definition
Explanation
Client
Engineer
Contractor
Terminal
Abbreviations
Abbreviation
Explanation
BS
British Standart
API, NEC
IEC
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STANDARDS
The design, manufacturing, construction, installation, testing and commissioning of terminal cathodic protection systems shall be in accordance with the relevant codes, standards, rules and regulations as listed below, all in latest valid edition.
The following standards shall be applied, at least:
API RP 540
API RP 500
EN 12954
ANSI/API RP651
BS 7561
EN 14505
EN 13509
IEC 60947
As far as the energy provider or permits of other authorities require additional codes and
standards, respectively impose additional requirements, these are also part of the contract.
In the case of the conflict between the various codes, standards and order, the most
stringent of the requirements shall generally govern. The Contractor shall refer any such
conflict and any other matter to the attention of the Engineer and Clients, whose interpretation shall be final.
All conflicts between the requirements of this specification, contract documents, data
sheets, or drawings shall be referred to Engineer for clarification before proceeding with
the fabrication of the affected parts.
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ENVIRONMENTAL CONDITIONS
The cathodic protection system components shall be designed and constructed for continuous operation at full load under the climatic and environmental conditions as described in the specification Design and Construction of Power Supply Systems.
GENERAL REQUIREMENTS
5.1
5.2
Tagging
All components, equipment and installations shall receive the respective tagging plates,
labels, etc., which have to be of extremely durable material resistant against the environmental conditions. Tagging plates or labels on fronts of enclosures shall be fixed with
screws.
5.3
Description of Operation
The terminal cathodic protection system shall increase the local ground potential in the
vicinity of underground metallic structures. The minimum potential shift shall be at least
the value of the free corrosion potential while impressed current is being applied. This is
equivalent to the decreasing the metallic underground structures potential.
Corrosion protection is achieved when the following criteria are achieved:
An ON potential equal to or more negative than UCu/CuSO4 = -1.2 V against the surrounding soil shall be achieved on the surface of metallic underground structures.
While current is switched on a negative shift from the free corrosion potential by at
least 0.3 V indicates that probably sufficient current is entering the metallic underground structures.
The service life time of the terminal cathodic protection systems shall not be less than
forty (40) years. For anodes a life time of twenty five (25) years will be accepted.
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5.4
ILF-SPC-SRT-EL-810-0
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Design requirements
All underground steel pipes and other underground metallic structures of a station
(incl. grounding network, reinforcements, etc.) shall be protected by using a separate
terminal cathodic protection system.
The cathodic protection system shall mainly consist of the following parts:
single anodes,
distribution boxes,
In order to increase the negative pipe protective potential distributed anodes will be installed within the station. The anodes shall be fed via an anode distribution box
The potential test stations shall be placed at suitable locations within the station area.
5.5
Survey
A soil resistivity measurement shall be carried out within the station using the Wenner
four-pin method and/or any other approved measurement technique. The measurement
shall be included in a table. In addition to the measurements the following data shall be
recorded:
date,
measuring method,
soil conditions,
weather condition,
EQUIPMENT
6.1
Rectifiers
All cathodic protection transformer/rectifiers shall be designed for indoor application installed in metal enclosed cabinets with hinged doors. The degree of protection for the
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cabinets shall be minimum IP42. All instruments shall be readable without the need to
open the door. Therefore, a glazed door with safety glass shall be used. A client approved locking system shall be delivered.
Variable potentiometer for calibration of the anode currents, power terminals as well as
terminals for anodes, reference cells, pipe connections and remote monitoring shall be
included in the cabinets.
The rectifier units will be fed from the 400/230 V 50 Hz bus of Secondary Power Supply
System.
The size of the rectifiers shall be proofed by respective calculation. The rated output current shall not be less than three (3) times the calculated end of life current requirements.
Rectifier units shall mainly consist of the following parts:
surge protection devices (Dehnguard D or equivalent) to protect against discharges via the power supply
terminal strip for all cables individual terminal for each cable
To measure the ON/OFF potentials the rectifier units shall be equipped with an external
cyclical switch (interrupter). The interrupter module shall communicate and be controlled
via the station control system.
The transformer rectifier shall be able to operate in the following modes:
constant current,
constant voltage,
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6.2
ILF-SPC-SRT-EL-810-0
supply voltage,
output voltage,
07.11.2013
6.3
Test Stations
The potential test points shall consist of the following main parts:
6.4
measuring cable.
reference electrode.
Reference Electrodes
The permanent reference electrodes shall be of the Cu/CuSO4 type.
Each reference electrode shall consist of a terracotta vessel with inbuilt soft solid copper
wire and copper sulphate gel or solution filling. The reference electrodes are to be provided with minimum 10 m copper cable 1 x 10 mm. The cable connection point at the
electrode must be fully insulated and sealed with epoxy resin. Each electrode shall be
supplied with a backfill of a mixture from gypsum, bentonite and sodium sulphate.
6.5
Coupons
At critical areas external coupons shall be installed to measure the IR-free potentials.
The surface shall be A = 1 cm. The cable connection shall be1 x 10 mm and shall be
completely insulted.
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6.6
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Distribution Boxes
Distribution boxes shall be installed outside of hazardous areas. Within the distribution
boxes all anode cables, reference cells and coupon cables shall terminate. Each terminal
shall be used for one (1) conductor only. For fixing of cables a suitable pull relief device
must be provided. The terminals shall be mounted on aluminum rails on plates.
For a clear identification of conductors regarding their measuring purpose a common
termination system shall be applied and all cables shall be correctly identified and labeled.
REMOTE MONITORING
For remote monitoring, at least the following signals into the station control system shall
be provided:
For each feeder station:
For ON/OFF potential readings DCF-77 interrupter switch unit shall be provided.
WIRING
The wires shall be selected according to load, insulation level, function and operating requirements. The wires shall be adequately rated and equipped with fuses/circuit breakers
of adequate size.
The wiring shall be carried out solid and safe against damages. Wires shall be bundled
and fixed. The wiring shall be laid inside of wiring trays.
All circuits and auxiliary contacts including not used contacts for disconnecting devices
and relays shall be terminated on terminal strips. Terminal strips shall have a reserve for
future terminal expansion +10 % spare. If wires with different potential will be terminated
on one terminal strip the respective terminals shall be separated by means of isolating
plates. The termination of multiple stranded wires has to be carried out by means of multiple core cable ends.
Wires and terminals shall be marked durable and easy readable, corresponding to the
drawings.
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1 x 25 mm
spark gaps
1 x 25 mm
grounding connections
1 x 50 mm
5 x 6 mm
1 x 10 mm
2 x 2.5 mm
3 x 2.5 mm
For cable laying, labeling and further details, reference is made to the document Cable and
Cable Laying Specification.
10
PAINTING
All appropriate components and devices shall have a resistant, long term stable, high
quality painting. Damages, caused by transport, installation, cabling or commissioning
shall be repaired in a way, that the original quality is restored.
11
PRE-COMMISSIONING
After complete installation of all devices the terminal cathodic protection system shall be
tested to confirm satisfactory installation and operation of all equipment. In this course
the impressed protection current shall be adjusted.
During pre-commissioning the following measurements/checks shall be carried out (minimum requirements):
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The Contractor shall provide a detailed description and procedure for pre-commissioning
and shall submit to the Client.
All pre-commissioning results have to be recorded on standard forms and shall be submitted for approval.
12
COMMISSIONING
Not earlier than 2 to 3 months after pre-commissioning the commissioning of the terminal
cathodic protection system including required adjustments shall be carried out.
During commissioning the following measurements/checks shall be carried out (minimum
requirements):
Interference between pipeline and foreign lines (if necessary connection between the lines via resistor).
Client shall provide a detailed description and procedure for commissioning and shall
submit to the Client .
All results shall be recorded on standard forms and shall be submitted for approval.
After commissioning a respective report shall be prepared which shall include all commissioning results. The report shall also include a discussion of the results giving conclusion.
The report shall contain as a minimum the following information:
ON/OFF potentials and currents at all test point in both tabular and graphical
formats,
calculation of protection current average and of station piping coating resistance average,
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The Contractor shall brief the operation personnel in operation and maintenance during
installation, pre-commissioning and commissioning phase and during on-site training.
13
TESTS
All components of the terminal cathodic protection systems shall be tested in manufacturers workshop.
All tests required by the codes and standards as well as all manufactures tests have to
be performed. The rectifiers and other pre-assembled equipment shall be completely
tested in manufacturers workshop, for devices such as anodes, surge arrestors, cables,
heads of test posts, etc. a type test shall be performed.
The test program for the test of transformer/rectifiers and other pre-assembled equipment has to be submitted at least 3 weeks prior to start of the tests.
Detailed test protocols of all tests performed have to be submitted prior to shipment.
14
ADDITIONAL INFORMATION
For documentation requirements, shipping instructions, spare parts policy refer to document: Design and Construction of Power Supply Systems - Specification.
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