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STANDARDS PUBLICATION
FOR
I STANDARDSTEAM I
DOC. NO. KOC-L-026 Page 1 of 31 REV. 2
STANDARDS PUBLICATION
FOR
STANDARDS TEAM
-
DOC. NO. KOC-L-026 Page 2 of 31 REV. 2
FOR
ISSUING AUTHORITY:
STANDARDS TEAM
Page No.
FOREWORD 5
SCOPE 7
APPLICATION 7
TERMINOLOGY 7
3.1 Definitions 7
3.2 Abbreviations 8
ENVIRONMENTAL CONDITIONS 10
MARKING 19
AS BUILT DRAWING 20
APPENDICES 21-29
16.1 Appendix-A: Inspection and Test Plan for
Tank Bottom (Impressed Current
Cathodic Protection System) 21
16.2Appendix- B: Check Lists for 22-28
- Tank Bottom Cathodic Protection
System (Grid System 1
- Reference Electrode Function Test
- Boxes (J. B and Test Box)
- TIR Rectifier Check List
- Pre-commissioning Checklist for Impressed
Current Cathodic Protection S y s t e ~
(New Tank Bottom External)
- Tank Bottom CP Summary Data Sheet
16.3 Appendix -C: Drawing No. CP-002 :
Typical Cathodic Protection Details for
Underside o f Tank Bottom Using
Grid System 29
ACKNOWLEDGMENT 30
FOREWORD
This KOC RP (Rev.2) has been approved by Standards Team in consultation with
Standards Technical Committee (STC) for consistent use throughout the corporate
engineering and operational functions of Kuwait Oil Company (K.6.C).
The Preparation of this Recommended Practice has been entrusted by the Standards
Technical Committee (STC) of the Task Force No (TF-CPI021 comprising of the
following members:
SCOPE
This document is for guidance only and does not desigqate specific system
design or practices for every application. Therefore, the CP system designer
shall investigate all system requirements and other pre-design requisites such
as tank design, tank bottom materials, tank size, etc.
APPLICATION
Any exceptions or deviations from this document, along p i t h their merits and
justifications, shall be brought t o the attention of KOC controlling Team for
their review, consideration and amendment by Standards Team (if required).
Compliance with this KOC Recommended Practice does not of itself confer
immunity from legal or statutory obligations.
TERMINOLOGY
Definitions
Cathode
Cathodic Protection
Current Density
- -
Electrical Isolation
Foreign Structure
Impressed Current
Membrane Liner
Reference Electrode
Stray-Current Corrosion
Corrosion resulting from current through paths other than the intended
circuit, e.g., by any extraneous current in the earth.
Abbreviations
In the event of conflicts between this Standard and the standards / codes
referenced herein, or other contractual requirements, the most stringent
requirement shall apply. In case further clarificationg are required, the
subject shall be brought t o the attention of KOC Controlling Team.
The latest edition of the following standards, codes and specifications shall
apply:
ASTM B 265 Specification for Titanium and Titanium Alloy Strip, Sheet,
and Plate
BS 7361 Part 1 Cathodic Protection, Code of Practice for Land and Marine
Applications
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DOC. NO. KOC-L-026
W Page 10 of 31 REV. 2
ENVIRONMENTAL CONDITIONS
For environmental conditions in Kuwait, refer t o KOC Standard for Basic Design
Data, (KOC-G-007), which provides the detailed design iqformation regarding
the environmental, site and utility supply conditions prevailing throughout the
KOC facilities.
All relevant safety requirement of the KOC Fire & Safety Pegulations and the
KOC Health, Safety and Environment (HSE MS) procedures shall be adhered
to within KOC areas.
DOC. NO. KOC-L-026 Page 11 of 31 REV. 2
Obiective
The design requirements of storage tank bottom and tqnk foundation shall
be in accordance with "KOC Standard for Field Erected $tee1 Storage Tank"
(KOC-MV-007)" and "KOC Standard for Storage Tank ~bundation"(KOC-C-
026), respectively.
The CP potential of the entire external bottom surface pf the tank shall be
monitored with adequate monitoring means to ensure proper corrosion
protection.
Design Life
Potential Ranqe
Design including anode type and layout must ensure un/forrn distribution of
protective current t o the tank bottom surface.
Membrane Liner
Anodes shall be placed between the membrane and tank bottom so that a
uniform current will flow t o the metallic surfaces requiriqg protection.
Impressed current anodes must not contact the metallic surfaces of the
tank and the tank rimlfoundation. It is recommended that the grid system
shall be a t least 5 0 m m away from the membrane line at the tank
rimlfoundation.
Adequate space shall be provided between the tank bottom and the
membrane liner t o allow installation of the cathodic prolection system with
uniform current distribution. The tank foundation requi&ments specified in
"KOC Standard for Storage Tank Foundation" (KOC-C-026) shall be
considered in this regard.
The sand backfill between the anode ribbon bed and the tank underside
shall be conductive clean washed sand. A sample of the sand fill t o be
utilized shall be tested for contamination (chlorides, sulphates, etc).
Proposed sand shall have a pH value between 6 and 11.5.
DOC. NO. KOC-L-026 I Page 13 of 31 REV. 2
Tank test facilities shall comprise CuICuSO, reference electrodes and test
boxes as follows:
d. Two (2) perforated UPVC pipes of 3" dia. with mipimum thickness of
6.7 m m shall be installed for retractable reference electrodes. For tank
size above 45 m in diameter, three (3) parallel UPVC pipes shall be
installed.
d. each insulating flange and joint shall be fitted with ap appropriate device
to provide electrical isolation of CP DC voltage$ and currents but
provide a path for the safe passage of AC fault and lightning currents.
e. polarization cells between the tank safety earth ring and the plant main
earth system.
DOC. NO. KOC-L-026 Page 14 of 31 I REV. 2
Electrical Connections
The cable connections t o tank shell shall be by means of bolted cable iug
connections t o carbon steel plates welded t o the structure. The steel plates
shall be welded t o the structure prior t o the application of coating. The
steel plate and weld method shall be compatible with the structure material.
The steel plate coating shall be removed t o facilitate the bolted cable
connection. Only highly rated pure Brass bolts and nuts $hall be used.
This Recommended Practice can be utilized for existing tank if the tank
bottom is being replaced.
Information on the degree of the tank bottom corrosion is useful for the
design of the Cathodic Protection.
Anodes
The anode material shall be catalyzed Titanium anode ribbon coated with
highly conductive Mixed Metal Oxide (MMO). The Titanium base shall be of
ASTM 9265 Gradel. MMO shall comprise a mixture of ljidium and Tantalum
oxides. Vendor shall provide technical data sheet of The proposed MMO
anode clearly mentioning the oxides, MMO applic$tion method, and
thickness of the MMO, breakdown voltage across the substrate oxide and
maximum voltage across the MMO film.
1 DOC. NO. KOC-L-026 I Page 15 of 31 l REV. 2
The M M O coating shall be dimensionally stable and shall have a proven track
record that their resistances t o earth do not increase with time.
Manufacturer test certificate shall provide all the above ipformation including
a test for each of the anode under various charge densitigs.
Titanium Conductor
The Titanium conductor bar and power feed connecting rod shall be of
ASTM B265 Grade 1. The titanium rod shall be factpry spot welded a t
minimum three (3) locations using high powered resiqtance welder. The
exposed rod shall be compression crimped t o the positive cable and the
connection insulated with adhesive lined heat shrink a t least 6 0 m m either
side of the connection.
Cables
Cables shall be Cu XLPEIPVC. The cable sizes shall be determined t o suit the
current rating and voltage drop requirements of the CP design. However, the
following types with minimum sizes shall be used:
A TIR unit shall supply only one CP system. e.g one TIR unit for the
protection of one tank bottom.
AH TIR units shall be installed outside the fence of GCs, BSs etc and
protected under a shelter. For firewater storage tanks, tbe T/R units shall be
located adjacent t o the tanks.
The T/R unit output ratings for external CP systeqs shall satisfy the
following requirements:
L
DOC. NO. KOC-L-026 Page 16 o f 31
9.6.1 Junction boxes shall be certified for use in respective classified area with
minimum degree of protection as 1P55: The system dqsign shall have the
following types of junction boxes:
9.6.2 Inside the AJB & TJB, layout drawing with a glass cover shall be fixed t o
show the arrangement of permanent reference electrgdes & power feed
cables.
10.1 Materials and design requirements shall be checked for conformance with this
Recommended Practice, and the reference standardsls~ecificationsprior t o
installation. The Contractor shall propose the materials for approval with all
relevant information as needed elsewhere in this Recommended Practice.
Before start of installation all materials shall be inspectgd and verified with
Manufacturer's test certificate and approved ITP.
10.3 All cables shall be clearly identified and numbered such that no confusion
exists as t o their purpose or point of origin or termination.
DOC. NO. KOC-L-026 1 Page 17 of 31 1 REV. 2
The factory sealed power feed cable Ti rods shall be welded t o the
conductor bar at the designated locations. Required No. of power feed
cables shall be calculated such that the voltage drop in the anode circuit is
less than 300 mV. In any case, the power feeds shall be uniformly
distributed on any conductor bar and typically at the center of the anode if
one power feed on a single conductor bar as below.
c. Each conductor bar shall have at least one separatq power feed cable.
Anode grid resistance shall be checked before and after backfilling between
each power feed cables. In no case, the resistance shall be more than one
(1) Ohm.
Samples of installation check lists are attached in Appendix 8 of this RP. The
Contractor shall make suitable additions or changes fqr the particular job
work.
a. All terminations inside the junction boxes, test boxes, T/R shall be
checked.
Natural Potential
1 I .3 Preliminary Adiustment
Before energizing, the T/R output shall be kept at 10% of design current
output. After 48 hours, potential shall be measured and the output shall be
increased, if required to meet the following criteria.
a. It is required that the midpoint potentials shall not be less negative than
-0.850 V (IR corrected, instant off) with referencg to Cu/CuSO, (sat.)
and the station current outputs shall then be adjusted to achieve the
required midpoint potential.
11.5.1 The Contractor shall perform all interference testing and shall be fully
responsible for contacting all the responsible Authorities and arranging for
their presence at all required tests.
1 1 -5.2 Should any interference test results show a positive chqnge in the potential
of a foreign installation or structure of more than 20 mV, the Contractor shall
take remedial action to eliminate the interaction.
Measuring total current output from each station and the current in each
direction where current measurements are possible.
The Contractor shall submit their Quality System Manual & Quality
Assurance Plan that include all the activities in chronological order with
responsibilities. Inspection & Test Plan (ITP) for CP system installation and
commissioning shall be submitted for KOC approval. Columns shall be
provided so that KOC can mark up its "Witness" (W) points and "Hold" (H)
points.
MARKING
Deliverables
The following documentation, drawings, inspection & test plans and check
lists shall be submitted for approval:
Inspection Status
Reference Acceptance Inspection
No.
I Activity Description
Document Criteria Record sug-
Contrqctor
Contractor KOC
R: Review
S: Surveillance
W: Witness
DOC. NO. KOC-L-026 I Page 22 of 31 I REV. 2
APPENDIX B (contd.1)
St.
I Results
Act- I 1
I
Sub-Contractor
Inspection
I
Contractor
I
Comments:
Acc : Accepted
Rej : Rejected
NIA : Not applicable
APPENDIX B (contd.1)
lnppection
Potential of Calibrated Zinc
Sub-Contractor Contractor KOC
SI. No. Reference Electrode No. w.r+ Portable Ref. cell (mV)
1
2
3
4
5
6
7
R I
Comments:
Results Inspection
Sub-
Contractor
SI. No. Description. Acc. Rej, N / A contractor KOC
1 Support as per detail drawings
2 Foundation location and details correct
3 Installation as details drawing
4 Cable connections as per termination diagram
5 Cables installed & termination complete
6 All cable clearly identified with tags
1 I 1 I 1 I
1 Comments: I
Signature
Date 1 1
DOC. NO. KOC-L-026 Page 26 of 31 REV. 2
APPENDIX B (contd J )
I Comments:
APPENDIX B (contd.!)
PRE-COMMISSIONING CHECKLIST
FOR
IMPRESSED CURRENT CATHODIC PROTECTION SYSTEM
JNEW TANK BOTTOM EXTERNAL)
Description ...................................................................................................
I I I Inspector I Date ( Remarks ]
1 Pre-commissioning
Check if anode grid installation checklist are approved by Company
I
Check if all anodes cable are terminated and labeled i n the anode
Junction Box (JIB).
Check if all JIBS and test posts are marked and labeled inside and
I outside. I
1 Check if all JIBS shunt and resistor rating as per specifications.
Check i f all TiRs capacity, location, labeling, oil level,,silica gel are as per
specification.
Check if the TlR positive cable is connected to anode JIB and negative
cable is connected t o Structure JIB.
I Check if all reference cells and coupons are installed as per drawings. 1
Check if the isolation joint (IJ) are installed and there is no short circuit. I
Witness potential natural reading for all test posts before energizing the
TIRs.
APPENDIX B Icontd.1)
I I
Description
Total Surface Area To Be Protected:
Material
I
1
Value
I
Units
Sqr Meter
II Anode
Quantity
I I
Meter I
Spacing I Meter
Meter
I
Depth with respect to the tank bottom
Material type
Manufacturer
Conductor Bar Dimensions mm
I Spacing 1 Meter
I I
Size of power feed cables mm
Power Feed
No of cables No
Number No
UPVC
Depth with respect to the tank bottom Meter
Manufacturer
Permanent
Cable size mm
-
Reference of
Cell Number No
Depth with respect to the tank bottom Meter
I Manufacturer
I Retractable
Cable size mm
Reference of
Cell Number No
Depth with respect to the tank bottom Meter
Manufacturer
1 Transformer
Serial Number
/Rectifier
Capacity AmpN
1 Commissioning Average CP Potential , mV
I
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I DOC. NO. KOC-L-026 1 Page 29 of 31 1 REV. 2 1
ACKNOWLEDGEMENT
This Standard has been approved by the Standards Technical Committee (STC)
consisting of the following:
The draft of this Standard had been circulated t o the KOC User Teams for review
and the responses were received from the following:
Team Leader Opns. Tech. Svcs. Team Leader Opns. Tech. Svcs
Team Leader Opns. Tech. Svcs Team Leader Opns. Tech. Svcs.
Team Leader Export SVGS Team Leader Drilling & WlOver Svcs.
The Preparation of this Recommended Practice has been entrusted by the Standards
Technical Committee (STC) of the Task Force No (TF-CPl02) Comprising of the
following members:
Mr. Abdul Razzaq A1 Shamari Insp.& Corr. (NWK ) TF Leader Tel No. 61426
Mr. Hasan Sabri Insp. & Corr.(SEK) Member Tel No 67489
Mr. Govinda Mishra Design Team Member Tel No 61 097
Mr. Liakat Ali Maintenance (WK) Member Tel No 20061
Mr. Uppara Saibaba HSE Systems Member Tel No 71 837