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SP-60-18 Revision 3
CATHODIC PROTECTION
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2003-12-12
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This Specification is protected by copyright and is the sole property of Sasol. The information is proprietary to Sasol and is for the sole use
of the identified project or defined scope of work. Any unauthorised use, disclosure or copying or any other means of duplication or
reproduction, is prohibited.
Copyright 2003. Sasol. All rights reserved.
(SIGNED)
DG ROSS
Reviewer :
(SIGNED)
DFM GOODWIN
Approved by
(SIGNED)
JP NELL
Date
16 MARCH 1988
ISSUE DATE:
APRIL 1988
Reviewed By
Approved By
Date
Aug 2000
DG Ross
BAR Machado
C Thirion
5 June 2000
Oct 2003
T Erasmus
BAR Machado
C Thirion
26 Nov 2003
Rev No
This Specification is protected by copyright and is the sole property of Sasol. The information is proprietary to Sasol and is for the sole use
of the identified project or defined scope of work. Any unauthorised use, disclosure or copying or any other means of duplication or
reproduction, is prohibited.
Copyright 2003. Sasol. All rights reserved.
Revision 3
October 2003
SASOL SPECIFICATION SP-60-18
CATHODIC PROTECTION
NAME
BERGH, G (Gerhard)
COOKE, JH (Jack)
ERASMUS, T (Theuns)
HAYNES, GJ (Gerald)
HOLLER, RK (Rolf)
LOMBARD, ER (Sias)
MLLER, GH (Grant)
OOSTHUIZEN, PC (Pieter)
Sasol Oil
WILKINSON, W (William)
Page i of ix
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Revision 3
October 2003
SASOL SPECIFICATION SP-60-18
CATHODIC PROTECTION
REVISION SHEET
REVISION 3
Specification SP-60-18, Revision 2 is revised in its entirety.
Page ii of ix
Copyright 2003. Sasol. All rights reserved.
Revision 3
October 2003
SASOL SPECIFICATION SP-60-18
CATHODIC PROTECTION
FOREWORD
The first line of defence in the corrosion protection of metallic structures, whose external surfaces are
exposed to the electrolyte, unquestionably lies in the selection of suitable structural materials, as well
as the application of the correct coating system(s) to the correctly prepared metallic surface(s). This
must be given priority and be properly and adequately addressed in the early mechanical design phase
of any new process plant, transmission or distribution pipeline.
The application of cathodic protection shall be considered as a supplementary measure, unless
regulations state otherwise. The justification for installing cathodic protection shall be based on data
derived from cathodic protection surveys, corrosion surveys and / or operating records of similar
process plants, transmission or distribution pipelines located in similar environments. All of the
relevant economic, safety, environmental, legal and geographical factors shall be considered.
For this reason it is highly desirable that prior to any decision being taken to install cathodic
protection, an acknowledged cathodic protection design specialist should be commissioned to carry
out an initial cathodic protection and / or corrosion site / field survey. This is to gather the pertinent
data required to evaluate the need for cathodic protection and initiate and carry out any field test
programmes, required to determine data such as the Probable Performance Index (PPI) of the buried
structure and the soil resistivity measurements which will all serve as a basis for the cathodic
protection design. A written report must be submitted to SASOL, summarising findings and
recommendations. Should the recommendations favour the installation of cathodic protection, the
report shall include a conceptual design proposal, an order of magnitude cost estimate for the
installation, and an environmental, safety and economic justification for proceeding with the proposal.
Page iii of ix
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SP-60-18
Revision 3
October 2003
CATHODIC PROTECTION
Subject to SASOLs review of the report and acceptance of the conceptual design proposal, the design
specialists scope of work should then be extended to cover:
a.
The additional site survey in order to permit the preparation of a detailed cathodic protection
design complete with a detailed technical specification and bill of quantities. The latter shall
permit the procurement or a Request For Quotation (RFQ) document to be issued to enable
cathodic protection construction contractors to carry out the cathodic protection installation.
b.
The necessary liaison with the engineering contractor of the process plant, transmission or
distribution pipeline which is to be cathodically protected, so as to ensure the inclusion of all
cathodic protection field installation details in the final plant / pipeline engineering drawings.
c.
The site supervision, quality control and commissioning of the completed cathodic protection
system.
Page iv of ix
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SP-60-18
Revision 3
October 2003
CATHODIC PROTECTION
PAGE
TABLE OF CONTENTS
PAGE
1
GENERAL.............................................................................................................................. 1
1.1
SCOPE ........................................................................................................................ 1
1.2
LEGAL REQUIREMENTS........................................................................................ 2
1.3
ABBREVIATIONS .................................................................................................... 2
1.4
DEFINITIONS............................................................................................................ 9
1.5
PRECEDENCE......................................................................................................... 17
1.6
1.7
GUARANTEE PERIOD........................................................................................... 17
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
SP-60-18
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CATHODIC PROTECTION
PAGE
2.12
2.13
2.14
3.2
4.2
4.3
4.4
4.5
5.2
5.3
SPARE PARTS......................................................................................................... 55
5.4
6.2
GENERAL ................................................................................................................ 61
8.2
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SP-60-18
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CATHODIC PROTECTION
PAGE
9
GENERAL ................................................................................................................ 63
9.2
9.3
9.4
SURGE PROTECTION............................................................................................ 67
9.5
9.6
9.7
9.8
EARTHING .............................................................................................................. 72
9.9
SPARES .................................................................................................................... 72
9.10
9.11
9.12
CABINET CONSTRUCTION.................................................................................. 74
9.13
COATING................................................................................................................. 76
9.14
9.15
DOCUMENTATION................................................................................................ 78
9.16
GUARANTEE .......................................................................................................... 78
9.17
10
11
12
11.1
11.2
11.3
CHEMICAL COMPOSITION.................................................................................. 82
11.4
12.2
12.3
12.4
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CATHODIC PROTECTION
PAGE
13
14
15
16
17
12.5
12.6
12.7
13.2
CHEMICAL COMPOSITION.................................................................................. 92
13.3
13.4
INTRODUCTION .................................................................................................... 93
14.2
14.3
14.4
CP CABLE REQUIREMENTS................................................................................ 96
14.5
15.2
15.3
15.4
TESTING .................................................................................................................. 99
15.5
15.6
15.7
16.2
16.3
16.4
17.2
17.3
SP-60-18
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CATHODIC PROTECTION
PAGE
18
19
18.2
18.3
18.4
18.5
DOCUMENTATION.............................................................................................. 112
18.6
18.7
19.2
19.3
20
21
19.4
19.5
20.2
20.3
20.4
20.5
20.6
20.7
21.2
21.3
21.4
21.5
Page ix of ix
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October 2003
SASOL SPECIFICATION SP-60-18
CATHODIC PROTECTION
GENERAL
1.1
SCOPE
1.1.1
This Specification defines the minimum and mandatory requirements governing the design,
application, installation and commissioning of a Cathodic Protection (CP) system for the
following:
a.
Pipelines, process, fire water, cooling water and utility piping, as well as pipes located
inside chambers;
b.
c.
On-grade storage tank bottoms and the internal surface of storage tanks;
d.
Well casings;
e.
In the event of any detail that is not fully addressed in this specification and that is warranted
to be carried out by the contractor, the work shall be performed in accordance with the
relevant applicable codes and best recognised engineering practices in the CP industry. The
contractor shall develop detailed specifications, procedures and method statements required
to perform the CP design during the engineering phase of work and this shall be submitted to
SASOL for review and approval prior to construction, supply and / or installation work.
1.1.3
The specification covers the general requirements of the CP system. CP may be achieved
through the use of Sacrificial Anode CP (SACP) or Impressed Current CP (ICCP).
Page 1 of 127
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October 2003
CATHODIC PROTECTION
1.1.4
1.1.5
The details and extent of the plant or structure equipment required to be cathodically
protected, the site / locality and the meteorological data shall be both specified and supplied
by SASOL and / or the main contractor.
1.2
LEGAL REQUIREMENTS
The SASOL factories are subject to the statutory requirements of the following Acts and all
CP installations shall meet the requirements of these Acts:
1.3
a.
b.
The Occupational Health and Safety Act with Regulations - Act 85 of 1993;
c.
d.
e.
ABBREVIATIONS
The following CP abbreviations have been used:
A
Ampere
A / m
AC
Alternating Current
AFC
A.hr / kg
SP-60-18
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CATHODIC PROTECTION
Al
Aluminium
API
A.y
Ampere-years
AQL
ASME
ASTM
Br
Bromine
BSI
Carbon
CD
Current Drainage
CIP
COC
Certificate of Compliance
CP
Cathodic Protection
Cr
Chromium
Cu
Copper
CuSO4
Copper Sulphate
Cu-Ti
Copper - Titanium
DB
Distribution Board
DC
Direct Current
DCVG
DIN
ECTFE
EPR
ETFE
Ethyl Tetra-Fluoro-Ethylene
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October 2003
CATHODIC PROTECTION
Ex
EXW
Exothermic Welding
Fluorine
FBE
Fe
Iron
Fe-Si
Silicone Iron
FDU
GC
Grounding Cell
g / ml
GIS
GPS
H2SO4
Sulphuric Acid
HDPE
HMWPE
HVTL
Hz
Hertz
ICCP
ID
Inner Diameter
IEC
IJ
Insulating Joint
IF
Insulating Flange
IP
Ingress Protection
IR
ISO
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CATHODIC PROTECTION
IrO2
Iridium Oxide
kg
kilogram
kg / m
kPa
kilopascal
kV
kilovolt
kV / mm
kW
kilowatt
LCD
LMPE
metre
mA / m
Mg
Magnesium
mH
Milli-henry
Milli-ohm
mA
Milli-ampere
MIC
Mil
Thousandth of an Inch
MMO
MMP
MMWPE
Mn
Manganese
Mo
Molybdenum
MON
Monitor
MOV
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October 2003
CATHODIC PROTECTION
MPa
Megapascal
mV
Milli-volt
mV / C
NACE
NDU
NDT
NPS
OD
Outer Diameter
OMM
OWS
PC
Printed Circuit
PCB
Polycarbonate Based
PE
Polyethylene
pH
PIV
PMO
PO
Purchase Order
PPI
PPM
PRE
PSD
psi
P-TP
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SP-60-18
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October 2003
CATHODIC PROTECTION
PTFE
Poly-Tetra-Fluoro-Ethylene
PVC
Poly-Vinyl-Chloride
PVDF
Poly-Vinylidene Fluoride
QCP
Pub
Publication
RE
Reference Electrode
RFQ
RMS
RP
Recommended Practice
R-TP
SAACE
SABS
SACP
SANS
SEM
Si
Silicon
SI
System International
SIS
SP
Specification
SPIR
SRB
SS
Stainless Steel
SS-DCD
STDD
Standard Drawing
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CATHODIC PROTECTION
SWA
Ta
Tantalum
Ta2O5
Tantalum Oxide
TDS
Ti
Titanium
TP
TP-R
TRU
Volt
+VE
Positive Terminal
-VE
Negative Terminal
XLPE
Cross-linked Polyethylene
Zn
Zinc
% IR
Percentage
Degrees Celsius
Degrees Fahrenheit
micro
micro metre
micro second
.m
Ohm
cm
Ohm Centimetre
Page 8 of 127
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CATHODIC PROTECTION
1.4
DEFINITIONS
ANAEROBIC
ANAEROBIC BACTERIA
ANODE DISTRIBUTION
CABINET
ANODIC GRADIENT
ANODE GROUNDBED
APPROVAL OR
APPROVED BY SASOL
ANODE (IMPRESSED
CURRENT)
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October 2003
CATHODIC PROTECTION
ANODE (SACRIFICIAL)
See Corrosion.
AREAS
BONDING CABINET
BYPASS CURRENT
CATHODE (IMPRESSED
CURRENT)
CATHODIC PROTECTION
CLOSE POTENTIAL
SURVEY
COKE
COKE BREEZE
CONTINUITY BOND
Page 10 of 127
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SP-60-18
Revision 3
October 2003
CATHODIC PROTECTION
CONTRACTOR /
MANUFACTURER
CORROSION
DATA SHEETS
DC DECOUPLING
DEVICE
DRAIN POINT
EARTHING
ELECTRODE
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October 2003
CATHODIC PROTECTION
ELECTRODE
(REFERENCE
ELECTRODE [HALF
CELL])
ELECTROLYSIS
(ELECTROLYTIC
CORROSION)
ELECTROLYTE
EXOTHERMIC WELDING
FORCED DRAINAGE
UNIT
FOREIGN SERVICE
GALVANIC CORROSION
SP-60-18
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October 2003
CATHODIC PROTECTION
HALF CELL
HOLIDAY
HOLIDAY DETECTOR
HYGROSCOPIC
INORGANIC
INSULATING JOINT /
FLANGE
METAL OXIDE
VARISTOR
MONOLITHIC JOINT
NATIVE STATE
NATURAL DRAINAGE
UNIT
NATURAL POTENTIAL
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October 2003
CATHODIC PROTECTION
OVER PROTECTION
PIPE POTENTIAL
POLARISATION
POLARISATION CELL
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October 2003
CATHODIC PROTECTION
PROTECTION LIMITS
PROTECTION
POTENTIAL
RAIL RECORDING
REVIEWED/REVIEWAL
SOIL RESISTIVITY
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October 2003
CATHODIC PROTECTION
TEST POINT
TEST POST
TRANSFORMER
RECTIFIER UNIT
UNDER- PROTECTION
VIKING JOHNSON
COUPLING
VOLTAGE SURGES
WENNER FOUR
ELECTRODE METHOD
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CATHODIC PROTECTION
1.5
PRECEDENCE
Any conflict between the technical requirements stated in the RFQ or PO and the technical
requirements of this Specification shall be referred to SASOL for clarification.
The
1.6
b.
Data sheets;
c.
This Specification;
d.
MATERIAL REQUIREMENTS
The material requirements shall detail all of the necessary drawings, tabulations, sketches,
technical data, materials specification and relevant documentation which will be issued with
a RFQ and / or PO.
The latter shall clearly indicate the technical, electrical, metallurgical and physical
requirements of any equipment, together with the information that is required to be
submitted by the manufacturer.
1.7
GUARANTEE PERIOD
The contractor shall guarantee the CP system for a 36 month period, which shall commence
from the date of commissioning.
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CATHODIC PROTECTION
REFERENCE DOCUMENTS
Where reference is made to a code, specification or standard, the reference shall be taken to
mean the latest edition of the code, specification or standard, including addenda,
supplements and revisions thereto.
2.1
The
petroleum
industry
Part
2:
Electrical
SP-60-18
Revision 3
October 2003
CATHODIC PROTECTION
Reduced
shank
(shank
diameter
Fasteners Part 14: Hexagon nuts Section 1: Style 1 Product grades A and B
Fasteners Part 14: Hexagon nuts Section 2: Style 2 Product grades A and B
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October 2003
CATHODIC PROTECTION
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October 2003
CATHODIC PROTECTION
OF
STANDARDS
INTERNATIONAL
ELECTROTECHNICAL
Electrical
atmospheres
apparatus
Part
for
10:
explosive
gas
Classification
of
hazardous areas
2.3
OF
STANDARDS
INTERNATIONAL
ORGANISATION
FOR
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October 2003
CATHODIC PROTECTION
2.4
ASME B31.8
2.5
ASTM A325
Standard specification for structural bolts, steel and heat treated, 120 /
105 psi minimum tensile strength
ASTM A694
Standard specification for carbon and alloy steel forgings for pipe
flanges, fittings, valves and parts for high-pressure transmission
service
ASTM B265
Standard specification for titanium and titanium alloy strip, sheet and
plate
ASTM B338
ASTM A518
ASTM B571
ASTM D149
ASTM D229
Standard test method for rigid sheet and plate material used for
electrical insulation
ASTM D293
ASTM D709
ASTM D732
ASTM D785
SP-60-18
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October 2003
CATHODIC PROTECTION
ASTM D1248
ASTM D2000
ASTM D3222
ASTM E186
Standard reference radiographs for heavy walled (51 to 114 mm) steel
castings
ASTM G57
2.6
API RP651
API RP1632
API RP2003
2.7
NACE RP0169
NACE RP0177
SP-60-18
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CATHODIC PROTECTION
NACE RP0186
NACE RP0193
NACE RP0285
NACE RP0286
NACE RP0388
NACE RP0572
NACE RP0575
NACE Pub10A190
2.8
BS 1016
BS 1591
BS 1872
BS 6001
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Revision 3
October 2003
CATHODIC PROTECTION
BS 7361
Cathodic Protection
Part 1:
2.9
2.10
DIN 50918
DIN 50925
DIN 50929
2.11
Standard voltages
IEC 60144
2.12
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CATHODIC PROTECTION
ISO 2859-1
ISO 8501-1
2.13
CP monitoring plan
Pictorial visual standards for surface preparation for the painting of steel
surfaces
2.14
2.14.1
Specifications
SP-40-3
SP-50-6
SP-50-7
SP-60-1
SP-60-4
SP-60-10
SP-60-35
Earthing systems
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October 2003
CATHODIC PROTECTION
SP-60-37
2.14.2
SP-60-47
SP-90-32
SP-90-37
Data Sheets
E979
2.14.3
Standard Drawings
STDD-6005CA
STDD-6005CB
STDD-6005CD
STDD-6005CN
STDD-6005CP
STDD-6005CQ
STDD-6005CR
STDD-6005CS
STDD-6005CT
STDD-6005CU
STDD-6005CV
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CATHODIC PROTECTION
STDD-6005CW
STDD-6005CX
STDD-6005CY
STDD-6005CZ
CP SYSTEM REQUIREMENTS
3.1
3.1.1
SASOL and / or the main contractor shall appoint a specialist sub-consultant in order to carry
out a detailed site survey, to permit the drafting of both a conceptual and detailed CP design,
should they be warranted. The detailed design shall only be carried out upon the reviewal of
the conceptual design by SASOL.
3.1.2
The design of the CP system shall be carried out by a SASOL approved consultant. The CP
consultant shall be completely independent as defined by the Southern African Association
of Consulting Engineers (SAACE). The main contractor shall assist the CP consultant with
drawings to permit the AFC drawings to be issued. The CP consultant shall prepare and
submit to the main contractor / SASOL a detailed list of all materials and equipment required
permitting the relevant RFQ document to be formulated.
3.1.3
The CP construction contractor shall install the CP field installation elements, concurrently
with the construction of the associated process plant and / or pipeline. The CP consultant
shall provide field engineering support and site supervision necessary to ensure the integrity
of the as-built CP installation. The CP consultant shall prepare a quality control plan for the
progressive checkout and acceptance of the CP installation and assist the main contractor in
its implementation.
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CATHODIC PROTECTION
3.1.4
The CP consultant shall assist in the checkout, testing and commissioning of the installation
and the marking-up of AFC drawings to reflect the as-built status. He shall also submit a
final commissioning report in accordance with the requirements stipulated below.
3.2
3.2.1
ii)
iii)
Soil samples shall be taken at pipe invert depth or proposed burial depth along
the pipeline route nominally every 1000 m. The samples shall be analysed and
assessed in accordance with DIN 90529 Part 1 to 3, in order to determine the
PPI of the proposed or existing buried steel pipe.
iv)
The presence and probable magnitude of SRB shall be assessed every 1000 m
and / or at corrosive locations where the soil resistivity is less than 30 m.
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CATHODIC PROTECTION
b.
Petrochemical plants
i)
ii)
Soil samples shall be taken at pipe invert depth or proposed burial depth across
the site in accordance with BS 6001: Part1. The samples shall be analysed and
assessed in accordance with DIN 90529 Part 1 to 3, in order to determine the
PPI of the proposed or existing buried steel pipe.
iii)
iv)
Where on-grade carbon steel storage tank bottoms are encountered, all of the
items described in Section 3, of NACE RP0193, shall be evaluated in full for
both new and existing tanks, in order to determine whether or not CP will be
required.
v)
Redox measurements will not be carried out, as they are difficult to perform and
assess under normal site conditions.
3.2.2
ii)
SP-60-18
Revision 3
October 2003
CATHODIC PROTECTION
iii)
iv)
b.
Petrochemical plants
i)
ii)
The tests shall include but not be limited to obtaining natural potentials with all
of the CP system(s) de-energised. Measurements shall also be obtained with the
neighbouring CP systems re-energised one-by-one. The neighbouring TRU(s)
shall also be pulsed at a 1,1 Hz frequency and the pipe potential signal (On Off) influence be recorded, mapped and modelled.
iii)
Once the above surveys have been carried out, definitive recommendations can
be made as to whether CP is required or not. A conceptual CP design report
shall be issued to SASOL for reviewal, should CP deemed to be required. As
soon as the conceptual CP design has been reviewed by SASOL, the following
additional tests shall be carried out.
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CATHODIC PROTECTION
3.2.3
General considerations
When designing and / or selecting to use ICCP, consideration must be given to the
proper use and selection of the anode groundbed(s).
The groundbed location shall be determined early in the design process because its
location may affect the choice of which groundbed type may be best suited to a
particular application. The following factors should be considered when choosing a
groundbed location:
i)
ii)
iii)
iv)
v)
vi)
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October 2003
CATHODIC PROTECTION
FIGURE 2
b.
Anode Groundbeds
i)
ii)
iii)
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October 2003
CATHODIC PROTECTION
FIGURE 3:
c.
ii)
Where horizontal anode beds are to be installed, the soil resistivity shall be
measured at 20 m intervals along the entire length of the active anode bed
length at the proposed anode installation depth.
Page 34 of 127
SP-60-18
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CATHODIC PROTECTION
iii)
Soil resistivity measurements shall also be conducted at two, three, four and
five times the equivalent depth of the proposed anodes, at the beginning, half
way to the centre, centre, halfway between the centre and end and end of the
proposed anode bed, using the Wenner Four Electrode Method, as per
ASTM G57.
iv)
The minimum distance between the pipeline and anode bed shall be two and
half times the length of the anode bed.
v)
Where deep vertical anode groundbeds are required, the soil resistivity shall be
measured at a depth of 2 m, 4 m, 8 m, 16 m, 32 m, etc., until the final depth of
the proposed deep vertical anode groundbed is attained, using the Wenner Four
Electrode Method, as per ASTM G57. The values will be rechecked upon
drilling of the bore hole.
vi)
The minimum burial depth of the vertical anode bed (i.e. excluding the active
length) shall be determined according to the resistivity data obtained from the
bore hole, but shall nominally be two and a half times the active length of the
bed.
d.
Petrochemical plants
i)
ii)
In congested areas where electrical shielding can occur, only shallow vertical
and / or distributive anode groundbed systems shall be employed.
iii)
In both instances, the soil resistivity shall be measured at the active anode depth
of the proposed shallow vertical / distributive anode groundbed, using the
Wenner Four Electrode Method, as per ASTM G57. The values will be
rechecked upon the drilling of a test hole.
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3.2.4
b.
This survey cannot generally be carried out on new structures / pipelines or during the
construction of a new process plant or during construction of new on-grade steel
storage tank(s), as construction schedules generally preclude such testing.
c.
d.
e.
The pipe potential is measured along the pipeline / structure before (natural potential),
and after injection of current (On potential). The current is adjusted until adequate
protection is achieved over a meaningful length of pipe or meaningful area of the
structure requiring protection.
f.
It must also be appreciated that the On potentials of the structure / pipeline will also
vary as a result of temperature variations and due to the fact that the On potentials
also contain a voltage drop as a result of the current flowing through the soil /
electrolyte.
g.
From the magnitude of current required and the length of pipe and / or surface area of
the structure protected and taking into consideration the abovementioned variations,
one may proceed towards preparing a CP design based on the current requirements.
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3.2.5
This survey is generally conducted on old pipelines where the method of construction
may not be fully documented and on newly constructed OWS lines. The survey entails
measuring the voltage drop along the pipeline(s), with CP current flowing.
b.
c.
This survey is obligatory, as any break in electrical continuity will result in corrosion
occurring downstream of the break.
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FIGURE 4b:
3.2.6
Other CP Requirements
All other aspects pertinent to the installation of a CP system shall be addressed. These
include, but are not limited to the following:
a.
b.
Location of river, rail and / or road crossing where casing will be required;
c.
Location of test stations / points for CP, AC mitigation, foreign crossings, Insulating
Flanges (IF) or Insulating Joints (IJ);
d.
Once all of the above surveys have been carried out, a detailed CP design report will be
submitted to SASOL for reviewal.
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4.1
GENERAL CONSIDERATIONS
CP is perhaps the most important of all approaches to corrosion control. By means of an
externally applied electric current, corrosion may be reduced to virtually zero and the metal
surface may be exposed to a corrosive environment without any deterioration for an almost
indefinite period of time. CP is also one of the most economically viable methods available
in abating the corrosion process of submerged metallic structures.
4.2
COATINGS AND CP
4.2.1
Coatings (e.g. tape wrap systems, bitumen fibreglass, Fusion Bonded Epoxy (FBE), etc.)
applied to metal surfaces can be extremely effective in containing the corrosion of the steel
substrate in many environments.
However, no freshly applied coating is entirely free from defects and there will always be
small areas of steel which are exposed directly to the corrosive environment. It is possible to
reduce, but not eliminate these defects, by paying attention to workmanship. In practice it
becomes increasingly expensive to achieve fewer and fewer defects due to the need for high
quality inspection, detection and the repair of individual defects.
4.2.2
The coating provides the initial barrier against the corrosive environment and CP provides
protection at the coating defects. This apparently ideally complementary behaviour occurs as
a result of the low resistance path offered by the defects, as opposed to the high resistance
path offered by the coating.
4.2.3
A coating will deteriorate both chemically and mechanically during its lifetime. These results
in an increase in both the number of defects and the current required in order to protect the
newly exposed steel surface areas (defects).
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The defects will once again provide a low path of resistance and the CP current will flow to
it and provide protection, providing that it is of sufficient magnitude. This naturally implies
that the CP system must be designed such that it has sufficient reserve in order to provide the
necessary additional current.
4.2.4
In general, the choice of the coating system falls outside the scope of the CP Consultant.
However, the coating system must be compatible with the choice of CP utilised to protect the
structure.
4.2.5
Specification SP-50-6 must be complied with in full and any deviations must be reviewed by
SASOL prior to carrying out the work.
As a guideline, the protective coating system efficiencies should comply with the following:
COATING SYSTEM
4.2.6
EFFICIENCY (%)
> 98,5
FBE
> 97,5
Polyethylene Tapes
> 96
> 95
> 94,5
> 92
> 90
No Coating System
The pipeline shall be backfilled in accordance with ASME B31.4 / 8. This implies a selected
pipeline backfill material (size less than 9 mm) free from sharp objects, rocks, stones or any
other material which may damage the coating system. Pipelines located in the same trench
should nominally be separated by at least one and a half times the diameter of the largest
pipe, in order to prevent shielding.
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4.2.7
Where concrete encasement of the pipe is required, such as at river crossings, the reinforcing
steel shall be electrically isolated from the steel pipe. The pipeline shall be wrapped as per
Specification SP-50-6 prior to being concrete encased.
4.2.8
All buried pipelines when entering, passing through or leaving a chamber, reservoir, or any
concrete structure shall ensure a minimum clearance of 50 mm from the steel reinforcing and
the pipe or pipe puddle flange and shall be completely wrapped / coated as per Specification
SP-50-6 in the concrete covered section.
4.2.9
Pipeline sections which will be located inside chambers that may become flooded from time
to time or which will be continuously flooded, shall be wrapped / coated as per Specification
SP-50-6. Sacrificial magnesium anodes shall be employed to protect the pipeline or pipe
section in these chambers.
4.2.10
A DCVG survey shall be conducted on all transmission and distribution lines after
construction, in order to assess the condition of the coating subsequent to construction. The
pipeline construction contractor shall be responsible for the repair of all major defects
identified during the DCVG survey. Some 10 % of the defects will be exposed in order to
delineate defects and compare them to the DCVG % IR values prior to prioritising defects
for repair.
4.3
CHOICE OF CP SYSTEM
4.3.1
CP may be achieved by means of ICCP or SACP. The choice of which system to use shall be
based on both technical and economic factors.
4.3.2
ICCP utilises a TRU, which is supplied by a 230 V, 400 V or 525 V AC supply and produces
a low voltage direct current. The negative terminal of the TRU is connected to the structure
(tank / pipe), which becomes the cathode, and the positive terminal to an anode or a series of
anodes buried in the ground. This set-up is generally termed an anode groundbed.
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Current flows from the anode to the cathode through the electrolyte (soil or ground), and
provided it is of an adequate magnitude, protection will be attained.
4.3.3
A SACP system does not need an external source of power. It exploits the difference in
potential of various metals in the galvanic series and generates its own voltage, much like a
battery. For example, magnesium possess a natural potential of -1700 mV and steel a natural
potential of -500 mV with regard to a saturated copper / copper sulphate reference electrode.
Therefore, the two combined will produce a driving voltage of approximately 1200 mV.
4.3.4
If the structure is subject to moderate to severe stray current influence, only ICCP will be
used. If stray currents are absent, the choice is essentially an economic one, which shall be
fully justified by the consultant.
4.4
4.4.1
The design of the CP system shall be based upon, but not be limited to the following:
a.
b.
c.
d.
e.
f.
Operating temperature;
g.
Transient and / or stray currents (such as telluric currents, DC traction and HVTL
interference);
h.
i.
Pipeline separation i.e. distance between pipes located in the same trench or in close
proximity.
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4.4.2
Protected pipelines shall be isolated from other structures, such as above ground
processing facilities and / or loading / off-loading terminals, by suitable in-line
isolation components as per NACE RP 0286-97 or BS 7361, Part 1. Electrical
isolation of tanks shall comply with API RP 2003.
b.
All electrical and instrumentation cable conduit and / or cable armouring and /
or Lead sheathing;
ii)
All reinforcing steel at chambers, piles, below grade wall and bunds, etc;
iii)
iv)
Structural steel supports including but not limited to pipe racking, cable racking,
steel ladders, I-beams, etc.;
v)
4.4.3
IFs / IJs shall be provided with protective devices should damage from lightning or high
voltage earth currents be possible. SS-DCD(s) shall be used and the enclosure suitably rated
to SANS 60079 / SABS IEC 60079 and SANS 10108 / SABS 0108. In very wet areas
(moisture content greater than 35% during all seasons) and upon reviewal from SASOL,
Copper Titanium grounding cells (Cu-Ti GC) shall be permitted.
4.4.4
Corrosion by stray currents shall be considered on the unprotected side of IFs / IJs where
low-resistivity electrolytes exist either internally and / or externally. Where the process fluid
has a resistivity of 100 cm, isolating spool pieces shall be installed in unlined piping to
prevent anodic corrosion at the unprotected side of the IF / IJ. The spool piece shall be lined
(internally coated) with an amine cured epoxy or process fluid compatible system. The latter
shall include for an IJ / IF at each end. The spool piece shall be of sufficient length to
prevent corrosion, but shall not be less than one metre or four times the pipe diameter which
ever is greater.
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In instances where this proves to be a problem, an internal ICCP or SACP system shall be
designed to mitigate corrosion on the internal pipe surface in the vicinity of an IF / IJ.
4.4.5
Electrical continuity shall be provided across components, other than IFs / IJs which
increases the longitudinal resistance of the pipeline. The latter also implies the use of
multiple negative returns in congested plant areas.
Electrical continuity shall be achieved as follows:
a.
All continuity bonds made to buried piping except across flexible joints (non-welded
joints, flanges, Viking Johnson couplings, etc) shall be brought above ground in
process areas. On transmission and / or distribution pipelines the bonds may be buried
or brought above ground depending on the number and risk of vandalism. In any
event, the locations must be identified for future testing;
b.
The continuity bonds shall be carried out using two cables in parallel and suitably
sized to carry the current and any transient surges which may arise from time to time.
The insulation of the cable shall depend upon the prevailing environment;
c.
4.4.6
The tanks shall possess individual earths and shall be connected to the main plant
earth via a SS-DCD, as per API RP 2003. The tank earth shall not be bonded directly
to the plant earth in order to mitigate interference and prevent the loss of protection at
the tank. The latter does not apply to discrete tank CP systems located between the
impervious layer (lining) and tank base;
b.
The plant earth shall never be connected to the buried fire water, cooling water,
process piping, utility piping or any other buried metallic pipes which are cathodically
protected;
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c.
In-line motorised pumps, valves, etc., which are connected to the plant earth shall be
electrically isolated from the buried pipeline via IFs / IJs. The latter may be required
on either side of the buried pipeline section. Continuity bonding will then be
conducted across the isolated valve, pump, section etc.
4.4.7
Design calculations, shall as a minimum be based upon the following data in the design
report:
a.
b.
Applicable CP and other relevant standards. All design calculations and any
assumptions made during the preparation of the design. All assumptions will be
clearly stated;
c.
Soil resistivity, soil corrosivity (PPI data) and the geological soil type survey data;
d.
e.
f.
Calculations for type of coating and coating damage factors over the design and
project life;
g.
h.
i.
The mathematical modelling of steady state and fault current interaction between
pipelines and HVTL, including resistive, inductive and capacitive coupling and the
EPR in the vicinity of the HVTL earth mats, where applicable;
j.
The rating and design of DC decoupling devices and earthing / grounding electrode
systems for AC mitigation, IFs / IJs, etc., where applicable;
k.
l.
Any other pertinent CP design criteria, including the location and description of all CP
equipment, bonding requirements between foreign services, test point facilities, valves
and other major pipeline structures, etc.
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4.4.8
TRU design, including number, capacity / rating or the design of other DC power
source(s), should AC power be unavailable, e.g. solar stations;
b.
c.
Protection requirements prior to the commissioning of the CP system. That is, the use
of temporary CP, where it is deemed to be necessary;
d.
Cable runs, cable current carrying capacity and cable voltage drops;
e.
f.
g.
4.4.9
b.
c.
Anode material;
d.
e.
f.
Number of anodes;
g.
Distribution of the anodes (distance relative to the structure (remote earth / localised
protection), current distribution to the structure and structure voltage attenuation;
h.
Anode / cathode circuit driving voltage (initial and after cathode polarisation);
i.
j.
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4.5
4.5.1
In addition to the design requirements already detailed and discussed above, the CP
consultants CP design shall also be based on the following:
a.
The latest ICCP technology for all pipelines and plant structures;
b.
The anode groundbed capacity shall exceed 125% of the design requirements;
c.
The impressed current TRU or DC power supply unit shall exceed 125% of the design
requirements;
d.
Continuous operation of the system for the specified design life of the structures to be
protected. This will generally imply a minimum continuous operation period of
20 years or longer, as specified by SASOL. The availability factor shall exceed 97,5%
for ICCP and 99,5% for SACP systems;
e.
f.
The CP systems for on-grade storage tank bottoms shall incorporate a minimum of
two suitably rated negative cables installed within cable conduit from the tank centre
to the tank perimeter, as well as PRE installed within the tank foundation for potential
monitoring purposes.
g.
NUMBER OF PRE
15 m
> 15 m but 25 m
> 25 m but 50 m
> 50 m but 70 m
> 70 m but 90 m
The PRE cables shall exit the tank perimeter via their own cable conduit.
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h.
The tank centre negative connection is to ensure uniform distribution to the centre of
the tank, where shielding may occur, had the connection been made to the perimeter of
the tank.
i.
The negative tank cables shall be exothermically connected to suitable steel lugs
welded to the bottom centre of the tank base. Mechanical joints shall not be permitted.
j.
The cables and conduit shall be installed during construction and shall not be damaged
during welding and construction of the remainder of the tank base. Regular cable tests
shall be performed to ensure complete integrity.
k.
The negative and PRE cables shall be terminated in a suitably rated enclosure(s)
outside the tank perimeter for future access.
l.
The tank foundation mounds shall consist of fine grained, well compacted material.
Under no circumstances will Bitumen sand, oil filled sands, asphalt or asphalt and
Bitumen mixtures or compounds be permitted to be used as tank padding or as the
tank base material.
m.
The CP Consultant shall be responsible for the accuracy of all field conditions and
data used to prepare the CP system design.
n.
A list of materials and equipment required, including vendor, manufacturer, type, size,
model, quantity, warranty and all other pertinent technical documentation in order to
permit an RFQ to be issued for construction purposes shall be compiled by the CP
consultant.
Once the RFQ document(s) have been submitted by the various SASOL approved
contractors, the documents shall be evaluated by the CP consultant, in order to ensure full
compliance with the technical specification. Deviations will be evaluated technically and
commercially.
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5.1
5.1.1
All installation work shall be carried out in accordance with AFC drawings and
specifications.
5.1.2
No installation shall be undertaken unless the design and drawings have been duly reviewed
by SASOL.
5.1.3
The CP consultant shall prepare a QCP for the systematic monitoring of the installation of all
CP field equipment and piping details. The CP consultant shall be responsible for the
progressive inspection of all CP system details as each item is installed by the construction
contractor. The QCP shall be reviewed by SASOL prior to construction of the CP system.
5.1.4
Installation, checkout and acceptance of each detail must be properly coordinated to ensure
that no piping excavations are backfilled before the pipe coating has been Holiday tested and
the CP details have been checked, tested and passed by Inspectors. Inspection shall include,
but not be limited to the following details:
a.
Continuity and cross bonds on all metallic pipelines, including cooling water, utility
water, fire water, potable water and chemical and oil water sewers;
b.
Exothermic / pin brazed cable connections to the pipe or tank of all CP cables and
bonding conductors, and the reinstatement of protective coatings after completion of
each weld;
c.
Installation of reference electrodes (cells) underneath tank bases and above pipe at
location of connection of rectifier negative cable to pipe;
d.
e.
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f.
Impressed current anode groundbeds, including all associated cabling, coke backfill
material, anode installation, Perma-seal and graded sand installation where required
and applicable;
g.
h.
i.
j.
k.
Pipeline test posts / points, PRE test posts, bonding points, AC mitigation test points,
etc.
5.1.5
Full chemical and metallurgical data shall be obtained for all of the items listed below, as
detailed on the individual data sheets. The costs associated with these tests shall be for the
account of the CP manufacturer and / or CP construction contractor. Only SASOL approved
laboratories may be used and other proposed laboratories must be approved by SASOL prior
to their use:
a.
b.
Impressed current anodes (silicon iron or precious metal oxide (PMO) / mixed metal
oxide (MMO) anodes);
5.1.6
c.
d.
e.
The CP consultant shall provide field engineering and supervisory support to the
construction contractor, to ensure that all CP installations are in accordance with AFC
drawings and design specifications.
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5.1.7
A SASOL appointed inspection authority shall also monitor the application of wrapping and
coatings to pipelines and tank bottoms, to ensure their adequacy and compliance with
Specification SP-50-6 and may witness all Holiday testing of wrappings and coatings to
confirm their integrity before final acceptance. These QCP data sheets shall be made
available to the CP consultant.
5.1.8
The CP consultant shall monitor the QCP relating to the preparation of tank foundation
mounds to verify compliance with requirements of Paragraphs 4.5.1 (f) to (l) of this
Specification.
5.2
5.2.1
The consultant shall supervise the testing, commissioning and setting up of the complete CP
system. Appropriate measurements of structure to electrolyte (soil) potential shall be taken
at all of the various test points, to verify that the system is functioning in accordance with
design and that the protection criteria as set out in Section 6 are complied with in full.
5.2.2
5.2.3
After the system has been certified to be both mechanically and electrically compliant, the
initial switch-on of the protection shall be carried out. The measured structure to soil
potentials will continue to change (become more electro negative) for some 3 to 6 months
and test will have to be made at intervals until full protection has been achieved (polarisation
of the structure).
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5.2.4
In the setting up of the system, adjustments shall be made to the flow of the protective
current at all test points in the system so as to achieve stable operation with potentials at all
points on the protected structure. The values shall be more negative than the minimum
values specified in Section 6 of this Specification and where stray currents are absent,
protective potentials should not be more negative than 2500 mV.
5.2.5
The consultant shall make a comprehensive analysis of the measured potentials and provide
a schedule of test points at which future routine test measurements can be conveniently
taken, to confirm continued satisfactory operation of the CP protective system. These points
and the testing requirements will be submitted in a detailed OMM, which will be submitted
together with the CP commissioning report.
5.2.6
The consultant shall submit a final commissioning report, summarising the results of all tests
made and listing all measured values of structure to electrolyte potentials and the protective
CP currents recorded during commissioning and testing. The following shall as a minimum
be included in the commissioning report:
a.
Native State potential measurements shall be conducted at all structures test points,
including cased, thrust bored and / or jacked crossings;
b.
Groundbed continuity and the maximum, minimum and average output values,
including resistance, current and voltage data;
c.
Sacrificial anode connections, the maximum, minimum and average output values,
including resistance, current and voltage data at all installation points. Potential
measurements shall be conducted at points remote from the anodes (if possible);
d.
Pipeline continuity data, at all in-line flexible couplings, valves, pits, chambers, etc.;
e.
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f.
g.
Current output and operating parameters of internal CP equipment for vessels, tanks
and treaters;
h.
Evaluation of any electrical interference effects and their resolution, including the
cross-bond potentials, the magnitude and direction of current at each location. 24 hour
recordings, using a 10 second sampling rate shall be used in all DC traction stray
current environments;
i.
j.
5.2.7
The contractor in association with the CP consultant shall also provide as-built drawings of
the installation, which shall include, but not be limited to the following:
a.
b.
Date, dimension, type and location of anodes (sacrificial and / or impressed anodes);
c.
AC input, DC output, make, model, serial number and capacity of the TRU(s);
d.
e.
f.
Vendor drawings of the TRU(s) and any other relevant equipment, including but not
limited to the SS-DCD(s), monolithic IJs / IFs test points, etc., where applicable;
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g.
Ex rated equipment shall be supplied with the applicable accredited test certificates
relating to the area classification and level of protection where it may be installed;
h.
i.
j.
The TRU AC supply point, including the AC supply schematic and all relevant wiring
diagrams, cable schedules and junction box schedules;
k.
5.2.8
l.
Location of all pipeline insulators and their associated surge protection devices;
m.
n.
The consultant shall include in the report the schedule of test points developed in accordance
with the above section of this specification, together with a listing of the potentials recorded
during commissioning to serve as a basis of comparison for further (repeat) tests which
SASOL shall carry out every 3 months, 6 months, and 12 months after commissioning to
ensure that the system operates effectively over the 36 month guarantee period.
5.2.9
The commissioning report shall also include a summary of all design calculations and related
design formulae employed, as well as design data such as, surface area of protected
structures, current density allowances, anode bed resistance, anode current output (for both
impressed current and sacrificial systems), anode consumption rates and life expectancy, etc.
5.2.10
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The main contractor shall then check the drawings relating to the as-built status for
submission to SASOL with the relevant End-of-Job documentation. All drawings shall
comply with the requirements of Specification SP-90-32.
5.3
SPARE PARTS
Data Sheet E979, in accordance with Specification SP-40-3, shall be submitted for all
equipment supplied for the CP system. Spare parts list shall include parts location diagrams
or drawings and prices of all parts which the manufacturer recommends for the first two
years of operation.
5.4
CP ACCEPTANCE CRITERIA
6.1
ACCEPTANCE CRITERIA
6.1.1
The following criteria as indicated in the table below, shall be employed in order to verify
both the performance and efficacy of the CP system(s) and / or where applicable, any AC
interference mitigation system(s). The efficacy of the CP system shall be evaluated by
recording the structure to electrolyte potentials. Potentials will only be considered to be valid
if the IR error or voltage drop associated with the structure-to-electrolyte potential
measurements has been eliminated, or can be technically shown to be negligible.
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ACCEPTANCE
CRITERIA
STRUCTURE ENVIRONMENT
Cu / CuSO4 RE
Medium Type
Resistivity Range
Temp
(m)
(C)
100
> 100
1000
Electrolytes(2)
> 1000
High Resistivity
Electrolytes(5)
> 100
Oxygen
Potential (V DC)
Max(3)
40
Aerobic
-0,850
> 40
Aerobic
-0,950
65
Anaerobic
-0,950
65
Aerobic
65
Anaerobic
-0,750
Min(4)
-2,500
-0,650
-0,950
NOTES:
1.
2.
These values may only be used where documented high resistivity induced
measurement shifts can be attained.
3.
The protection potential criteria shown apply to the metal-medium interface and the
values correspond to IR free values.
4.
Minimum values only attainable in the absence of DC stray current influence and
where low alloy steel has been employed.
5.
High resistivity soils / electrolytes where water stagnates / collects in pipe trench
(rocky areas) and where MIC can occur. The protection potential criteria shown apply
to the metal-medium interface and the values correspond to IR free values.
6.1.2
For AC mitigation systems, the system shall be considered effective, if the measured steady
state (50 Hz) AC voltage on the structure is less than 15 V at all locations along the structure.
The SS-DCDs shall also block the DC current until the preset voltage (design DC blocking
voltage) threshold is exceeded.
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6.1.3
Under fault conditions, the maximum step and touch potentials as specified in SANS 10199 /
SABS 0199 shall be met in full at all exposed AC mitigation and CP test points. Under fault
conditions the induced structure voltages shall also be less than the structure coating
breakdown voltage, so as to prevent damage to the coating system.
6.2
6.2.1
General Considerations
a.
One of the perennial problems of CP is how to measure accurately the structure (tank /
pipeline) potential. Traditionally this is done by measuring the potential with the
current switched on and the reference located above the pipe or along the tank
periphery. The correct method is to place the RE right next to a bare location of pipe
(coating defect) so as to eliminate the IR drop due to current flow between the RE and
pipe.
b.
This is problematic since as a general rule the location of the defect is not known and
even if it were, it would be laborious and time consuming to dig a hole down to the
pipe to measure the potential. The potential measurement is even more complex for
large diameter flat bottom storage tanks.
c.
There are a number of techniques which can be used to measure the true structure
potential, free of voltage drop errors:
i)
One of these is to measure the instant off potential. With this method, the CP
current is turned off. The instant the current is turned off, the potential due to
the IR drop is removed but the polarised potential decays over a period of time.
It must be noted that this technique cannot be used if stray currents are present;
ii)
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iii)
iv)
combined with a standard man made coating defect (bare steel area) to
simulate a coating defect. The coating defect, which is to be utilised as part of
the PRE should be constructed in accordance with DIN 50 918. It is buried
with the structure and backfilled with the same material.
The probe is oriented so that the plate experiences the equivalent electric field
to that which applies to the other entire pipeline coating defects. The potential
is measured between the man made defect and the reference electrode located
within the centre of the defect so there is no soil voltage gradient. This satisfies
all the requirements for accurate measurements as well as permitting a
comparison with the conventional potential measurements;
v)
The preferred method is iv) where stray currents are present and iv) or v) in plant
environments where stray currents are not a problem. Consultants may also provide
details of other techniques or test methods, which may be employed in order to
determine true potentials (IR error corrected / free) and these proposed techniques
and / or methods shall be subject to reviewal by SASOL.
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6.2.2
IR free PREs should be installed at regular intervals along the pipeline route to
permit ostensible IR free measurements;
b.
Other techniques which contractors wish to use must first be reviewed by SASOL prior to
commissioning.
6.2.3
IR free PREs should be installed at regular intervals along the pipeline route to
permit ostensible IR free measurements;
b.
Instant Off measurements shall be obtained by pulsing the TRU(s). This may be
achieved by interrupting multiple TRUs using GPS interrupters or interrupting single
TRUs one at a time, with all other TRUs de-energised for testing.
Other techniques which contractors wish to use must first be reviewed by SASOL prior to
commissioning.
After complete construction of the CP system and commissioning, the system will be
required to be monitored by SASOL during the guarantee period.
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A complete and concise operation and maintenance manual (OMM) will be issued with all of
the relevant hand-over documentation. The OMM shall include but no be limited to the
following:
a.
b.
The CP monitoring plan shall include regular monthly monitoring of CP test point(s)
installed at the following locations:
i)
ii)
iii)
iv)
Changes in CP methods;
v)
vi)
vii)
c.
The impressed current CP rectifiers will be monitored twice monthly to verify that the
rectifiers are energized and functioning as designed;
d.
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8.1
GENERAL
The CP materials to be used, as part of the CP installation shall conform to the requirements
stipulated below. An equivalent item shall imply complete technical compliance or better,
than that specified. The alternative equivalent material / item shall be reviewed by SASOL
prior to its use.
8.2
8.2.1
Power supplies for ICCP systems are required to generate the DC current required in order to
confer protection. TRUs are the most common power sources for ICCP systems. Each
Manufacturer may offer a perplexing array of options regarding their TRU. The most
commonly noted options are offered in the following areas:
a.
Enclosure Type
b.
Cooling type
c.
Control type
d.
Rectifying element
Thyristor or diodes;
e.
Circuit type
f.
AC input
g.
h.
i.
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8.2.2
Great inefficiencies may result if the entire CP system is not designed with the power supply
in mind. The essential function of a TRU is to supply a DC between the structure to be
protected (the cathode) and the anode / anode groundbed system.
terminal is connected to the cathode and the positive to the anode. In all instances, the
current must flow from the anode to the cathode via the electrolyte (soil / ground).
8.2.3
For safety and technical reasons, 525 or 400 V AC mains voltage has to be stepped down to
at most 50 V DC while simultaneously increasing the output current to as much as 150 A,
depending on the application.
In order to provide a better appreciation of the conditions in which TRU have to operate, the
following should be kept in mind:
a.
The external load is resistive, but it is not generally constant. Seasonal fluctuations in
the moisture content of the ground can result in the total loop resistance changing by a
factor of three or more;
b.
Rectifiers are subject to frequent and severe lightning and other electrical transients
and surges, originating from the use of high quality dielectric pipe coatings;
c.
The overall reliability of the TRU is of great importance since the protection conferred
on the pipeline is directly dependent on it.
The TRU is often required to operate outdoors. The internal temperature may be
capable of reaching in excess of 60C unless steps are taken to vent the heat.
8.2.4
Automatic TRUs are required to maintain the output current constant at a preset value. A
manual control TRU is one where only the output voltage remains constant and the current
and pipe potential varies according to the prevailing circuit resistance.
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ELECTRICAL CONSTRUCTION
9.1
GENERAL
9.1.1
The rectifiers shall meet the requirements of all applicable electrical and safety codes.
9.1.2
The rectifier shall be capable of operating at a continuous full rated output in ambient
temperatures between 10C and +60C.
9.1.3
The TRU is to comprise a step down, double wound transformer requiring a 525 V / 400 V
supply, and a rectifier bridge to produce the required DC output. The maximum DC output
voltage may not exceed 50 V. A typical schematic / wiring diagram is shown in Standard
Drawing STDD-6005CN. This is only a type drawing and bidders must supply their own
drawings with the RFQ documents.
9.1.4
The transformer shall be double wound and continuously rated in accordance with BS 171.
Single wound (auto) transformers are not permitted except as a means of controlling the
primary current of the main double wound transformer. The transformer shall have an earth
screen between the primary and secondary to intercept voltage transients, and insulation on
the primary shall be able to withstand 10 kV (due to atmospheric pollution causing
flashovers) between phases, and between phases and earth. The transformer shall have a
minimum efficiency of 95% and regulation shall be no greater than 3% (for not stressing the
electronic components) from no load to full rated load.
9.1.5
The transformer shall have suitable taps on the primary or secondary winding, connecting to
Brass terminals for coarse selection of the voltage. These shall have an insulating cover in
order to prevent accidental contact with the live circuit. The voltage taps shall be equivalent
to 33,3%, 66,6% and 100% of the rated DC voltage.
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9.1.6
Protection against current surges shall be provided by means of a circuit breaker or fuses.
The circuit breaker shall be of the thermal or 100% magnetic type and located in the primary
circuit before the power transformer. The circuit breaker must engage / disengage all phases
of the AC supply and be capable of completely isolating the TRU except the 16 A 230 V
switch socket. A second circuit breaker with thermal overload protection shall be installed
between the power transformer and the rectifier bridge to protect the diodes.
9.1.7
A fuse is to be positioned in the negative DC leg. The fuse must not only be capable of
failing on a short circuit, but also when the output current exceeds the rated current by 40%
and such that no part of the circuit is damaged.
9.1.8
A 0,5 mH choke capable of continuously carrying 125% of the full load current is to be
included in the positive and negative DC legs immediately before the output terminals.
9.1.9
The rectifier bridge shall consist of six silicon diodes (manual units) or six silicon thyristors
(automatic units) connected for full wave rectification. The diodes and thyristors to be used
shall be derated to 50% of the manufacturers published rating and have a PIV of 1600 V
(RMS). Diode / thyristor packs or equivalent are not permitted in applications where the DC
output current is rated at 75 A or above. Above 75 A, discrete rectifier devices shall be used.
The diodes / thyristors shall be rated for continuous operation at 120C and are to be
mounted on aluminium heat sinks suitable for the type of cooling specified. The diodes /
thyristors are to be screwed onto the heat sink using a heat conducting paste which shall
exclude moisture. Care must be taken not to exceed the diode / thyristor manufacturers
torque value when screwing in the diodes.
9.1.10
The three phase crest values shall not exceed 10 % of the DC value at full rated load i.e.
output ripple voltage. At maximum output, the heat sink temperature and ambient
temperature difference shall not exceed 35 C above ambient operating conditions.
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9.1.11
9.1.12
In parallel with the negative cable, a monitor cable shall be connected to the pipeline and
connected to the monitor terminal. This cable shall not carry current and is to be used only
for the measurement of the structure potential.
9.2
OUTPUT CONTROL
9.2.1
9.2.2
b.
All the above functions shall be carried out by one control card. All the connections to the
control card are to be by means of plug-in ribbon cables.
The TRU must have a ready mounted spare control card such that in the event of a failure of
the primary control card, the ribbon cable may be disconnected and connected to the spare
card.
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The current limit facility shall be adjustable from 0% to 100% of current output via a
suitable potentiostat and the knob must be set against a graduated scale marked 0 to 10,
with 10 the maximum output of the TRU.
In the constant current mode, the feed-back signal is to come from 3 current transformers
installed on each phase of the mains supply.
In atmospherically polluted areas all control circuitry not contained in an oil tank is to be
sealed in an enclosure rated IP64 minimum.
9.3
9.3.1
b.
c.
d.
e.
The pipe potential voltmeter is to be digital with a minimum input impedance of 10 M, and
a LCD. The height of the digits shall not be less than 12,5 mm with an accuracy of MMP
1%.
9.3.2
The pipe potential voltmeter shall be connected to the pipe monitoring terminal and the
reference electrode terminal. The pipe monitoring terminal shall not be connected to the
pipe terminal.
9.3.3
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9.3.4
The analogue meters shall be 96 mm2 with an accuracy of 2% at maximum output and 25C.
The meters shall be compensated to a maximum of 0,85% error over 100C for temperatures
other than 25C.
9.3.5
9.3.6
9.3.7
a.
DC output voltage;
b.
Reference potential;
c.
DC output current;
d.
DC hour-off;
e.
AC Voltage.
Two differently coloured captive terminal sockets (female banana jacks) must be located
beneath each of the output voltmeter, output ammeter and reference voltmeter, to enable one
to check that the meters are reading correctly, with the exception of the AC voltmeter. The
value of the shunt must also be indicated below the ammeter e.g. 100 mV 100 A.
9.3.8
The 3,5 mm banana socket connected to the pipe must also be indicated for the potential
voltmeter. The DC hour-off meter shall indicate the time the DC current has not been
flowing.
Manufacturers are to submit the details of the DC hour-off meter circuit during the RFQ
stage.
9.4
SURGE PROTECTION
9.4.1
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9.4.2
Moving away from the rectifier bridge towards the output terminals, surge protection will be
sequentially installed as follows:
a.
b.
This shall be followed by a 0,5 mH choke in the negative leg (pipeline) and a 0,5 mH
choke in the positive leg (anode) rated at 125% of the full rated load current (output
current) of the TRU.
9.4.3
On all long transmission and distribution pipelines, the negative leg (pipeline) of the DC
output shall be connected to a suitably rated earth via a solid state DC decoupling device, in
order to permit transient, steady state induced AC and DC fault currents to be diverted from
the pipeline directly to earth.
9.5
9.5.1
9.5.2
All conductors excluding bus bars shall be routed in trunking. Bus bars shall be tinned
copper. The latter shall be tinned after cutting, forming and drilling. Tinning shall be in
accordance with Grade Sn6C of BS 1872. Bulbar joints shall be bolted.
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9.5.3
Bolted bulbar joints shall be tinned after cutting, forming and drilling and treated with
petroleum jelly or a similar water repellent paste prior to assembly. Bolted joints shall be
provided with spring washers.
9.6
9.6.1
9.6.2
a.
Metal cabinets
b.
Red;
c.
Black;
d.
Earth cables
Green-Yellow;
e.
Red;
f.
Yellow;
g.
Blue;
h.
Red;
i.
j.
Monitoring cable
Black.
Power transformer secondary cables shall be grey and have an approximately 30 mm heat
shrink sleeve at either end, the colour is to be red, yellow or blue as appropriate to the phase.
9.6.3
If bus bars are used on the power transformer secondary, they are to be insulated by means
of a correctly coloured heat shrink sleeve per phase.
9.6.4
9.6.5
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9.6.6
Labels shall be of the engraved sandwich Traffolyte type with black letters on a white
background, except the positive output label which shall be in white letters on a red
background. Alternatively aluminium silk screen labels may be used.
9.6.7
Labels shall be in upper case letters with a height of 6 mm for component labels and 10 mm
for output terminal labels.
9.6.8
At Natref, all metal cabinets shall be painted according to the highest voltage colour and
other voltages be indicated as per individual colour code via a 40 mm diameter dot.
9.6.9
9.6.10
+VE GROUNDBED;
b.
-VE PIPE;
c.
PIPE MON;
d.
RE;
e.
EARTH.
Labels shall be fixed by means of screws or pop rivets such that they shall not dislodged
during the life of the unit. Screws and rivets are to be Brass or Aluminium. Cable tags shall
be plastic.
9.6.11
Cables shall be identified by means of permanently marked ferrules with black lettering on a
white background. Ferrules shall be slip-on-type and matched to the size of the cable.
9.6.12
Ferrules shall be situated so as to read right way up on a horizontal cables and from lug to
insulation on vertical cables.
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9.7
9.7.1
9.7.2
9.7.3
Power cable lugs shall be insulated by means of heat shrink sleeves or slip-on rubber shrouds
colour-coded as follows:
9.7.4
a.
AC:
b.
Red;
c.
DC Negative (Pipe):
Black.
All terminals shall be suitably labelled and be completely accessible after completion of all
wiring.
9.7.5
Terminals on power connections shall be provided with lock nuts and / or spring washers.
9.7.6
Output terminals shall be fully insulated from the metal of the housing and shall comprise of
Brass bolts, each provided with nuts, lock nuts, washers and tinned Copper cable lugs
suitable for the specified cable size.
9.7.7
The negative terminal shall be M10 and the positive terminal M16.
9.7.8
Separate terminals size M6 shall be provided for the pipe monitoring cable, and reference
electrode cable.
9.7.9
A 10 mm diameter hole shall be drilled in the earth bar in order to facilitate the connection
via a lug to the earth cable.
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9.8
EARTHING
9.8.1
The surge diversion units shall be connected to the common earth incorporating the primary
AC supply earth, transformer screen and the transformer rectifier housing.
9.8.2
9.8.3
9.8.4
9.9
SPARES
The following minimum spares are to be supplied with the TRU in accordance with
Specification SP-40-03:
a.
Fuses:
b.
Diodes:
c.
MOV:
d.
Spark gap:
one of each type and rating used and one for the SS-DCD.
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9.10
COMPONENT LAYOUT
9.10.1
Convection Cooled
The transformer, choke and rectifier bridge shall be housed in the bottom of the cabinet and
the meters at the top.
All components are to be mounted such that they may be easily removed for repairs and also
for in-situ repair work. The surge protection devices shall be mounted as close as possible
to the item requiring protection.
Particular attention shall be taken to ensure that the heat is efficiently dissipated and that the
heat of one component does not interfere with the operation of adjacent devices. The spares
detailed in Paragraph 9.9 shall be located on the inside of one of the large doors.
9.10.2
Oil Cooled
All transformers, chokes, rectifier devices, heat-sinks, and any other devices requiring oil
cooling to maintain safe operating temperatures at ambient conditions, are to be placed in an
enclosure containing an adequate volume of insulating (less than 50 ppm PCB) mineral oil to
SANS 555 / SABS 555. All connections through the wall of the oil tank are to be effected
through sealing bushes of the correct electrical and hydraulic pressure rating.
In applications where atmospheric pollution or excessive humidity pose a threat to the
operation of the components, this configuration may be specified even though devices may
be adequately cooled by means of natural convection.
All oil cooled equipment shall be maintenance free, i.e., totally enclosed and sealed. No oil
testing, purification or topping up shall be necessary.
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However, under exceptional circumstances and upon SASOLs reviewal, the oil tank may be
designed to accommodate an adequate volume of oil and to provide ease of access to
components for maintenance purposes (bolted tank cover).
constructed to withstand the pressure of the specified volume of oil and is to be fitted with a
sealable filler tube, a drain valve and a sight-glass for determining oil level indicating
maximum and minimum permissible levels. A breather pipe with a silica-gel desiccant
element is to be fitted to the highest point of the oil-tank.
9.11
AUXILIARY AC SUPPLY
The TRU shall be provided in the front and back with a standard 230 V single phase 5 A
(1 kW) 3-point plug for providing power to auxiliary devices.
9.12
CABINET CONSTRUCTION
9.12.1
The cabinet shall be manufactured from 2 mm thick 3Cr12 steel. It shall be suitably designed
to prevent ingress of dust and rain (at least IP55). The cabinet shall be of sufficient size to
allow easy access for servicing and maintenance.
9.12.2
The housing shall allow for adequate ventilation of the heat-sinks and power elements
(natural convection cooled). It should be borne in mind that as the units generally stand in
the open sun, the internal temperature may reach 60C.
9.12.3
Insect proofing shall be bolted to the inside of the cabinet where the cabinet is open to the
atmosphere.
9.12.4
Cabinet doors shall be sealed by means of closed cell expanded rubber or approved
equivalent.
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9.12.5
Cabinet doors shall be provided with door stays to hold the door open during servicing and
maintenance.
9.12.6
All external welds shall be continuous seam welds. Stitch or tack welding is not permitted.
9.12.7
Cabinets shall be provided with channel section bases and lifting lugs suitably designed to
prevent distortion during transport, handling and installation.
9.12.8
9.12.9
The cabinets shall be provided with a bottom plate which shall incorporate a removable
gland plate. The gland plate shall be manufactured from 304 L SS and the entire assembly is
to minimise the ingress of moisture from the ground.
9.12.10 The cabinet must be so designed that there are no inherent moisture traps.
9.12.11 The following information (as a minimum) is to be hard stamped onto the manufacturers
nameplate attached to the inside of the cabinet door:
Owner
AC rating
DC rating
Serial No.
Date of manufacture
Fault level
Manufactured to specification
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9.13
COATING
9.13.1
Manufacturers shall submit a complete specification relating to the coating system they
intend using, prior to coating the cabinets.
9.13.2
The colour shall be Signal Yellow (RAL 1003), in accordance with RAL-FARBEN.
9.13.3
Application shall be by means of electrostatic spray and the coating systems shall be from
one manufacturer only. The TRU cabinet case shall be finished with two coats of corrosionresistant primer and an outdoor environment-resistant finish (fusion bonded polyester or
equal). The coating shall not chalk in sunlight.
9.13.4
Manufacturer must include in their proposed specification, details relating to the surface
preparation and painting.
performance and a two year guarantee. The successful contractor may only use his coating
system upon reviewal from SASOL.
9.14
The tests detailed below shall be carried out at the manufacturers works.
9.14.1
All the components shall pass the stipulated tests and the tests shall be carried out in the
presence of SASOL. The manufacturer will issue a test certificate on completion of the tests
and it shall be signed by SASOL. All of the testing shall be carried out at the manufacturers
expense.
9.14.2
The cabinet and AC input, the DC output and cabinet and the primary to secondary sides of
the main transformer shall withstand a 1 kV insulation test.
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9.14.3
Efficiency tests shall be conducted at 10% and 100% of the maximum current and at the full
rated voltage.
9.14.4
The TRU shall operate for 24 hours continuously at maximum current and voltage output
with all the doors closed or until the temperature is stable for a period of not less than
3 hours. Where the temperature continues to rise after 24 hours, the testing shall continue
until the temperature becomes stable.
9.14.5
In the event of the TRU being constructed on a chassis for use inside a Durasafe, the heat
sink temperature shall be recorded.
9.14.6
The ambient, internal cabinet and heat sink temperatures shall be plotted against time. The
temperatures shall be logged by means of a digital data logger at a sampling rate of 1 value
every 15 minutes. The test shall be terminated when there is no further increase in the
temperature difference between the ambient and heat sink temperature. The maximum
temperature difference between the latter two shall not exceed 40C.
9.14.7
9.14.8
The insulation test described in Paragraph 9.14.3 above shall be repeated immediately on
conclusion of the temperature test run.
9.14.9
SASOL may call for other pertinent tests in order to prove compliance with the specification.
The construction contractor shall supply a COC upon installation.
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9.15
DOCUMENTATION
The TRU shall be supplied with the following items, which are to be mounted to the inside
of the front door:
a.
b.
Two hard copies and one electronic (PDF format) copy of the Operation and
Maintenance Manual (OMM) shall be supplied to SASOL.
9.16
GUARANTEE
9.17
MANUFACTURER QUALIFICATIONS
10
CONCRETE PLINTHS
10.1
Concrete plinths shall be installed at the transformer rectifier unit, anode cabinet and
potential monitoring cabinet.
10.2
The plinth shall be reinforced with steel or hot dipped galvanised steel in corrosive
environments and shall have a strength equal to 25 MPa and installed a minimum of 0,5 m
above ground.
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10.3
The plinths shall have a square concrete surround 75 mm thick (25 MPa), the size of the
surround shall be based upon the site and whether a transformer rectifier unit, anode cabinet
or potential monitoring cabinet is to be installed.
10.4
10.5
The TRU plinth shall have a minimum clearance of the open cabinet door width plus an
additional 0,5 m at the front and the back of the cabinet for access.
10.6
All the plinths shall be installed with two 100 mm diameter 2 m long PVC conduits for cable
entry. There shall be two separate conduits for the AC and DC cables.
10.7
The plinths shall be coated with a concrete bonding liquid and then painted with white (or
SASOL required colour) road marking paint.
11
11.1
GENERAL CONSIDERATIONS
11.1.1
Iron containing a high silicon percentage was developed in the early 1900s. The cast
material was extremely hard and brittle and was first seriously considered for impressed
current anode application in the early 1950s. It was introduced as an anode material in
1954. A subsequent modification to the alloy in 1959 produced better anode performance
characteristics. This alloy consisted of the addition of 4,5% chromium and this anode
material has been widely used and accepted in industry. High silicon chromium cast iron is a
solid, non-porous material. This alloy consists of a matrix of Silica-ferrite in which the
majority of the carbon is in the form of graphite flakes at grain boundaries.
Adding
chromium results in the elimination of the graphite. The standard metallurgical composition
of silicon iron anodes conforms to ASTM Standard A518-86 Grade 3.
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11.1.2
This alloy is cast by several methods including sand mould casting, chill-casting, and
centrifugal casting; the latter results in the most stable and homogenous structure. A variety
of anode shapes and sizes are available. The most common anode shapes are cylindrical
tubes and solid bars in lengths up to 2,13 m and diameters ranging from 25,4 mm to 150 mm,
weighing up to 127 kg.
11.1.3
Each silicon iron anode is normally provided with an individual cable of varying length.
Silicon iron anodes are provided in both end-connected and centre-connected configurations.
The solid bar anodes are cast with a hole at one end to accommodate a connecting cable.
Centre-connections are used for cylindrical tube shapes. There have been numerous methods
and procedures for connecting cable to cast iron anodes. The most common connector for
solid anodes is a poured and tamped lead connection in the cast hole. Centre-connected
anodes utilise a one or two piece lead assembly attached to the interior centre of the anode.
11.1.4
High silicon cast iron anodes are widely used in under ground applications in both shallow
and deep groundbeds. Although the performance is improved with coke breeze, its use is not
critical. This material is also widely used in freshwater and saltwater environments.
11.1.5
The performance of cast iron as an anode is dependent upon the formation of a layer of
silicon dioxide on the surface of the anode. Oxidation of the alloy is necessary to form this
protective film. Silicon-chromium cast iron is highly resistant to acid solutions and it does
not perform particularly well in alkaline environments.
11.2
11.2.1
The silicon iron anodes shall be centrifugally cast tubular anodes and manufactured in
accordance with ISO9002. ISO 9002 certification shall be required.
11.2.2
The anodes shall typically have an external diameter of 71 mm and an internal diameter of
55 mm, and be nominally 1071 mm long.
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11.2.3
The anode shall possess a steel terminal which shall be located centrally within the walls in
order to ensure that the anode is consumed uniformly and to ensure that a balanced spread of
current is achieved throughout its length.
11.2.4
The cable insulation shall be as per the requirements specified in Section 14 and the capacity
shall be determined in accordance with the current requirements, the associated voltage drop
and tensile strength required to adequately support the anode during installation. The
minimum cable length shall be detailed in the bill of quantities and an additional 2 m of slack
shall be supplied with each anode.
11.2.5
The entire connection area, with the exception of the top and bottom 150 mm shall be filled
with hot (85 C) pourable bitumen.
11.2.6
The top and bottom 150 mm shall be filled with Hydrochloric acid (10 % solution) resistant
two pack epoxy. All proposed equivalent epoxies shall be submitted to SASOL for reviewal.
11.2.7
Great care must be taken to ensure that the cable insulation is not damaged by the lead
caulking. Care must also be taken to ensure that the bitumen covers the entire cable
connection.
11.2.8
The anode connection and encapsulation shall be suitable for continuous use in wet and / or
submerged conditions for the duration of 20 years.
11.2.9
Care must be taken not to damage the cable insulation during transport, storage and
installation. If there is any sign of damage, the entire anode and cable shall be replaced.
11.2.10 The anodes shall be free from defects which may impair the anode performance. The anode
shall be free from internal porosity, blow holes, cracks or inclusions. The level of defects
present shall not exceed ASTM E186 (Volume II) Level 1 / 2.
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11.2.11 The manufacturer shall submit the pertinent documentation required in order to verify the
level of defects present. The weight of the anode without cable and epoxy, shall be a
minimum of 14 kg and possess a minimum density of 7,0 g / m.
11.2.12 The anode life shall be 70 A.y minimum as determined for use without coke.
11.3
CHEMICAL COMPOSITION
The anode composition shall be in accordance with ASTM A518-86 Grade 3 as indicated in
the table below:
ELEMENT
PERCENTAGE BY WEIGHT
(%)
Silicon (Si)
14,20% to 14,75%
Carbon (C)
0,70% to 1,10%
Manganese (Mn)
1,5%
Molybdenum (Mo)
0,2%
Copper (Cu)
0,5%
Chromium (Cr)
3,35% to 5%
Iron (Fe)
Balance
11.4
11.4.1
An analysis certificate shall be provided of the batch from which the anodes were cast.
11.4.2
SASOL shall witness that the resistance of the cable to anode connection does not exceed
0,004 . This shall be conducted at the factory.
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11.4.3
Type test certificates shall be submitted at the time of RFQ. These shall give details of the
life of the anode, including the Ampere-years / kg, when tested in a steel drum containing
10% sodium sulphate solution.
11.4.4
A minimum of one week prior to installation, an anode shall be selected and tested for
capacity (A.y), porosity and other tests deemed pertinent by SASOL.
11.4.5
Anodes shall not be dispatched to site prior to testing and / or without the reviewal of
SASOL.
11.4.6
During installation of the anodes, SASOL reserves the right to select a percentage of
anode(s) at random, as stipulated in BS 6001 Part 1, for inspection and testing. A full set of
chemical and metallurgical tests shall be carried out in order to ensure complete compliance
with the specification. The testing shall be for the contractors account.
11.4.7
Great care must be taken to ensure that no damage occurs to the silicon iron anodes during
storage, transport and / or installation.
12
12.1
Upon completion and testing of the bore, the anodes shall be installed as follows:
12.1.1
A predetermined amount of coke will be poured into the bore hole and allowed to settle prior
to installation of the first anode. This shall ensure that the bottom anode is resting on a layer
of pitch coke.
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12.1.2
Anode centralisers shall be employed where it cannot be guaranteed that the anode will
ostensibly be located in the centre of the coke column.
12.1.3
Anodes shall be lowered on an individual basis and coke poured into the bore hole in order
to ensure that the anode is centrally surrounded by the pitch coke and the correct anode
separation is achieved. If MMO / PMO anodes are used, the coke must be pumped.
12.1.4
12.1.5
Upon installation of the top anode (last one), the cables shall be located inside a plastic high
density polyethylene (HDPE) pipe, which shall protect the outer insulation sheath. Graded
washed river sand with a particle size distribution of 0,5 mm to 3,5 mm shall be poured into
the anode bed to a depth of 1,5 m below the surface. The top 1,5 m of the anode bed (bore
hole) shall be sealed with Bentonite or a equivalent.
12.1.6
The anode tails shall be terminated into a suitably rated DC distribution cabinet / enclosure.
Inside process plant areas, cognisance shall be taken of the area classification, environment,
type and rating of enclosure required.
12.2
12.2.1
Anodes shall be pre-packed in 300 mm diameter, 2 m long and 1,5 mm (minimum) spirally
welded galvanised steel canisters.
12.2.2
The anode shall be centrally located inside the canister and encapsulated in pitch coke.
12.2.3
Anodes located inside the canisters shall be lowered into the typically 2,5 m deep horizontal
trench or lowered into the augured vertical distributive hole, on an individual basis. Coke
shall be poured around the canister and augured hole to ensure that there are no voids. This
is generally not required when installing the anode and canister in the horizontal trench.
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12.2.4
Anode canisters filled with pitch coke shall be used in order to ensure that the correct anode
separation is achieved, in horizontal anode beds. This is not required in vertical distributive
systems.
12.2.5
The anode tails shall be hydraulically crimped to the ring main cable via a suitably sized
T-ferrule. The T-ferrule shall be wrapped with self-vulcanising tape and the entire
connection be placed into a T-shaped cable splicing kit. The ring main cable shall be joined
in a similar fashion to the positive DC header cable. All cable connections shall be inspected
by SASOL prior to backfilling.
12.2.6
Cable warning tape shall be placed along the entire length of the horizontal anode bed at the
required burial depth. This is typically 550 mm below grade outside the SASOL factory
limits. All cabling located inside the SASOL factory shall be installed as per Specification
SP-60-01. The relevant inspection shall be carried out during the cable installation as
stipulated in the SASOL cable installation specification.
12.3
12.3.1
The MMO and PMO anodes covered in this specification will be limited to tubular, mesh
and wire anodes. The MMO / PMO anode shall ostensibly consist of an electro-catalytic
iridium oxide (IrO2) and tantalum oxide (Ta2O5) coating on a titanium (Ti) substrate. The
coating shall be applied by an automated coating process in order to maximise
reproducibility, coating uniformity and consistency. Manual application is not permitted. The
loading requirements shall be carried out in accordance with the manufacturers proprietary
data in order to achieve the stipulated requirements in soils, backfill, fresh, brackish and
seawater applications.
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12.3.2
The MMO / PMO operating voltage shall not exceed 50 V for soil and 9 V for sea water
applications. The latter assumes that no Halide pollutants are present such as fluorine (F) or
bromine (Br). Where deleterious pollutants are to be expected, the precise soil and ground
water chemistry shall be determined, prior to the use of any MMO / PMO anodes. The
anode manufacturers maximum current output for the various anode configurations and
dimensions shall not be exceeded under any circumstances.
12.4
The titanium anode substrate shall comply as detailed below, for the various anode
configurations. A chemical data sheet shall be supplied with the anodes confirming
compliance to the substrate material.
ANODE
CONFIGURATION
TITANIUM SUBSTRATE
MATERIAL
Tubular
Tubular
Mesh (Diamond)
Wire
All configurations
Severely polluted
environments
COMMENTS
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DIMENSIONS
CONFIGURATION
(mm)
Tubular
CAPACITY
160 A.y
120 A.y
COMMENTS
Installation depth
> 100 m and seawater
applications
160 A.y
Installation depth
< 100 m
120 A.y
1200 x (6 x 4) x 40 x 1
(length x diamond mesh 60 A.y
x width x wall thickness)
Wire
l x 1,5
(length x cross section)
l x 3,0
(length x cross section)
l x 3,2
(length x cross section)
Strip
l x 6,35 x 0,635
length x width x
thickness
0,5 A / m @ 20
years
1,0 A / m @ 20
All installation depths
years
1,07 A / m @
20 years
0,017 A / m @
50 years
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12.5
12.5.1
The minimum operating life of the anodes shall be 20 years. Manufacturers shall ensure that
a 10% safety factor is applied to the coating loading, in order to ensure that the required life
is met. The maximum rated output is to be based on the fact that the anodes will be
encapsulated in Corr-Carb pitch coke or an equivalent calcined petroleum coke. Other
carbonaceous backfill materials are not suitable, nor permitted to be used with MMO / PMO
anodes.
12.5.2
The following guidelines are to be used for anodes based on a current output of 100 A / m
for calcined petroleum / pitch coke, fresh and brackish environments:
MAXIMUM RATED
OUTPUT AMPERE
ANODE DATA
MINIMUM
LIFETIME
TUBULAR
500 mm x 25,4 mm x 1,6 / 0,9 mm
4,0
20 Years
8,0
20 Years
3,0
20 Years
6,0
20 Years
3,0
20 Years
1000 mm x 1,5 mm
0,5
20 Years
1000 mm x 3,0 mm
1,0
20 Years
1000 mm x 3,2 mm
1,07
20 Years
0,017
50 Years
MESH (DIAMOND)
1200 mm x (6 x 4) mm x 40 mm x 1 mm
WIRE
STRIP / RIBBON
1000 mm x 6,35 mm x 0,635 mm
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12.6
12.6.1
Tubular Anodes
a.
The cable connection shall meet the following minimum standard requirements for the
tubes. The anode wire shall be attached internally in the longitudinal centre of the
tubular anode by means of titanium wedge, which will be forced fitted into the
centre of the tube. The tube is to be crimped in the centre prior to coating in order to
ensure a tight forced fit.
The end of the anode wire will be stripped and soldered using low temperature silver
solder or it shall be hydraulically crimped into the designated half of the Ti wedge.
b.
Heat shrink shall be applied to seal the end of the wedge where the cable exists. The
entire tube shall then be filled with a hydrochloric acid (10 % solution) resistant epoxy
resin. The resistance of the completed cable to anode connection shall not exceed
0,001 .
c.
The cable size to be used for the anode positive cable connection shall be stipulated by
the engineer. All positive anode cable insulation shall be PVC / HMWPE in nonpolluted environments and PVC / HMWPE / PVDF insulation in polluted or seawater
environments. The minimum thickness of each layer of the insulation shall be 2 mm.
No cable joints will be permitted under any circumstances in the buried or submerged
portions of the positive anode cable. The minimum cable to anode breaking strength
shall be 1175 kg for the 25 mm OD tubular anode.
12.6.2
The cable connection shall meet the following minimum requirements for both wire
and mesh anodes. The anode wire shall be attached internally in the longitudinal
centre of the tubular polymer connector, using a stud which has been welded to the
mesh or wire. The wire or mesh anode with the attached stud shall be coated with a
MMO / PMO coating.
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b.
The end of the anode wire will be stripped and hydraulically crimped onto the MMO /
PMO coated stud. Heat shrink shall be applied to seal the cable joint. The entire
tubular polymer connector shall be filled with a hydrochloric acid (10% solution)
resistant epoxy resin. The resistance of the completed cable to anode connection shall
not exceed 0,001 .
c.
The cable size to be used for the anode positive cable connection shall be stipulated by
the engineer. All positive anode cable insulation shall be PVC / HMWPE in nonpolluted environments and PVC / HMWPE / PVDF insulation in polluted or seawater
environments.
The minimum thickness of each layer of the insulation shall be 2 mm. No cable joints
will be permitted under any circumstances in the buried or submerged portions of the
positive anode cable. The minimum cable to anode breaking strength shall be 105 kg
and 25 kg for the mesh and wire anode respectively.
12.7
12.7.1
A specified number of anodes will be randomly selected from the batch to be supplied and
tested as detailed below. The anodes for testing will be selected as per BS 6001, Part 1 and
ISO 2859-1.
12.7.2
The anodes will be tested by an accredited third party laboratory, in order to confirm
compliance with the specification. The third party laboratory must be approved by SASOL.
TEST
Test Solution
Test Temperature
20 kA / m2 minimum
Test Duration
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CATHODIC PROTECTION
TEST
X-ray / NDT
13
13.1
Carbonaceous backfills include various coke products produced from coal, tar (pitch cokes),
bitumen (petroleum cokes) and graphite granules. The coke is in essence the solid residue
left from coal after its volatile constituents have been driven off by heating in the absence of
air and as such, coke is amorphous. This also implies that any metallurgical coke contains
significant amounts of sulphur, ash and volatiles. The ash also generally entraps the heavy
metals, such as lead, cadmium, mercury, copper, zinc, etc., which would not be
environmentally acceptable. The effective resistivity of the soil surrounding an electrode
(anode) is confined to the immediate region of the anode; it is therefore common practice to
reduce the local resistance by using these so-called backfill materials. The backfill being a
conductor carries a measure of the current, reducing to some extent, the consumption rate
of the anode. Therefore, the essential purpose of the carbonaceous backfill is to lower the
anode / soil interface resistance, increase the current capacity by increasing the effective
anode area and thus prolonging the anodes life.
The backfill must also allow for the egress of anodic gases during its normal operation and
be as environmentally safe and friendly, as possible.
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13.2
CHEMICAL COMPOSITION
Preference shall be given to Sasol Carbo-Tar pitch coke (Corr-Carb : Product code 3397).
However, calcined petroleum cokes may be permitted, providing that it is fully compliant
with the technical specification. The manufacturer must be an ISO 9002 or equivalent
accredited organisation. Alternatives will only be permitted to be used upon reviewal from
SASOL. The following shall apply:
CHEMICAL COMPOSITION OF IMPRESSED CURRENT ANODE BACKFILL
MATERIAL CORR-CARB
ELEMENT / COMPOUND SPECIFICATION
TEST METHOD
ASTM D5373 / D3172
Fixed Carbon
99,5% Minimum
Sulphur
0,25% Maximum
0,50% Maximum
Moisture
0,15% Maximum
ASTM D3173
550 m Maximum
Alusuisse C109
Bulk Density
1000 kg / m Maximum
ASTM D527
13.3
13.3.1
The particle size distribution (PSD) of the impressed current anode backfill material is a very
important variable and shall vary according to the anode material and burial depth.
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13.3.2
The PSD shall be determined in accordance with ASTM D293 or BS 1016 Section 110.2.
The following shall apply:
PARTICLE SIZE DISTRIBUTION (PSD) (ASTM D293)
13.3.3
ANODE TYPE
ENVIRONMENT
BURIAL
DEPTH
MAX, PSD
MIN, PSD
MMO / PMO
Soil / Brackish
< 15 m
5% < 0,5 mm
MMO / PMO
Soil / Brackish
> 15 m
5% < 0,5 mm
MMO / PMO
Soil / Brackish
> 50 m
5% < 0,5 mm
Graphite
All
All
100% < 3 mm
5% < 0,5 mm
Silicon Iron
Anode
All
All
100% < 3 mm
5% < 0,5 mm
Technical motivations for the use of other PSDs will be considered by SASOL, should the
above values not suffice.
13.4
The material shall be supplied in 20 kg polypropylene bags and no more than 52 bags shall
be placed onto each pallet. Upon approval from SASOL, the material may also be supplied
in one ton bulk bags. Paper bags may not be used as packaging, unless the material is to be
used within 10 working days and / or will not be damaged by rain prior to use.
14
14.1
INTRODUCTION
14.1.1
The CP cable insulation should be based on the environmental requirements; therefore the
best insulating material for the application should be selected. The selection may involve the
examination of various different performance properties.
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14.1.2
The choice of materials for cable design in order to satisfy any given combination of
installation and environmental conditions can often be more critical than the electrical
requirements.
14.1.3
These insulation materials can generally be split into thermoplastic and thermoset materials.
14.1.4
Thermoplastic materials soften and flow when heated and usually possess a definitive
melting point. The material will become firm again upon cooling. These materials can be
moulded and shaped with a heating and cooling process and the process can be repeated.
Extrusion of melt flow polymers on wire is an example of this type of material.
14.1.5
Thermoset are soft and pliable during one stage of the processing, can be moulded and
extruded at this state after which they are set or cured, usually at a higher temperature. After
the setting or curing process (cross linking) is complete, they cannot be softened by
reheating, hence the heat and solvent resistance properties are improved over thermoplastic
materials.
14.2
14.2.1
The primary insulation material is the most important of the cable material for overall
performance reasons. The following must be considered:
14.2.2
a.
b.
c.
d.
Insulation compounds serve an electrical function first. Secondary properties consider the
environmental factors.
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14.2.3
a.
Fire resistance;
b.
c.
Chemical resistance.
Some of the insulation compounds available include, but are not limited to:
a.
Poly-vinyl-chloride (PVC);
b.
Polyolefins;
c.
Polyethylene (PE):- low (LMPE), medium (MMPE) and high density (HMWPE);
d.
Polypropylene;
e.
Cellular polyolefins;
f.
Non-halogen compounds;
g.
14.3
14.3.1
CP cables shall be insulated and rated for voltages up to 600 V / 1000 V and shall possess
stranded copper conductors in accordance with SANS 1507 / SABS 1507 or ASTM B-8. The
cable conductor size and cable voltage drop shall be calculated in accordance with SANS
10142-1 / SABS 0142-1.
14.3.2
For insulated CP cables, the PVC insulation Type S5 shall comply with the requirements
stipulated in SANS 1507 / SABS 1507 and SANS 1411 / SABS 1411.
14.3.3
For insulated CP cables, the HMWPE insulation Type I, Class C, Category 5 grades 8-5 shall
comply with the requirements stipulated in ASTM D1248.
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14.3.4
14.4
CP CABLE REQUIREMENTS
14.4.1
Table 14.4 shall be used when selecting DC cables for CP. The insulation layers are
specified from the inner layer (conductor surface) to the outer layer (environment).
TABLE 14.4
CABLE DETAIL
INSTALLATION
ENVIRONMENT
INSULATION
LAYERS AND TYPE
INSULATION
COLOUR
Positive DC
Direct sun
PVC / HMWPE
Red
Partial sunlight
PVC / HMWPE
Red
Soil (non-polluted)
PVC / HMWPE
Red
Soil (polluted)
Direct sun
PVC / HMWPE
Black
Partial sunlight
PVC / HMWPE
Black
Soil (non-polluted)
PVC / HMWPE
Black
Soil (polluted)
Negative DC
AC Mitigation
Earthing
Soil (non-polluted)
PVC / HMWPE
Soil (polluted)
Sacrificial Anodes
Soil (non-polluted)
PVC / HMWPE
Red
Pipe Monitor
Soil (non-polluted)
PVC / HMWPE
Black
Soil (polluted)
Soil (non-polluted)
PVC / HMWPE
Soil (polluted)
Soil (non-polluted)
PVC / HMWPE
Soil (polluted)
Above ground
PVC / Al / PVC
White
Below ground
PVC / Al / PVC /
HMWPE
White
Reference Electrode
Corrosion Coupons
CP Instrumentation
(single / multi-core)
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Green-Yellow
Red
Black
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CATHODIC PROTECTION
In certain instances, where CP installations are conducted outside the SASOL plant battery
limits, multi-core power cabling is required, such as:
14.4.3
a.
b.
AC Feeder cable:
The cross sectional area of the positive DC header cable core size shall be determined by the
contractor.
14.5
All cables shall be installed as per Specification SP-60-01. Cables shall be identified as per
Specification SP-60-10.
15
15.1
Unless otherwise specified all cable connections to the pipe are to be by means of thermit
(exothermic) welding.
continuity and cross bonding cables, test post cables, DC decoupling device cables, etc.
Exothermic welding is not permitted if any of the following conditions are present:
a.
The pipeline wall thickness is less than 3,0 mm or severe corrosion has occurred and
the wall thickness is unknown;
b.
The pipeline is lined internally and contains no product or is partially filled with
product (can only be welded when filled);
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c.
15.2
SURFACE PREPARATION
15.2.1
The area where the pin / thermit welding is to take place shall be thoroughly cleaned to
provide an area slightly larger than the graphite mould (approximately 50 mm x 50 mm).
15.2.2
All traces of petroleum mastic, concrete, Bitumen coating, primer material or any other
matter shall be removed and the surface shall be brushed with a steel wire brush, in order to
ensure that the surface complies with St3, ISO 8501-1, Part 1 to 3 and Supplement 1994 as
part of the surface preparation. Prior to making the weld, the area shall be roughened using a
coarse file or an angle grinder. Always ensure that the steel surface is dry.
15.3
15.3.1
The end of the double insulated cable shall be bared for a distance of 25 mm;
b.
A retaining cap shall be placed in the bottom of the mould and the weld powder
poured into the mould;
c.
The weld powder shall be covered with the starting powder and some simultaneously
sprinkled on the lip of the mould. The cable shall be placed on the pipe and the mould
squarely pressed down firmly over the cable. It shall be ensured that the mouth of the
mould is turned away from the welding operator;
d.
The lid shall be closed, and the starting powder ignited with a flint gun and the weld
allowed solidifying. The mould shall be removed and the residue cleaned out in
preparation for the next weld.
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15.3.2
The end of the double insulated cable shall be bared and connected to the appropriate
lug using a hydraulic crimping tool;
b.
The crimped cable shall be placed against the cleaned steel surface;
c.
The appropriate power setting shall be selected for the cable and the trigger of the pin
brazing gun pressed down firmly. It shall be ensured that the correct setting, pin
brazing consumables and lugs have been selected prior to brazing;
d.
The pin brazing gun shall be removed from the cable connection and any residue
cleaned from the brazed connection.
15.4
TESTING
15.4.1
After the above procedure has been carried out, a number of welds shall be tested by
SASOL, by striking the exothermic weld with a 2 kg hammer. Should any movement occur
the cable shall be re-welded and re-tested.
15.4.2
The pin brazed connection shall be gently tugged. Should any movement occur the cable
shall be re-welded and re-tested.
15.4.3
If deemed necessary by SASOL, additional welds / pin brazed connections will be tested
especially where failures have occurred.
15.5
The powder / cable combinations specified in Table 15.5 shall be used. It must however be
noted that in the case of ASME constructed pipelines, all of the stipulated ASME
requirements shall be complied with in full. The latter requirements imply that no powder
(charge) size shall exceed 15 g.
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TABLE 15.5
15.6
TYPE OF MOULD /
WELD
POWDER SIZE
10
Single entry
25 g
16
Single entry
25 g
35
Single entry
32 g
70
Single entry
45 g
PRECAUTIONS
While exothermic welding and pin brazing are generally safe procedures, certain precautions
should nevertheless be exercised:
a.
Ensure that the powder, mould and surface to be welded are perfectly dry;
b.
c.
Prior to welding ensure that the retaining metal disc fits properly in the welding
chamber and that it prevents the powder from partially or wholly falling through to the
bottom, prior to ignition;
d.
Ensure that the correct mould, consumables and pin brazing settings are used. Do not
attempt to use moulds past their design life or force a cable into an incorrect mould;
e.
When welding, wear appropriate eye protection, welding gloves and protective
clothing. Always ensure that the mouth of the mould is away from the body of the
operator. Hold feet back from the mould;
f.
Centre the mould over the pipe, holding it steady during welding. Use exothermic
putty on small bore pipes, in order to prevent liquid copper from escaping through the
base of the mould and damaging the coating system and / or the operator;
g.
Use only a pistol type igniter, matches and / or cigarette lighters are not permitted;
h.
Follow all SASOL permit conditions prior to and during the exothermic and / or pin
brazing operation;
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15.7
The pipeline coating shall be reinstated in accordance with Specification SP-50-6 to the
satisfaction of SASOL.
16
16.1
GENERAL CONSIDERATIONS
16.1.1
The PRE shall consist of a long lasting permanent copper / copper sulphate reference
electrode located next to a bare steel coupon, which shall permit the measurement of
substantially IR free potentials in accordance with DIN 50925.
16.1.2
The PRE shall be installed at pipe invert depth and shall be placed in the same soil as the
pipeline, that is, the probe will be exposed to substantially identical forces acting on the
exposed areas of the pipe. Similarly, it shall be located under flat bottom storage tanks and
exposed to the same forces acting upon the tank.
16.2
MANUFACTURER QUALIFICATIONS
16.3
16.3.1
The ion entrapment membrane must be manufactured from a graded sintered silica carbide
material which is tubular in section and design; the minimum wall thickness shall be 5 mm.
The 25 micron () graded density ion entrapment membrane shall be manufactured from a
pure grade of silica carbide powder.
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CATHODIC PROTECTION
16.3.2
The solid steel coupon whose internal diameter is slightly larger than tubular ion entrapment
membrane shall be located around the periphery. The steel coupon may be bare or coated in
order to regulate the size of the defect. The defect size shall be determined by the CP
consultant. The steel coupon shall be completely isolated from the ion entrapment membrane
and copper sulphate gel. Manufacturers shall submit details with the RFQ detailing their
method of isolation.
16.3.3
Two 2,5 mm2 double insulated flexible copper cables shall be connected to the steel coupon
by brazing or silver soldering. The one cable shall be a monitor cable and the other the
negative cable. The negative cable shall be connected to the pipe via a suitably rated shunt,
located on the printed circuit board inside the test post in order to measure the current flow to
the steel coupon. The monitor cable shall permit the measurement of the coupon potential.
These cables shall be external to the PRE.
16.3.4
The permanent copper sulphate reference electrode shall comprise of a solid chemically
etched and annealed copper rod. The copper rod shall be manufactured from 99,9% pure
copper and shall be at least 10 mm in diameter and 150 mm long.
16.3.5
A single 2,5 mm2 double insulated flexible copper cable shall be connected to the copper rod
by brazing or silver soldering. The cable connection shall be completely encapsulated in acid
and alkaline resistant epoxy.
16.3.6
The gel shall be manufactured from a chemically inert inorganic and hygroscopic gel and
analytically pure copper sulphate. The electrode shall contain a minimum of 250 m of
copper sulphate gel. Contractors shall indicate the type of gel they intend to use during the
submission of their RFQ.
16.3.7
The overall physical dimensions shall not exceed 100 mm in diameter and 450 mm long,
excluding the length of the cable. The top PRE outer casing shall be polypropylene or
equivalent, in order to withstand the forces due to the expansion and contraction of the soil
resulting from variation in its water content.
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16.3.8
Contractors shall submit all of the pertinent details and drawings pertaining to the PRE they
intend using. SASOL shall review the use of the proposed PRE.
16.4
16.4.1
The PRE shall possess a minimum operating life of 10 years, operating with the stability
detailed below:
16.4.2
a.
b.
Both the potential and current drawn by the probe shall be conveniently measured at the test
point. Details of the PC board pertaining to the latter measurements shall be submitted to
SASOL for reviewal. Each PRE shall posses an individual serial number and shall be
supplied with a calibration certificate.
17
17.1
INTRODUCTION
17.1.1
There are several CP Test Post types available. Test posts are used in order to monitor the
efficacy of a CP system and / or to ensure the correct operation of a CP system, e.g. where
anodes are located inside test posts.
17.1.2
Due to vandalism, theft and / or damage which occur during normal operation of a TP, it is
not possible to detail all of the TPs available. Only the most common test posts acceptable to
SASOL shall be detailed below.
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17.2
17.2.1
Test posts / stations for potential monitoring and for the operation of the CP system shall be
installed at the following locations:
a.
b.
At all pipeline crossings (SASOL and foreign) which are cathodically protected and
major pipeline (> 200 mm OD) crossings which are not cathodically protected;
c.
d.
e.
f.
On either side of all national, provincial and major roads. On one side of all frequently
used (> 50 vehicles per day) roads and / or heavy haul sand / dirt roads;
g.
At intermediate locations on long piping runs (maximum separation 1 km). Care shall
be exercised in order to ensure that they are suitably located in order to facilitate
monitoring;
h.
In severe DC traction stray current environments, all TPs shall included IR free
monitoring facilities and permanent IR free reference electrodes every 1 km
(maximum separation between any two TPs);
i.
j.
At all under ground pipeline isolators in order to permit testing of live and dead sides
and current measuring facilities during temporary cross bonding;
k.
On both sides of a major water crossing. A major crossing shall constitute any river
where water flows for at least 6 month of the year on a continuous basis and the river
crossing exceeds 3 m in length;
l.
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m.
On both sides of a major vlei, marsh and / or wetland (pipeline traverses nominally >
500 m through the obstacle during the wet season). If the crossing is shorter, one TP
may be permitted upon approval from SASOL;
n.
In plant areas in order to monitor the efficacy of the CP system. Care shall be
exercised relating to hazardous area classification, and avoiding obstruction relating to
normal plant operations.
17.2.2
17.2.3
The test point shall be selected based on a number of considerations, such as:
a.
b.
c.
d.
17.3
Three types of test posts shall be discussed, that is, the potential / reference monitoring test
post (TP-R), recordable / lockable test post and the process plant potential test post.
The TP-R is used to monitor the pipe potential, whereas the other two may be used for
monitoring and / or operating CP systems.
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17.3.1
DIMENSION (mm)
Overall Length
1 400
Overall Width
155
Overall Depth
135
Monitoring Points
b.
As supplied by Manufacturers
Approximately the bottom 0,5 m shall be concreted into the ground. The TP-R shall
be installed over the pipeline as detailed in Standard Drawing STDD-6005CW.
c.
A single / multiple cable(s) from the pipe and / or reference cable(s) from IR free
PREs may terminate inside the top section of the TP. This aspect shall be covered
during the design of the CP system.
d.
The TPs shall be painted with a concrete bonding liquid and then with road marking
paint. The colour shall be determined by SASOL, as several colours are currently
being used by SASOL and other foreign services. A circle shall be painted with road
marking paint around the aluminium number plate for easy identification.
e.
The chainage and TP-R number must be engraved in letters approximately 6 mm high,
on an aluminium plate 50 mm x 50 mm x 2 mm thick. The plate shall be screwed to
the test post and the heads damaged upon installation, in order to prevent the
removal of the plate. The test post and cable shall not be damaged during the
installation of the identification plate.
17.3.2
The R-TP is used to monitor the pipe potential, as well as for the installation of
permanent IR free reference electrode installations and magnesium anode
installations.
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b.
DIMENSION (mm)
Overall Length
1 400
Overall Width
210
Overall Depth
210
350
250
170
Approximately the bottom 0,5 m shall be concreted into the ground. The R-TP shall be
installed over the pipeline as detailed in Standard Drawing STDD-6005CE. The
enlarged head shall contain a hot-dipped galvanised vandal resistant enclosure suitable
for IR free PC cards and / or data loggers.
c.
The R-TP shall be painted with concrete bonding liquid and then road marking paint.
The colour shall be determined by SASOL, as several colours are currently being used
by SASOL and other foreign services.
d.
17.3.3
The P-TP, ostensibly consists of a hot dipped galvanised stand and a suitably sized, ex rated
box / enclosure, which will permit the installation of the required cabling and / or bonding
and / or testing facilities, such as an IR free PC card.
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The P-TP is used to monitor the pipe potential, as well as for the installation of permanent
IR free reference electrode installations and magnesium anode installations. The P-TP is
numbered using engraved polymer which shall be fixed with pop-rivets to the hot dipped
galvanised stand.
18
18.1
INTRODUCTION
18.1.1
CP is most effectively, efficiently and uniformly applied when the primary structure
requiring CP is electrically isolated from those structures not requiring CP. Electrical
isolation implies that all metallic / electrical contacts with foreign metallic structures are
completely eliminated.
18.1.2
Restriction of the required protective current to the surface of the primary structure to
produce a uniform polarised level of protection;
18.1.3
b.
c.
The use of SS-DCDs are the most superior form of ensuring electrical isolation. This
equipment must not only ensure that it meets the safety standards enforced relating to
effective earthing of a structure, but it must also ensure adequate electrical isolation for the
CP system.
18.1.4
The SS-DCD shall protect personnel and equipment during all types of electrical
disturbances by providing an effective earth path which will instantaneously conduct:
a.
AC fault currents;
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18.1.5
b.
Lightning;
c.
Induced AC;
d.
AC fault current protection across insulation joints (IF / IJ) and other devices;
b.
c.
d.
18.2
ELECTRICAL CONSTRUCTION
18.2.1
Essentially two Solid State DC Decoupling (SS-DCD) devices are available. A diode type
device is generally used where low blocking DC voltages are encountered and a thyristor
type device which is used where high blocking DC voltages are encountered. For all SASOL
transmission and distribution pipeline applications the thyristor units shall be used, as the
pre-set DC blocking voltage can be set to any value i.e. used in any application, moved to a
new location and the voltage value re-set.
This cannot be carried out if a diode type unit is used. The blocking voltage is also limited to
6 V on a diode type unit and may only be used in process areas.
18.2.2
The magnitude of the steady state AC fault current and transient surges, shall be determined
from site tests and other pertinent information. The SS-DCD shall be designed such that all
of the electrical components are suitably sized and rated, in order to ensure its uninterrupted
operation. The typical electrical wiring diagram is shown in Figure 5.
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FIGURE 5:
18.2.3
The following shall be included in the design and quoted as a minimum for each SS-DCD
prior to them being reviewed by SASOL:
a.
b.
Surge / lightning protection - Peak surge current @ 8 / 20 sec. e.g. 100 kA / 70 kA;
c.
d.
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e.
18.2.4
18.2.5
Fail-safe shall imply that the failure of any SS-DCD component shall result in an open
circuit system and not a short circuit system. That is, the pipeline or structure shall never be
directly connected to the earthing system.
18.3
ENCLOSURE CONSTRUCTION
The SS-DCDs shall be enclosed in a suitably rated enclosure as required by SANS 10108 /
SABS 0108, SANS 10089-2 / SABS 089-2 and SANS 10086-1 / SABS 086-1. The enclosure
shall also be rated according to the environmental conditions prevailing. This includes but is
not limited to vandal resistant concrete reinforced structures where required on transmission
and distribution pipelines and ex type rated enclosures in Zone One / Two process plant
areas.
18.4
18.4.1
The testing of the SS-DCD shall be carried out at the contractors works or at the third party
Inspectors laboratory / works. A sample of the SS-DCD to be supplied shall be selected in
accordance with BS 6001, Part 1 for testing purposes.
18.4.2
All of the SS-DCD device components shall pass the tests and the testing shall be carried out
in the presence of SASOL or at the discretion of SASOL. The contractor will issue a test
certificate upon completion of the tests and it shall be signed by SASOL. All of the testing
shall be carried out at the contractors expense.
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18.4.3
The SS-DCD shall be tested at 125 % of the fault current rating and for at least 3 cycles of a
standard 50 Hz cycle. The pre-set DC blocking voltage shall be tested and confirmed. At
least 125% of the steady state AC shall be passed through the unit for a minimum 15 minute
period. No item and / or component of the SS-DCD shall fail. Failure of a single item /
component shall imply complete failure of the SS-DCD.
18.4.4
SASOL may also call for other pertinent tests in order to prove compliance. The construction
contractor shall supply a COC upon completion of the installation.
18.5
DOCUMENTATION
b.
Operation and Maintenance Manual (OMM). Two hard copies and one electronic
(PDF format) copy of the OMM for each type of SS-DCD shall be supplied to
SASOL.
18.6
GUARANTEE
The equipment shall carry an unconditional three year guarantee from commissioning.
The only exceptions shall be for damages arising from vandalism, mechanical damage,
external fire or flooding.
18.7
MANUFACTURER QUALIFICATIONS
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19
19.1
GENERAL CONSIDERATIONS
19.1.1
Pipeline electrical insulating flange (IF) materials shall be selected with consideration given
to quality and standard material availability. The chosen material shall be able to withstand
the maximum line temperature, pressure and predicted line movement. All IF materials shall
be crossed-referenced to the manufacturers specifications to ensure compatibility between
materials, service and the environment.
19.1.2
The materials required per IF, shall be supplied as one complete set. The latter shall consist
of an insulating non-metallic central gasket, non-metallic bolt sleeves and non-metallic
washers and steel thrust washers, as well as the associated high tensile steel studs, nut and
bolts.
19.2
MATERIAL SPECIFICATIONS
19.2.1
The non-metallic central gasket and non-metallic washers shall conform to the following
materials specification:
VALUE
ASTM TEST
METHOD
D149
SI
21 kV / mm
IMPERIAL
540 V / mil
D625
340 MPa
49,000 psi
D229
0,1 %
0,1 %
N/A
-17 C
0 F
N/A
+93 C
200 F
D785
115
115
D732
150 MPa
22,000 psi
MATERIAL PROPERTY
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19.2.2
Steel thrust washers shall be machined with diameter and thickness to SANS 1149 / SABS
1149 Table 3 or to ASTM A325-61T. Thrust washers shall have machined, parallel faces.
19.2.3
Insulating sleeves shall be a minimum 0,8 mm thick glass fibre-reinforced polyester sleeve
for each bolt. Total length of each sleeve is to be 2,3 mm longer than the length between
outside faces of the steel washers. The insulating sleeves shall fit completely inside the
insulating washers and extend partially inside the steel washers.
19.2.4
Insulating washers shall be manufactured from 3,2 mm thick fabric reinforced phenolic resin
with the outer diameter (OD) being the same as that of machined steel washer - two for each
stud bolt. The inner diameter of the insulating washer shall be a sliding fit over the OD of
insulating sleeves.
19.2.5
Stud bolts and studs shall be Grade 8.8 and nuts grade 8 to SANS 1700-7 / SABS 1700-7
and SANS 1700-14 / SABS 1700-14. Stud bolt diameters shall be selected to the next
smaller size for installation in standard drilled flanges. Stud bodies shall be machined down
to the next standard smaller size and a smaller nut is also to be used.
19.2.6
A SS-DCD shall be installed across the flange faces complete with hot-dip galvanising mild
steel mounting brackets to suit the flange bolt. The decoupling device shall be located in a
suitably hazardous area classification rated enclosure as stipulated in SANS 60079-10 /
SABS IEC 60079-10 and SANS 10108 / SABS 0108.
19.2.7
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19.3
19.3.1
A 25 mm wide plastic backed electrical tape to SANS 122 / SABS 122 colour red shall be
applied in the centre on the horizontal surface.
19.3.2
19.3.3
The aluminium plate shall be fixed to the insulating flange with stainless steel strapping.
19.4
19.4.1
Where IFs cannot be employed, then IJs shall be used. Due to the large variety of IJs
available, e.g. gas, liquid Hydrocarbon, water, etc., the following shall be used as a
guideline, in conjunction with Standard Drawing STDD-6005CY:
a.
All welds in contact with the pipe shall undergo 100 % radiographic inspection;
b.
c.
d.
e.
f.
Insulating rings shall be manufactured from glass / epoxy laminated material to ASTM
D709 G10 / G11 or Polycarbonate reinforced with glass fibre for oxygen use;
g.
Gaskets shall be manufactured from Nitrile rubber to ASTM D2000 or FPM fluoridated rubber for oxygen use;
h.
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i.
The external surface shall be shot blasted and coated with a high build epoxy dry film
thickness (DFT) of 150 m;
j.
The internal surface shall be blasted to SA 2, ISO 8501-1. The internal surface shall be
left bare and then capped and sealed with internal silicon gel bags, or coated with a
high build amide cured epoxy DFT 150 m depending upon its application.
19.4.2
Reviewal from SASOL shall be obtained prior to specifying and / or supplying an IJ, due to
the lead times and costs associated with their supply.
19.5
This section defines the materials, surface preparation, application and inspection of internal
lining for piping NPS 24 and larger in cooling water services only.
This work is intended to be performed at the job site. All welding, which could be damaging
to the lining, shall be completed before any lining work is done.
The lining of pipes, weld fittings and weld joints shall be carried out in accordance with a
detailed written procedure, reviewed by SASOL.
19.5.1
Extent of Lining
The lining shall be applied from the insulating coupling for a distance as indicated in
Table 19.5.1:
TABLE 19.5.1:
EXTENT OF LINING
NOMINAL PIPE
SIZE (inches)
LENGTH OF
INTERNAL LINING
(m)
24
1,5
28
30
2
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NOMINAL PIPE
SIZE (inches)
LENGTH OF
INTERNAL LINING
(m)
36
42
48
54
66
72
10
84
14
The length of lining shall be measured from the edge of the insulating coupling along the
pipe on the cathodically protected (under ground) portion.
In the case of a T connection where an insulating coupling is above grade on the centre leg
of the T, the lining shall extend for the tabulated length from the insulating joint into each
of the two under ground pipe legs, as detailed in Figure 6.
FIGURE 6:
T CONNECTION LINING
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In the case of a T connection where the insulating couplings are above grade in each of the
two legs of the T, the lining shall extend for the tabulated length from each insulating
coupling into the under ground pipe leg, as per Figure 7. The minimum distance between
insulating joints in this case shall be the tabulated length of lining as indicated in Table
19.5.1.
FIGURE 7:
T CONNECTION LINING
Short lengths, such as under-road crossings, shall be totally coated from insulating joint /
flange to insulating joint / flange.
19.5.2
Lining Material
The lining material shall be a self-priming high build polyamide or amine epoxy system.
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19.5.3
Surface Preparation
The interior surface preparation of all pipe sections scheduled for internal lining shall
conform to visual Standard Sa2 in accordance with ISO 8501-1 / SIS 05 59 00.
Abrasives for blast cleaning shall be clean and dry and shall be selected to provide the
correct surface profile for the subsequent lining materials.
19.5.4
Application
The lining materials shall be applied on the same day during which cleaning is done and
before rust bloom or re-contamination occurs. All lining work shall be applied in strict
accordance with the manufacturers instruction and as reviewed by SASOL.
The lining system shall be applied in multiple coats to produce a minimum dry film
thickness of 250 m.
Where the distance of the lining extends beyond a weld joint, the pipe and / or pipe fittings
may be lined before erection provided the lining is held back a minimum of 150 mm for
welding purposes. Written procedures shall be submitted for reviewal by SASOL for repair
and making good of the weld lanes.
19.5.5
Inspection
Materials supplied and / or used in connection with this lining work are subject to inspection
and reviewal from SASOL.
Dry film thickness measurements shall be taken with a SASOL reviewed and calibrated dry
film gauge. Details shall be submitted to SASOL for reviewal prior to using the instrument.
The pictorial visual standards ISO 8501-1 / SIS 05 59 00 shall be used as inspection
standards for acceptable surface preparation. Any surfaces found to be incorrectly prepared
shall be corrected.
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The finished surface shall be free from pinholes, voids, holidays, runs, sags or other surface
imperfections. The method of testing shall be reviewed by SASOL.
20
20.1
GENERAL CONSIDERATIONS
20.1.1
The performance characteristics of the 1,75 V high potential magnesium alloy, is detailed
below. The high potential alloy is specially formulated from pure virgin magnesium and
other elements to produce the higher voltage. The advantages of the high potential anode
versus its 1,55 V counterpart, is as follows:
a.
The higher driving potential permits fewer anodes in this specific application;
b.
The capacity of a high potential anode is some 4 % greater than that of the other
anodes, improving the overall life of the anode;
c.
The material will be produced from virgin magnesium and shall contains no scrap,
thus ensuring points (a) and (b) above.
20.1.2
The anodes shall be manufactured in accordance with ISO 9002. The contractor shall submit
written confirmation from the relevant standards authority, confirming complete registration
in this regard.
ELEMENT
PERCENTAGE (%)
Aluminium (Al)
0,001 Maximum
Zinc (Zn)
N/A
Silicon (Si)
N/A
Manganese (Mn)
0,50 to 1,30
Nickel (Ni)
0,001 Maximum
Iron (Fe)
0,03 Maximum
Copper (Cu)
0,02 Maximum
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ELEMENT
PERCENTAGE (%)
Other
N/A
N/A
Magnesium
Balance
20.2
20.2.1
The high potential magnesium anode shall conform to the following chemical composition:
20.2.2
20.3
20.3.1
The high potential magnesium alloy anode shall have a net minimum weight of 10 kg and a
minimum length of 533 mm and nominal diameter of 114 mm, when unpacked. The
unpacked and packed dimensions are detailed in Standard Drawing STDD-6005CZ.
20.3.2
The anode shall be free of blow holes, cold laps, porosity seams and any other imperfection
which may impair its performance. Extruded anodes shall be used and cast anodes may be
used if reviewed by SASOL.
20.3.3
A 5 mm diameter pre-galvanised steel threaded stud or rod shall be centrally located within
the anode. The latter shall extend for at least 95% of the anode length and shall be extruded
or cast into it. The pre-galvanised threaded steel stud or rod shall be suitable for the electrical
connection of the anode to anode cable, which shall terminate in a recess at the one end. The
connection shall be suitable for 20 years under submerged conditions.
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20.4
20.4.1
The anode cable shall be as specified in Section 14 of this Specification and the length shall
be 6 m or as specified in the RFQ document and detailed in Drawing STDD-6005CU.
20.4.2
In all instances a suitable hole will be drilled into the end of the thread or rod and the cable
shall be brazed / soldered into the hole.
20.4.3
The insulation of the cable shall be removed for a length such that at least 25 mm of the
copper is inserted into the drilled galvanised steel rod hole.
20.4.4
The cable shall then be brazed / soldered into the hole. At least 25 mm of insulation shall
extend into the anode recess.
20.4.5
Mechanical connections between the anode cable and the pre-galvanised steel rod or thread
shall not be permitted under any circumstances.
20.4.6
The anode recess shall be completely flooded with hydrochloric acid (10% solution) resistant
epoxy. All proposed epoxies shall be submitted to SASOL for reviewal, prior to their use.
The epoxy shall completely fill the recess without spilling over onto the external surface of
the anode.
20.4.7
No bare copper cable shall extend outside the epoxy; the insulation shall extend at least
25 mm into the epoxy as stipulated above.
20.4.8
The maximum cable to anode resistance shall be 10 m. The cable shall be pulled or tugged
initially as a test after making the cable to anode connection.
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20.5
ELECTROCHEMICAL PROPERTIES
20.5.1
The solution potential of the anode when fully submerged in the test chamber, shall be more
negative than -1,65 V with respect to a saturated copper / copper sulphate reference
electrode.
20.5.2
The anode shall maintain this potential at a 100 mA output and shall possess a capacity of
1200 A.hrs/kg.
20.6
20.6.1
A complete set of both chemical and metallurgical tests shall be conducted on a number of
randomly selected anodes, as determined in accordance with BS 6001, Part 1, prior to
installation of the anodes. Anodes may only be installed subsequent to testing and reviewal
from SASOL.
20.6.2
Complete chemical and metallurgical compliance shall be ensured prior to their installation
and a detailed report shall be submitted to SASOL for reviewal. Testing shall be carried out
at the contractors expense.
20.6.3
The natural anode potential and current drawn shall be measured prior to permanently
connecting the anode to the pipe / structure. This data shall be submitted with the
commissioning report.
20.7
20.7.1
All anodes shall be installed at a minimum depth of 2,5 m or pipe invert depth, which ever is
the deeper. The anodes shall be located a minimum of 3,5 m from the pipe or as determined
by the CP Design. The anode / pipe separation distance shall be stipulated in the bill of
quantities of the RFQ document.
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20.7.2
The distribution of the anodes shall also be stipulated in the in the bill of quantities of the
RFQ document.
20.7.3
The anodes shall be located in a cotton bag which shall ensure that a minimum of 35 mm of
crushed natural granular gypsum / bentonite / anhydrous sodium sulphate in the ratio by
volume of 75% / 20% / 5% respectively, surrounds the entire anode surface.
20.7.4
The anodes shall be completely submerged for 2 hours prior to installation and the entire
anode excavation (hole) into which they are to be placed shall be thoroughly soaked prior to
backfilling. Care shall be exercised when backfilling in order to prevent damage to the anode
cable.
20.7.5
21
21.1
The zinc tube required for AC mitigation shall comply in full with the following details.
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21.2
21.3
DIMENSION
Length
1500 mm 5%
Diameter
80 mm 5%
Wall Thickness
5 mm 5%
The chemical composition of the zinc shall comply with those of high purity zinc materials
in accordance with ASTM B418 Type I and as indicated below:
TYPE I
ELEMENT
21.4
Aluminium (Al)
0,1 to 0,5
Cadmium (Cd)
0,025 to 0,07
Iron (Fe)
0,005 Maximum
Lead (Pb)
0,005 Maximum
Copper (Cu)
0,005 Maximum
Others - total
0,1 Maximum
Zinc
Remainder
HARDNESS MEASUREMENTS
The zinc tube average hardness shall be 39 6,5 Hv10 using a Vickers hardness tester.
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21.5
METALLOGRAPHY
A transverse and longitudinal section (as indicated by figures 8 and 9) shall be removed from
the supplied tube, mounted in cold mounting resin and prepared for metallographic. The
samples shall be etched in a solution of chromic acid to which sodium sulphate shall be
added, to reveal the microstructure of the tube. No significant differences shall be observed
between the transverse and longitudinal sections. The grain size shall be estimated using the
comparison method described in ASTM E112.
longitudinal and transverse sections shall be less than one. The microstructure of the tube
shall consist of equi-axed grains.
FIGURE 8:
REQUIRED
MICROGRAPH
OF
LONGITUDINAL
SECTION
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FIGURE 9: