Installation and Commissioning of Onshore Cathodic Protection Systems

DEP SPECIFICATION
INSTALLATION AND COMMISSIONING OF ONSHORE

CATHODIC PROTECTION SYSTEMS
Copyright Shell Group of Companies. No reproduction or networking permitted without license from Shell. Not for resale
DEP 30.10.73.33-Gen.
September 2011
ECCN EAR 99
DESIGN AND ENGINEERING PRACTICE
© 2011 Shell Group of companies

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Nooter Eriksen lmatza@ne.com 02/07/2018 18:09:45
ECCN EAR 99 DEP 30.10.73.33-Gen.
September 2011
Page 2
PREFACE
DEP (Design and Engineering Practice) publications reflect the views, at the time of publication, of Shell Global
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TABLE OF CONTENTS
1. INTRODUCTION ........................................................................................................6
1.1 SCOPE........................................................................................................................6
1.2 DISTRIBUTION, INTENDED USE, AND REGULATORY CONSIDERATIONS ........6
1.3 DEFINITIONS .............................................................................................................6
1.4 CROSS-REFERENCES .............................................................................................9
1.5 PROPRIETARY NAMES ............................................................................................9
1.6 SUMMARY OF MAIN CHANGES...............................................................................9
1.7 COMMENTS ON THIS DEP .......................................................................................9
1.8 DUAL UNITS...............................................................................................................9
2. GENERAL.................................................................................................................10
2.1 GENERAL GUIDELINES FOR CATHODIC PROTECTION.....................................10
2.2 INSTALLATION AND COMMISSIONING OF GROUNDBEDS................................10
3. INSTALLATION OF DEEP ANODE BED SYSTEMS FOR CATHODIC
PROTECTION ..........................................................................................................11
3.1 GENERAL REQUIREMENTS...................................................................................11
3.2 MATERIALS..............................................................................................................12
3.3 HYDROGEOLOGIC SURVEY ..................................................................................12
3.4 INSTALLATION OF CASING....................................................................................13
3.5 ANODE HOLE ..........................................................................................................14
3.6 INSTALLATION OF ANODES ..................................................................................15
3.7 INSTALLATION OF CABLES ...................................................................................18
3.8 SYSTEM REQUIREMENTS AT GRADE..................................................................19
3.9 INSPECTION AND TESTING...................................................................................20
3.10 ENERGIZING THE SYSTEM....................................................................................21
3.11 SYSTEM DATA.........................................................................................................22
4. INSTALLATION OF IMPRESSED CURRENT SURFACE ANODE BED
SYSTEMS .................................................................................................................23
4.2 MATERIALS..............................................................................................................24
4.3 INSTALLATION OF ANODE BED ............................................................................24
4.4 INSTALLATION OF ANODE SHUNT BOXES..........................................................28
4.5 INSTALLATION OF RECTIFIERS............................................................................28
4.7 ENERGIZING THE SYSTEM....................................................................................28
4.8 DATA AND DOCUMENTATION ...............................................................................30
5. INSTALLATION OF HORIZONTAL IMPRESSED CURRENT ANODE
SYSTEMS FOR NEW AND REPLACEMENT TANK BOTTOMS ...........................31
5.2 MATERIALS..............................................................................................................32
5.3 INSTALLATION ........................................................................................................33
5.4 INSPECTION ............................................................................................................36
5.5 COMMISSIONING ....................................................................................................36
6. INSTALLATION OF HORIZONTALLY BORED IMPRESSED CURRENT
ANODE SYSTEMS UNDER EXISTING TANKS......................................................37
6.2 MATERIALS..............................................................................................................38
6.3 INSTALLATION EQUIPMENT ..................................................................................38
6.4 INSTALLATION ........................................................................................................39
6.5 INSPECTION ............................................................................................................41
6.6 COMMISSIONING ....................................................................................................41
6.7 SUBMITTALS ...........................................................................................................42
7. INSTALLATION OF IMPRESSED CURRENT GRID SYSTEMS FOR ON
GRADE STORAGE TANK BOTTOMS ....................................................................44

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7.2 MATERIALS..............................................................................................................46
7.3 INSTALLATION ........................................................................................................48
7.4 INSPECTION ............................................................................................................51
7.5 TESTING AND COMMISSIONING...........................................................................52
7.6 SUBMITTALS ...........................................................................................................53
7.7 WARRANTY REQUIREMENTS ...............................................................................53
7.8 DRAWINGS – TYPICAL DRAWING LIST ................................................................54
7.9 SAND PAD MATERIAL REQUIREMENTS ..............................................................54
7.10 SAND PAD INSTALLATION REQUIREMENTS.......................................................55
7.11 PLATE INSTALLATION ............................................................................................55
7.12 MISCELLANEOUS ...................................................................................................56
8. INSTALLATION OF GALVANIC ANODE BED SYSTEMS.....................................57
8.2 INSTALLATION OF GALVANIC ANODE SYSTEMS IN SOIL .................................58
8.4 COMMISSIONING ....................................................................................................60
9. DESIGN, MANUFACTURE, AND INSTALLATION OF AIR COOLED
CATHODIC PROTECTION RECTIFERS.................................................................61
9.1 GENERAL .................................................................................................................61
9.2 DESIGN ....................................................................................................................62
9.3 MANUFACTURE ......................................................................................................65
9.4 INSTALLATION ........................................................................................................66
9.5 SOLAR POWERED GENERATOR STATIONS .......................................................68
9.6 COMMISSIONING ....................................................................................................69
10. DESIGN, MANUFACTURE, AND INSTALLATION OF OIL COOLED
CATHODIC PROTECTION RECTIFIERS................................................................71
10.1 GENERAL .................................................................................................................71
10.2 DESIGN ....................................................................................................................71
10.3 MANUFACTURE ......................................................................................................76
10.4 INSTALLATION ........................................................................................................77
10.5 COMMISSIONING ....................................................................................................79
11. TEST STATIONS......................................................................................................81
11.2 INSTALLATION GUIDELINES FOR ALL TEST STATION CONFIGURATIONS.....82
11.3 CABLE-TO-STRUCTURE CONNECTIONS.............................................................84
11.4 PIPE-TO-SOIL POTENTIAL STATION CONFIGURATION .....................................87
11.5 FOREIGN LINE CROSSING STATION CONFIGURATION ....................................89
11.6 ELECTRICAL ISOLATION STATION CONFIGURATION .......................................91
11.7 CASED CROSSING STATION CONFIGURATION .................................................92
11.8 SACRIFICIAL ANODE STATION CONFIGURATION ..............................................93
11.9 COUPON TEST STATION CONFIGURATION ........................................................94
11.10 IR DROP STATION CONFIGURATION ...................................................................96
11.11 IR FREE COUPON STATION CONFIGURATION .................................................101
12. INSTALLATION OF CATHODIC PROTECTION BONDS ON FOREIGN
STRUCTURES .......................................................................................................103
12.1 GENERAL ...............................................................................................................103
12.2 MATERIALS............................................................................................................104
12.3 INSTALLATION ......................................................................................................105
12.4 INSPECTION ..........................................................................................................105
13. INSTALLATION OF ELECTRICAL ISOLATION FOR CATHODIC
PROTECTION ........................................................................................................106
13.1 GENERAL ...............................................................................................................106
13.2 MATERIALS............................................................................................................107
13.3 INSTALLATION ......................................................................................................109
13.4 SPECIAL INSULATING REQUIREMENTS ............................................................112
13.5 INSPECTION ..........................................................................................................112

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14 INSTALLATION OF SYSTEMS FOR MITIGATING ALTERNATING

CURRENT EFFECTS AND FAULT CURRENTS ..................................................113
14.1 GENERAL ...............................................................................................................113
14.2 SYSTEMS ...............................................................................................................114
14.3 UNPACKING AND MAKING READY .....................................................................117
14.4 POTENTIAL GRADIENT CONTROL MATS AT ABOVE GROUND
APPURTENANCES ................................................................................................117
14.5 POTENTIAL GRADIENT CONTROL MATS AT VALVES AND REMOTE
BLOWDOWNS........................................................................................................119
14.6 ZINC GROUNDING CELL SYSTEMS....................................................................120
14.7 GROUNDING AND ISOLATING DEVICES............................................................121
14.8 COUPON TEST STATIONS ...................................................................................121
14.9 INSPECTION ..........................................................................................................121
15. PERFORMING CLOSE-INTERVAL PIPE-TO-SOIL POTENTIAL SURVEYS......122
15.1 GENERAL ...............................................................................................................122
15.2 EQUIPMENT AND MATERIALS ............................................................................122
15.3 GENERAL REQUIREMENTS FOR SURVEYS......................................................124
15.4 ON/OFF SURVEYS ................................................................................................126
15.5 RIVER CROSSING SURVEYS ..............................................................................129
15.6 NATIVE POTENTIAL SURVEYS............................................................................129
15.7 ON POTENTIAL SURVEYS ...................................................................................129
15.8 SURVEY DOCUMENTATION ................................................................................129
15.9 SURVEY OPTIONS ................................................................................................131
16. REFERENCES .......................................................................................................134
APPENDICES
APPENDIX 1 – Partial List of Materials for Graphite / Silicon Iron Anode System ......................137
APPENDIX 2 – Partial List of Materials for MMO or LIDA® Anode System ................................138
APPENDIX 3 – Deep Anode Bed Drilling Log..............................................................................139
APPENDIX 4 – Deep Well Anode Installation Log.......................................................................141
APPENDIX 5 – Partial List of Materials for Surface Anode Bed System .....................................142
APPENDIX 6 – Partial List of Materials for Galvanic Anode System...........................................143
APPENDIX 7 – Installation Checklist for Rectifiers ......................................................................144
APPENDIX 8 – Material Requirement Sheet for Air Cooled Rectifier Installation........................145
APPENDIX 9 – Installation Checklist for Impressed Current Surface Ground Bed .....................146
APPENDIX 10 – Installation Checklist for Impressed Current Deep Well Ground Bed ...............147
APPENDIX 11 – Installation Checklist for Underground Sacrificial Anode Bed...........................148
APPENDIX 12 – Material Requirement Data Sheet for Isolation Fittings ....................................149

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1. INTRODUCTION
1.1 SCOPE
This DEP defines requirements and gives recommendations for the installation and
commissioning of onshore cathodic protection systems. The installation and commissioning
of cathodic protection systems for subsea pipelines and hardware is covered in
DEP 30.10.73.32-Gen.
This is a revision of the DEP of the same number dated January 2000. See (1.6) for a
summary of historical revisions to this document.
1.2 DISTRIBUTION, INTENDED USE, AND REGULATORY CONSIDERATIONS

Unless otherwise authorised by Shell GSI, the distribution of this DEP is confined to Shell
companies and, where necessary, to Contractors and Manufacturers/Suppliers nominated
by them. Any authorised access to DEPs does not for that reason constitute an
authorization to any documents, data or information to which the DEPs may refer.
This DEP is intended for use in facilities related to oil and gas production, gas handling, oil
refining, chemical processing, gasification, distribution and supply/marketing. Application in
other similar facilities may also apply.
When DEPs are applied, a Management of Change (MOC) process should be
implemented. This is of particular importance when existing facilities are to be modified.
If national and/or local regulations exist in which some of the requirements may be more
stringent than in this DEP, the Contractor shall determine by careful scrutiny which of the
requirements are more stringent and which combination of requirements will be acceptable
with regard to the safety, environmental, economic and legal aspects. In all cases, the
Contractor shall inform the Principal of any deviation from the requirements of this DEP
which is considered to be necessary in order to comply with national and/or local
regulations. The Principal may then negotiate with the Authorities concerned, the objective
being to obtain agreement to follow this DEP as closely as possible.
1.3 DEFINITIONS
1.3.1 General definitions
The Contractor is the party that carries out all or part of the design, engineering,
procurement, construction, commissioning or management of a project or operation of a
facility. The Principal may undertake all or part of the duties of the Contractor.
The Manufacturer/Supplier is the party that manufactures or supplies equipment and
services to perform the duties specified by the Contractor.
The Principal is the party that initiates the project and ultimately pays for it. The Principal
may also include an agent or consultant authorised to act for, and on behalf of, the
Principal.
The word shall indicates a requirement.
The word should indicates a recommendation.
1.3.2 Specific definitions
Term Definition
Cathodic Protection Process of reducing or preventing corrosion of metal structures
in contact with an electrolyte by the flow of direct current from
the electrolyte into the structure surface.
Cathodic Protection Combination of equipment installed to provide cathodic
Station protection to the structure to be protected.
Current Density Amount of current per unit area of the steel surface, coated or
uncoated, in contact with the electrolyte.

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Term Definition
Drain Point Point on the pipeline or structure where the connection of the
negative terminal of the cathodic protection voltage source is
made to conduct [drain] the returning current from the pipeline
to the voltage source.
Electrolyte Conductive liquid or material such as soil or water in which an
electric current can flow.
Foreign Metal structures or pipelines other than the structure or pipeline
Structures/Pipelines under consideration, in contact with the same electrolyte, and
which are or may fall under the influence of the cathodic
protection system; they may be owned by the Principal or other
companies and may or may not be equipped with cathodic
protection.
Groundbed System of buried or submerged electrodes, to conduct the
required current into and through the electrolyte to the steel
surface to be protected.
Isolating Flange Set of two flanges assembled with an insulating gasket and
insulating sleeves and washers, for the purpose of electrically
isolating two metallic pipe sections.
Isolating Joint Factory assembled pipe fitting provided with insulating gaskets
and resins, to be welded into a pipeline or piping for the
purpose of electrically isolating two metallic pipe sections.
IR Drop The voltage across a resistance in accordance with Ohm’s law.
Natural Potential Pipe-to-soil potential measured when no cathodic protection is
applied and polarisation caused by cathodic protection is
absent.
"OFF" Potential Pipe-to-soil potential measured immediately after the cathodic
protection system is switched off and the applied electrical
current stops flowing to the pipeline surface, but before
polarisation of the pipeline has decreased.
"ON" Potential Pipe-to-soil potential measured while the cathodic protection
system is continuously operating.
Pipeline Pipeline and associated equipment as defined in the scope of
the cathodic protection design contract.
Pipe-To-Soil Potential Difference in electrochemical potential between a pipeline or
foreign structure/pipeline and a specified reference electrode in
contact with the electrolyte. Similar terms such as structure-to-
soil potential, pipe- to-electrolyte potential and pipe-to-
[sea]water potential are sometimes used as applicable in the
particular context.
Polarisation Change of the pipe-to-soil potential caused by the flow of DC
current between an electrolyte and a steel surface.
Polarisation Cell Device inserted in the earth connection of a structure that
[Kirkcell] isolates for DC in the cathodic protection range.
Reference Electrode Non-polarising electrode of which the electrochemical potential
is accurately reproducible and which serves as a reference for
pipe-to-soil potential measurements.

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Term Definition
Stray Currents Electrical currents running through the electrolyte, originating
from a foreign DC source and causing interaction with the
corrosion and cathodic protection processes of the structure or
pipeline. Stray currents may also originate from the pipeline's
cathodic protection system and act upon foreign
structures/pipelines.
Structure Structure and associated equipment as defined in the scope of
the cathodic protection design contract.
1.3.3 Abbreviations
Term Definition
AC Alternating Current
API American Petroleum Institute
ASTM American Society for Testing and Materials
AWG American Wire Gauge
CIS Close Interval Survey
CP Cathodic Protection
CPDM Cathodic Protection Data Manager®
Cu/CuSO4 Copper/Copper Sulphate as used for the Copper/Copper
Sulphate type of reference electrode
DC Direct Current
DOC Depth of Cover
GPS Global Positioning System
HDPE High Density Polyethylene
HMWPE High Molecular Weight Polyethylene (HMWPE) insulated cable
is suitable for direct burial in cathodic protection applications for
storage tanks, pipelines and other buried or submerged units.
HVAC / HVDC High Voltage Alternating Current / High Voltage Direct Current
IEC International Electric Code
IR 'I' represents current (amps) and 'R' stands for the amount of
resistance (Ohms), IR stands for Current (I) x Resistance (R)
MMO Mixed Metal Oxide
MOVs Metal Oxide Varistors
NACE National Association of Corrosion Engineers
NEC National Electrical Code
NEMA National Electrical Manufacturer’s Association
NFPA National Fire Protection Association
PCR Polarization Cell Replacement
PVC Poly Vinyl Chloride
SSD Solid State Decoupler
TGIC Triglycidyl Isocyanurate
THHN Thermoplastic High Heat Nylon insulated wire

September 2011
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Term Definition
TW/THW/THWN Thermoplastic Heat and Water Resistant insulated Wire
UL Underwriters Laboratories
VAC Volts Alternating Current
XHHW XLPE (cross-linked polyethylene) High Heat-resistant Water-
resistant
1.4 CROSS-REFERENCES
Where cross-references to other parts of this DEP are made, the referenced section is
shown in brackets ( ). Other documents referenced by this DEP are listed in (16).
1.5 PROPRIETARY NAMES

The names “Wenner,” "Kirkcell," and "Swain" are used in this DEP to indicate measuring
techniques or equipment types, commonly understood by those names in cathodic
protection engineering. They are not intended to indicate a requirement to apply equipment
of that particular brand name.
1.6 SUMMARY OF MAIN CHANGES

This DEP is a major revision to the previous DEP dated January 2000, and represents a
consolidation of subject matter from various Shell entities. The technical content of the
previous DEP was preserved, however, references to offshore and marine cathodic
protection has been removed and is now referenced in DEP 30.10.73.32-Gen. When the
local standards from various Shell entities contained similar technical information, drawings,
or forms, a comparison was performed and the most comprehensive and technically current
content was adopted.
1.7 COMMENTS ON THIS DEP

Comments on this DEP may be sent to the Administrator at standards@shell.com, using
the DEP Feedback Form. The DEP Feedback Form may be found on the main page of
“DEPs on the Web”, available through the Global Technical Standards web portal
http://sww.shell.com/standards and on the main page of the DEPs DVD-ROM.
1.8 DUAL UNITS

This DEP contains both the International System (SI) units, as well as the corresponding
US Customary (USC) units, which are given following the SI units in brackets. When
agreed by the Principal, the indicated USC values/units may be used.

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2. GENERAL
2.1 GENERAL GUIDELINES FOR CATHODIC PROTECTION

General guidelines for cathodic protection are given in DEP 30.10.73.10-Gen.
It is Shell’s policy to protect all buried or submerged metallic pipelines from corrosion using
a combination of coatings and cathodic protection systems. The effects of corrosion and
the design of corrosion protection shall be an integral component of all pipeline projects. In
addition, local regulations may outline specific coating and cathodic protection
requirements.
It is very important to plan for Cathodic Protection (CP) early in the design phase of the
project. A qualified Corrosion Specialist shall be included in the design phase of all pipeline
and tank projects. Early input from the Corrosion Specialist will help prevent unforeseen
costs and ensure that corrosion mitigation issues are addressed in a timely and effective
manner. Right of Way (ROW) issues, permits to drill deep wells or install distributed
groundbeds, material delivery, and Contractor availability are items that require advanced
scheduling.
CP shall be applied immediately after construction to protect all buried and submerged
structures from corrosion.
Installation of cathodic protection systems will normally not be handled by the General
Contractor responsible for laying the pipe. Corrosion Contractors specialize in cathodic
protection installations and should be used to install cathodic protection systems.
Design, installation and commissioning of cathodic protection systems shall be carried out
under the supervision of qualified and experienced NACE Cathodic Protection Specialists,
preferably the design consultant's representative.
2.2 INSTALLATION AND COMMISSIONING OF GROUNDBEDS

The installation and commissioning of groundbeds and permanent monitoring facilities shall
be closely supervised. A qualified corrosion control inspector shall be used to inspect the
installation of CP systems to ensure all design and installation requirements are met. As-
built drawings and data books shall be provided for all work performed. Upon completion of
pipeline or tank construction, a baseline CP survey shall be conducted, recording native
structure to soil potentials, AC potentials and current densities at all test leads, checking
insulating devices and verifying that foreign crossings are not an interference concern. After
energizing the new rectifiers, a second comprehensive survey shall be conducted to
confirm there is adequate protection on the pipeline and again verify that AC or DC
interference problems do not exist. All reports shall be submitted to the Principal
representative.

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3. INSTALLATION OF DEEP ANODE BED SYSTEMS FOR CATHODIC PROTECTION
3.1 GENERAL REQUIREMENTS

3.1.1 General installation requirements
1. Deep anode bed systems shall be installed in accordance with applicable government
regulations, local requirements, and this DEP.
2. Electrical portion of the deep anode bed systems shall be installed in accordance with
applicable local codes, the National Electrical Code, and API RP500.
3. Deepwell groundbeds shall be constructed in accordance with the design documents
and drawings. Type, number, depth, and spacing of anodes shall be in accordance with
(Appendix 1) and (Appendix 2).
4. Cable connections to protected structures shall conform to (11.3) of this DEP.
5. The installation checklist for deep well groundbeds (Appendix 10) shall be used by the
inspector and included as part of the deliverable package to the Principal.
3.1.2 Contractor/personnel qualifications
1. Installation Contractor shall have a minimum of five years experience in the installation
of deep anode beds for impressed current systems.
2. Installation of deep anode bed systems shall be carried out under the supervision of a
NACE-certified cathodic protection or corrosion specialist.
3.1.3 Equipment and tools
1. Equipment and tools used to install anode beds shall be adequate for the job.
2. Equipment and tools shall be maintained in a manner that ensures safe use.
3. Safety equipment shall be used by installation personnel as required for the job.
3.1.4 Environmental considerations
Installation of deep anode beds shall conform to local environmental and groundwater
requirements and to applicable government regulations.
3.1.5 Technical literature for materials
1. If the Installation Contractor also supplies the materials, Manufacturer’s technical
literature shall be provided for each item required by this DEP. Items required are
those indicated in (Appendix 1) and (Appendix 2) of this DEP.
2. Technical literature shall include the Manufacturer’s name and shall verify that the
material meets the requirements of this DEP.
3. If more than one item or catalog number appears on a technical brochure, the
proposed item shall be clearly identified.
3.1.6 Principal inspection
1. All equipment, materials, fabrications, and installations are subject to inspection,
testing, and approval by the Principal.
2. Unless otherwise specified, a party designated by the Principal shall inspect installation
work.
3.1.7 Permits
Installation Contractor shall obtain the required safety and work permits, including hot work
permits, before proceeding with the installation work.
3.1.8 Safety
Installation Contractor shall be familiar with applicable government regulations and Shell
safety guidelines and requirements and shall adhere to them.

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Location of third party structure locations shall be performed before any excavation by
making the required local contacts with One Call or equivalent service providers.
3.2 MATERIALS
3.2.1 Anodes
Type, size, and number of anodes shall be designated by the Principal and provided to
Contractor in a Partial List of Material form (Appendix 1) and (Appendix 2).
3.2.2 Lead cable
1. Lead cable type, size, and length shall be designated by the Principal and provided to
Contractor in a Partial List of Material form (Appendix 1) and (Appendix 2).
2. Lead cable shall be continuous from the anode to the shunt box without splices.
3.2.3 Positive header and negative cables
1. Positive header and negative cable shall be AWG stranded copper conductor with
HMWPE, Kynar® or Halar® insulation (or Principal-approved equivalent) and of
adequate size to carry the current from the entire anode bed.
2. Type, size, and length of cable shall be provided to Contractor in a Partial List of
Material form (Appendix 1) and (Appendix 2).
3.2.4 Coke breeze
Type and quantity of coke breeze shall be and provided to Contractor in a Partial List of
Material form (Appendix 1) and (Appendix 2).
3.3 HYDROGEOLOGIC SURVEY

3.3.1 Review of existing data
1. Unless otherwise specified, existing hydrogeological data, such as drilling logs of
observation wells, previous deep anode bed installations, hydrogeology studies, and
water well data shall be reviewed by the Principal before drilling starts.
2. Existing data shall be reviewed:
a. To determine if any conditions exist that could result in contamination due to the
installation of the deep anode beds.
b. To determine if the deep anode bed needs to be relocated or extended casing and
vent pipe lengths are required.
3. Results of review of existing data shall be furnished to the Installation Contractor.
3.3.2 Pilot hole
1. If required, a pilot hole shall be drilled to obtain hydrogeologic information.
2. Pilot hole shall be drilled with rotary type drilling equipment. Drilling mud (bentonite)
shall be used to stabilize the hole.
3. Principal shall determine depth of pilot hole from review of the existing hydrogeological
data.
4. Pilot hole shall be drilled to determine depth and thickness of the upper water table,
confining bed intervals, and characteristics of additional aquifers.
5. Contractor shall produce a drill log of the pilot hole.
6. If the pilot hole is drilled deeper than the required depth and this results in penetration
of a lower aquifer, the portion of the hole in the lower aquifer shall be cemented.
7. If the pilot hole is not used for an anode bed, its entire length shall be cemented.
8. If pilot hole is to be cemented, the cement grout specified in this DEP shall be used.

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3.3.3 Hydrogeologic profile

1. A hydrogeologic profile shall be developed from the pilot hole-drilling log.
Hydrogeologic profile shall include:
a. Identification of any subsurface hydrocarbon contamination.
b. Depth and thickness of aquifers.
c. Depth and thickness of subsurface soil strata.
d. Depth and thickness of impervious clay formations.
e. Evaluation and extent of contamination of aquifers.
2. The following characteristics of the anode bed shall be determined from the
hydrogeologic profile:
a. Depth and thickness of clay stratum at which casing will be terminated. If the clay
stratum has a thickness greater than 1.5 m (5 ft.), the casing shall penetrate
1 m (3 ft.) into the stratum.
b. Length of casing.
c. Location and distribution of anodes below the casing.
3.4 INSTALLATION OF CASING

3.4.1 Casing hole
1. Casing hole shall:
a. Be drilled with rotary type drilling equipment.
b. Have drilling mud (bentonite) used to stabilize well bore.
c. Have a nominal diameter as designated in (Appendix 1) and (Appendix 2).
d. Be drilled to a depth 0.3 m (1 ft.) deeper than the casing length designated in
(Appendix 1) and (Appendix 2).
e. Be drilled so that there is a uniform minimum 50 mm (2 in.) annulus between the
casing and the hole wall.
2. Depth of hole shall be known at all times during drilling operation.
3.4.2 Mud/slurry pits

1. Unless otherwise specified, mud/slurry pits shall be above ground portable containers.
Use of dug pits requires approval in writing by the Principal.
2. Dug pits shall be lined with a heavy-duty plastic liner.
3. Contractor shall be responsible for vacuum truck services and disposal of cuttings and
fluids.
4. Removal and disposal of cuttings and fluids shall be done in a manner and at a location
that complies with all applicable federal, state and local laws, rules and regulations.
3.4.3 Aquifers
Prior to the installation of a deepwell groundbed, the Contractor shall consider the
environmental aspects since the groundbed may be installed through underground
aquifers.
1. If the anode bed is installed in a zone with a single aquifer:
a. Casing shall extend to a depth of at least 6 m (20 ft.) below the lowest annual water
table or as instructed by applicable government regulation.
b. Casing does not have to terminate in a clay zone.

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2. If the anode bed is installed in a zone with multiple aquifers:

a. Casing hole shall be drilled using mud (bentonite) with a specific gravity higher than
1.06 to prevent cross contamination of aquifers.
b. Bottom of casing shall terminate in a confining zone (clay formation) or other area
as determined by the hydrogeologic profile, or as instructed by applicable
government regulation.
c. Entire length of the anode string shall be located in a single aquifer, if possible.
3.4.4 Insertion of casing
1. If specified, a casing shall be set in the bore hole. Normally a non-conductive (plastic)
casing is used for the inactive length of the groundbed. Casing pipe and centralizers
shall conform to (Appendix 1) and (Appendix 2).
2. Casing string shall be assembled one joint at a time while lowering the casing string
with a drilling rig.
3. Centralizers shall be installed on the casing string at maximum intervals of 6 m (20 ft.).
Casing string shall have a minimum of two centralizers.
4. Casing string shall be assembled until it rests at the bottom of the hole and then raised
0.3 m (1 ft.) to facilitate cementing of casing.
5. If bentonite grout is used, a 0.6 m (2 ft.) plug of bentonite gravel shall be poured into
the hole prior to lowering the casing.
6. Casing pipe shall be nominal DN 250 (NPS 10) I.D. Schedule 40 PVC, glued bellied
end, or as approved by the Principal.
3.4.5 Cementing of casing
1. Annulus between casing and hole shall be cemented after casing is inserted using
either Portland cement grout or a high solids bentonite grout. Refer to DEP Standard
Drawing 41.016.
2. Portland cement grout mix shall have 22.7 L (6 gal.) of water for every 42.6 kg (94 lbs.)
of Portland cement and 4% by weight [2.6 kg (5.76 lbs.)] of sodium bentonite powder.
3. Bentonite grout mix shall have 53 L (14 gal.) of water for every 22.6 kg (50 lbs.) of
bentonite (30% solids ratio). Mix shall have a specific gravity of 1.19 Kg/ LITER
(9.9 lbs./gal.).
4. Grout shall be pumped through the annulus from the bottom up, until it fills the annulus
between casing and hole up to grade. Method for pumping the grout in the annulus
shall be approved by the Principal.
5. Portland cement grout shall be allowed to cure for 12 hours prior to drilling anode hole.
6. Anode hole may be drilled immediately if bentonite grout is used.
7. Quick setting Portland cement grout or grout additives shall not be used without prior
approval by the Principal.
3.5 ANODE HOLE

3.5.1 Drilling hole
1. Depth of anode hole shall be determined from the hydrogeologic profile and shall not
penetrate any lower confining zone.
2. An anode hole shall be drilled with rotary equipment at the diameter and depth as
designated by the Principal. Data related to the drilling and installation of deepwell
groundbeds shall be recorded in (Appendix 1) or (Appendix 2), based on designated
anode material.

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3. A drilling log shall be completed by the Contractor using the form provided in
(Appendix 3). All underground strata shall be listed on the form. Drilling log shall be
submitted to the Principal prior to installation of the anodes.
4. Air drilling without prior approval by the Principal is prohibited.
5. Adequate drilling aids, such as bentonite, shall be used to preclude “booting” or
“ringing” and to provide a smooth, slick bore.
6. Water used in the drilling operation shall be clean and fresh.
7. The anode hole shall have a uniform wall from top to bottom. Wall cavities or
excessive hole-enlargements are not acceptable.
8. Drill collars shall be of correct size to produce a smooth straight hole that offers
minimum resistance to passage of the anodes.
9. All drill cuttings shall be disposed of as instructed by the Principal.
3.5.2 Testing hole
1. Anode hole shall be tested for presence of protrusions or irregularities with a rigid non-
weighted cylinder lowered by wire cable.
2. Cylinder shall have a minimum length of 3 m (10 ft.) and a nominal diameter of 38 mm
(1½ in.) smaller than diameter of the anode hole.
3. If the hole has irregularities that cannot be corrected, an additional hole shall be drilled
at a location determined by the Principal. Cost of additional hole shall be borne by the
Contractor.
3.5.3 Electrical log
1. Prior to cleaning the anode hole, an electrical log shall be performed by lowering a
single anode into the hole.
2. Anode used for electrical log shall not be one of the anodes to be installed in the hole
and it shall be furnished by the Contractor.
3. Current output and associated voltage shall be recorded at 1.5 m (5 ft.) intervals
throughout the entire depth of the anode hole.
4. Electrical log data, as shown in (Appendix 3), shall be produced and submitted to the
Principal prior to installation of the anodes. Test results may require modifications, e.g.,
anode depth, location etc., to the design.
3.6 INSTALLATION OF ANODES

3.6.1 General
1. A roller or sheave shall be used to control the cables during the anode lowering
operation.
2. Details of anode string shall conform to DEP Standard Drawing 41.016.
3. Spacing of anodes in the string shall be as specified by the Principal in (Appendix 1)
and (Appendix 2).
4. Anodes and associated components shall be inspected concurrent with their
installation. Damaged and/or defective components shall not be used.
5. Anode cables shall be checked for proper length prior to installation of anodes.
6. Anode cables shall be free of splices, nicks, gouges, or other defects.
7. Anode cables shall not be damaged during the lowering operation. If a cable is
damaged, the entire length of cable shall be replaced including the connection to the
anode. Splicing or patching the cable is prohibited.
8. Anodes shall be provided with centralisers to centre them in the hole and to prevent
cable damage of lower anodes.

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9. Anodes shall be lowered on PVC vent pipe in the hole to the specified depth. Anodes
shall not be handled, lifted, or lowered using the anode cable, unless specifically
allowed by the Manufacturer in the installation instructions, e.g., stringed anodes.
10. Anode lead wires shall be permanently identified before installation. Each anode cable
shall be tagged with a unique number or code showing at what depth the anode was
set at. This identification shall also be made within the anode shunt box. Care shall be
taken that anode cables have sufficient slack to cope with any backfill settlement.
3.6.2 Vent pipe
1. Plastic vent pipe shall extend from the bottom of the anode hole to a minimum of 1.5 m
(5 ft.) above grade.
2. Vent pipe section in the anode string area shall be nominal DN 25 (NPS 1) ID slotted
PVC Allvent™ as manufactured by Cathodic Engineering Equipment Co., or approved
equal.
3. Vent pipe section inside the casing and above grade shall be nominal DN 25 (NPS 1)
PVC solid pipe without perforations.
4. Bottom of the vent pipe shall have a cap that can withstand 8.3 bar g (120 psig).
3.6.3 Installation of graphite/cast iron anodes

1. A partial list of materials required for installing a graphite or cast iron anode bed shall
be furnished by the Principal as in (Appendix 1).
2. The electrical log data and soil strata, as shown in (Appendix 3), shall be used to
determine spacing of anodes in the anode hole.
3. The anode hole shall be flushed prior to installing anodes.
a. Unless otherwise specified, flushing shall be done with clean, fresh water.
b. Hole may be flushed with another method if, in the opinion of the Principal, a water
flush may damage the hole wall.
4. Bottom anode shall be strapped to the vent pipe to facilitate insertion of the vent pipe.
Anode shall be strapped to the vent pipe at top and bottom of anode with a stainless
steel hose clamp or glass reinforced filament tape. Plastic tape, such as electrician’s
tape, shall not be used.
5. Unless otherwise specified, bottom anode, with vent pipe attached, shall be lowered to
within 1.5 m (5 ft.) of the bottom of the hole.
6. Other anodes shall be manually lowered individually to their required depth.
7. After the anodes are at their required depth, their cables shall be temporarily anchored
during installation of the coke breeze.
8. Details of anode placement shall be documented using (Appendix 4).
3.6.4 Installation of mixed metal oxide or LIDA® anodes

1. A partial list of materials required for installing a mixed metal oxide or LIDA® (or
equivalent) anode bed shall be furnished by the Principal in (Appendix 2).
2. If the anodes are mounted on a single conductor, spacing of the anodes shall be
determined from the hydrogeologic profile, prior to drilling the anode hole.
3. The anode hole shall be flushed prior to installing anodes.
a. Unless otherwise specified, flushing shall be done with clean, fresh water.
b. Hole may be flushed with another method if, in the opinion of the Principal, a water
flush may damage the hole wall.
4. Anode centralizers and bottom weight shall be installed prior to lowering the anode
string.

September 2011
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5. After anode string is lowered to its required depth, cable(s) shall be temporarily
anchored at the top of the hole.
3.6.5 Installation of coke breeze
3.6.5.1 General
1. Unless otherwise specified by the Principal in (Appendix 1) or (Appendix 2),
Loresco SC-3® calcined petroleum coke breeze shall be used.
2. Unless otherwise specified, coke breeze for graphite/cast iron anodes shall be installed
by the pumping method. Installation of coke breeze by the pouring method requires
approval by the Principal prior to drilling the anode hole.
3. Coke breeze for mixed metal oxide or LIDA® anodes shall be installed by the pumping
method.
3.6.5.2 Pumped coke breeze
1. Pumped coke breeze shall be installed in a slurry form.
2. Pipe for coke breeze slurry shall be installed prior to installation of the vent pipe and
anode string.
3. Pump size shall not be larger than required to move the slurry to the bottom of the
anode hole.
4. A column of fresh water shall be pumped through the pipe prior to pumping the slurry.
5. Slurry shall be prepared using clean, fresh water.
6. Velocity of the slurry at the pipe discharge point shall be slow enough to permit uniform
settling and compaction of the coke breeze.
7. During the pumping operation, the pipe shall be pulled out of the slurry at a rate that
prevents excessive backpressure on the pump.
8. Excessive agitation of in-place coke breeze indicated by excess coke breeze being
carried to top of the hole is prohibited.
9. An electrical test shall be used to confirm that the anodes are being covered with coke
breeze.
10. If the top anode is within 7.6 m (25 ft.) of the bottom of the casing, the top of the coke
breeze column shall be a minimum of 3 m (10 ft.) above the top anode and a minimum
of 1.5 m (5 ft.) above the bottom of the casing.
a. If the top anode is placed more than 7.6 m (25 ft.) below the bottom of the casing,
b. the top of the coke breeze column shall be a minimum of 4.6 m (15 ft.) above the
top anode.
11. The anode hole, above the coke breeze column, shall be filled with pea gravel to within
1.5 m (5 ft.) of the bottom of the casing.
12. Height of coke breeze column shall be checked with a gage line a minimum of 12 hours
after the coke breeze is installed. If required, additional coke breeze shall be poured
into the casing to obtain proper column height.
3.6.5.3 Poured coke breeze
1. Coke breeze shall be poured in a manner that precludes soil or other extraneous
material from lodging against the anode or becoming entrapped within the coke breeze.
2. Coke breeze shall be poured after each anode is lowered to its required depth. This
may be done using a large diameter hose that is lowered down to the bottom of the
hole and is retracted as the level of coke backfill rises. The quantity of the backfill
material shall be recorded. The top of the hole shall be backfilled with graded soil or
gravel to prevent cable isolation damage.

September 2011
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3. Resistance measurements shall be taken for each anode during pouring of the coke
breeze to confirm that the coke breeze has covered the anode.
4. If the coke breeze bridges the hole, the next anode may be lowered and used to gently
tap the bridge open.
5. If the top anode is within 7.6 m (25 ft.) of the bottom of the casing, the top of the coke
breeze column shall be a minimum of 3 m (10 ft.) above the top anode and a minimum
of 1.5 m (5 ft.) above the bottom of the casing.
6. If the top anode is placed more than 7.6 m (25 ft.) below the bottom of the casing, the
top of the coke breeze column shall be a minimum of 4.6 m (15 ft.) above the top
anode.
7. The anode hole, above the coke breeze column, shall be filled with pea gravel to within
1.5 m (5 ft.) of the bottom of the casing.
8. Height of coke breeze column shall be checked with a gage line a minimum of 12 hours
after the coke breeze is installed. If required, additional coke breeze shall be poured
into the casing to obtain proper column height.
3.6.5.4 Bentonite plug
1. After the coke breeze column has been adjusted, a bentonite plug shall be installed
above the coke breeze to provide an environmental seal.
2. Bentonite shall be AquaPlug™ or PermaPlug™ as supplied by Corrpro or Principal-
approved equal.
3. If the top of the coke breeze column is 1.5 m (5 ft.) above the bottom of the casing, a
1.5 m (5 ft.) minimum bentonite plug shall be installed above the top of the coke
breeze.
4. If the coke breeze is covered with pea gravel to within 1.5 m (5 ft.) of the bottom of the
casing, a 3 m (10 ft.) minimum bentonite plug shall be installed above the pea gravel.
3.7 INSTALLATION OF CABLES

3.7.1 Digging of cable trench
Prior to digging the cable trench, drawings and maps shall be reviewed and trench route
shall be surveyed with pipe and cable locators to determine location of underground piping,
cables, or other objects. The following requirements apply:
1. Location of underground objects crossing the trench shall be flagged and dug out by
hand.
2. Unless otherwise specified, the Installation Contractor shall notify the Principal prior to
crossing a foreign pipeline or cable.
3. Trench shall conform to the requirements of the location and this DEP.
4. Trench shall be dug to allow a minimum clearance of 0.3 m (1 ft.) between the cable
and other buried structures.
5. Unless otherwise specified, depth of trench shall be 0.6 m (2 ft.).
6. Trench shall be free of objects that may damage the cable such as sharp rocks.
3.7.2 Laying of cable
3.7.2.1 General
Unless otherwise specified, cable “moles”, or other mechanical laying devices, shall not be
used.
3.7.2.2 AC cable
Unless otherwise specified, laying of AC cable from the disconnect switch (breaker) to the
rectifier shall be the responsibility of the Contractor installing the rectifier.

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3.7.2.3 DC cable
1. DC cable shall be installed so that it is not twisted and with sufficient slack to allow for
future shifting of the soil.
2. Cables installed underground shall be suitable for direct burial. The cable between the
rectifier and the junction box may be installed in conduit.
3. If required by local plant regulations, the cable conduit shall be encased in concrete.
4. Cable shall be inspected to ensure that it is free of cuts, nicks, gouges, and other
defects.
5. Direct-buried cable shall have a plastic warning tape installed directly above the cable
300 mm (12 in.) below grade.
a. Tape shall extend throughout the length of the direct-buried cable.
b. Tape shall be yellow, 75 mm (3 in.) wide, and shall be labelled “Cathodic Protection
Cable Buried Below.”
6. Above ground cables shall be installed in conduit as directed by the Principal, in
accordance to API RP500. Conduit shall be free of burrs or other foreign material.
7. Cathodic protection cables shall be handled and laid with extreme care as damage to
the insulation and/or sheathing may result in premature cable failure. During installation
the cable reel shall be supported so that cable can be pulled from the reel without
causing kinking or twisting.
8. The cable type and size shall be checked for compliance with the design. Underground
cables shall be identified by color or tags.
9. Header cables shall be installed at the specified depth in sand padding. Cable warning
tape and/or cable tiles shall be used.
10. A cable run shall be of one continuous length. Joints shall not be acceptable except
with the written permission of the Principal.
11. When allowed, cable joints shall be made using an approved splice and seal, using
splice encapsulation kits. The joints shall be sealed to prevent moisture penetration and
ensure electrical isolation from the environment. Submerged joints require seals
suitable for the water pressures and environment to which they can be subjected.
12. Any damage to the insulation or sheathing of all cables, including anode connection
cables, shall be reported to the Principal.
3.8 SYSTEM REQUIREMENTS AT GRADE

3.8.1 Casing
1. Holes shall be drilled in the casing at the top to accommodate anode cables and the
cable tie-off bar.
2. The casing shall have a cap with a 38 mm (1½ in.) hole for the vent pipe.
3. Holes for tie-off bar and anode cables shall be sealed with electrical duct seal, or equal,
prior to grouting.
4. The area outside the casing holes shall be sealed with cement grout to prevent entry of
surface water.
3.8.2 Anode cable tie-off
1. Anode cables shall be tied-off using a temporary tie-off bar as near the top of the
casing as possible. Refer to DEP Standard Drawing 41.017.
2. Tie-off bar shall be a nominal DN 50 (NPS 2) fibreglass-reinforced Schedule 80 pipe or
a DN 50 (NPS 2) steel pipe with a polyethylene outer sleeve.

September 2011
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3. Anode cables shall be bundled, neatly nested, and covered for approximately
0.6 m (2 ft.) with plastic electrician’s tape. This covered section of cables shall be
looped around the tie-off bar.
4. Below the tie-off bar, the anode cables shall be bundled, neatly nested, and covered for
approximately 150 mm (6 in.) with three layers of glass reinforced filament tape. End of
tape shall be multiple half-hitched for long time security.
5. Cable loop and cable slack shall be pushed into the top of the casing and secured by
inserting the tie-off bar through casing holes and cable loop.
6. Anode cables shall have enough slack inside the casing to allow settlement of the coke
breeze.
3.8.3 Concrete pad
1. Unless otherwise specified, the concrete pad shall conform to DEP Standard Drawing
41.017.
2. Outside ends of cable and tie-off bar shall be positioned near the center of the concrete
pad, approximately 75 mm (3 in.) below the concrete pad surface.
3.8.4 Vent pipe
1. Juncture of the vent pipe through the casing cap shall be sealed with a rubber grommet
to obtain a water-tight seal.
2. Vent pipe shall extend to a sufficient height above the casing cap to prevent intrusion of
liquids. For anode beds inside tank dikes, the vent pipe shall include a horizontal
clapper type check valve as shown in DEP Standard Drawing 41.017.
3. End of vent pipe shall have a screw-on PVC cap or a plastic screen.
a. PVC cap shall have four 1.5 mm (1/16 in.) drilled holes.
b. Screen shall be attached to the vent pipe with a stainless steel gear hose clamp.
Screen shall have openings of 1.5 mm (1/16 in.) or smaller.
3.8.5 Shunt box
1. Unless otherwise specified, anode bed shall have an aboveground shunt box.
2. The shunt box shall conform to DEP Standard Drawing 41.018 or 41.019.
3. The underground shunt box may be used around roads and high traffic areas.
4. The underground shunt box shall be properly sealed with a plumber’s plug or similar
device to prevent subsurface contamination.
5. Each anode cable within the shunt box shall be tagged with a unique number or code
showing at what depth the anode was set at.
3.9 INSPECTION AND TESTING

3.9.1 Visual inspection
1. Anodes, anode lead wires and cables shall be visually inspected prior to installation.
2. Anode lead wires and cable shall be free of breaks, kinks and insulation flaws.
3.9.2 Destructive testing
At the request of the Principal, an anode shall be cut open to allow inspection of the lead
cable connection to the anode core. Cost of the anode shall be borne by the Principal.
3.9.3 Electrical inspection
1. At the request of the Principal, all positive circuit cable, including anode lead cables,
shall be subjected to an electrical inspection of the insulation.

September 2011
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2. Inspection voltage shall be 150 volts per mil (0.001 inch or 0.025 mm) of insulation
thickness for dry inspection and 70 volts per mil of insulation thickness for wet sponge
inspection.
3.10 ENERGIZING THE SYSTEM

3.10.1 General
1. The system shall be energized and tested as specified below.
2. Adequate level of corrosion protection shall be determined in accordance with NACE
SP0169.
3.10.2 Pre-Energizing requirements
1. All temporary cathodic protection, bonds with foreign structures, and grounding facilities
that could affect CP, shall be disconnected.
2. If sacrificial anodes are installed on the carrier pipe or a related casing, they shall be
disconnected to allow the natural potential of the carrier pipe and the open circuit
potential of the anodes to be measured.
3. Prior to energizing the deep anode bed system, native structure-to-soil potentials for
the structure(s) to be protected, and any other structure in the vicinity that may be
affected by the deep anode bed system, shall be recorded at designated test points.
4. Recorded potentials shall be submitted to the Principal.
3.10.3 Energizing
1. System shall initially be energized on low tap settings to verify/determine the following:
a. Rectifier(s), shunt boxes, and cables are operational.
b. Polarity of the cables is correct.
c. Interference from stray currents is not present.
d. Requirement for any remedial measures such as installation of additional test
stations.
2. After initial energizing, the rectifier shall be set at an operating output as instructed by
the Principal. Individual anode outputs shall be measured and recorded. If resistors
have been provided in individual anode circuits, the outputs of the anodes shall be
balanced within the design capacity. Resultant voltage and current outputs shall be
recorded.
3. If more than one structure is protected by the same power source, the current to each
structure shall be adjusted by changing the resistor value in each drain cable.
4. After polarization is complete, structure-to-soil ON/OFF potentials shall be measured at
all test facilities. The measurements shall be carried out by interrupting the power
source at a duration cycle as instructed by the Principal. The permissible duration of
the interruption depends on the rate of depolarization, which is determined by local
conditions.
NOTE For uncoated structures and for structures with aged coatings, full polarization may require from
several days up to several months. For these structures, interruption cycles shall not be more than one
second per minute.
5. If grounding facilities/polarization cells have been installed to mitigate induced AC

voltages, AC potentials shall be recorded prior to, and after, the connection of the
grounding.
6. The insulating effectiveness of isolating joints and isolating flanges shall be checked in
accordance with the procedure in (13).
connected and the potential of the carrier pipe and the current output of the sacrificial

September 2011
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anode shall be measured and recorded. The current measurement shall be done
performed using a shunt.
8. Interference testing on all foreign structures/pipelines crossing or in close proximity to
the object shall be carried out. If bonds exist, adjustments shall be made to the resistive
bonds so that interference between the structures/pipelines remains within acceptable
limits.
9. If automatic potential controlled power sources are used, ON/OFF potential
measurements shall be performed with the potential control circuit switched off and the
unit adjusted manually to the required potential. Once testing is complete, the potential
setting shall be adjusted to the required drain point potential and the potential control
switched on.
10. If voltage and/or current limiting circuits have been installed, the settings of these
circuits shall be adjusted to a value approximately 10% higher than the recorded
voltage and current output. Such a setting prevents overprotection in case of failure of
the potential control circuit, while allowing sufficient swing in case of a change in
current demand.
3.11 SYSTEM DATA

3.11.1 General
The following data shall be prepared for the deep anode bed system:
1. Material list that contains:
a. Size, type, and number of anodes.
b. Type and amount of coke breeze.
c. Size, type, and length of positive and negative cables.
2. Preliminary hydrogeology profile.
3. Installation log that contains:
a. Drilling log with types of soil and approximate depth.
b. Anode resistance log.
c. Anode current output log.
d. Anode depth log.
3.11.2 Manual
A manual shall be prepared for the deep anode bed system. Manual shall contain:
1. Location of the system.
2. Rectifier data.
3. Inspection, testing, and energizing data.
3.11.3 Plot plan
A plot plan of the as-built deep anode bed system shall be prepared. Plot plan shall show:
1. Exact location of the various components of the system including rectifiers, ground
beds, bond boxes, cross bonds, test points and insulating devices with reference to the
structures being protected.
2. Foreign flanges and foreign lines in the protected area.

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4. INSTALLATION OF IMPRESSED CURRENT SURFACE ANODE BED SYSTEMS

1. Installation of surface anode beds shall be conducted by a company that has been
engaged in the installation of surface anode beds for a period of no less than five
years.
2. Anode bed systems shall be installed in accordance with applicable government
regulations, local requirements, NACE SP0169 and this DEP.
3. Electrical portion of the anode bed systems shall be installed in accordance with
4.1.2 Personnel qualifications
1. Personnel engaged in installing cathodic protection surface anode beds shall be
qualified by education, training, and experience to fulfill requirements of this DEP.
2. Documentation of qualifications shall be available upon request.
1. Equipment, tools, and materials used to install surface anode beds shall be proper and
adequate for the job.
2. Equipment and tools shall be maintained in a manner that ensures their safe use.
1. Manufacturer’s technical literature shall be provided for each item required by this DEP.
3. If more than one item or catalog number appears on the technical literature, the
work.
4.1.6 Drawings
Installation Contractor shall provide as-built drawings with details of the cathodic protection
system installation. Details shall include types, locations, and number of anodes and
details of the connections to electric power, rectifier, and protected structures.
4.1.7 Permits
4.1.8 Safety
1. Installation Contractor shall be familiar with applicable government regulations and
Shell safety guidelines and requirements and shall adhere to them.
2. Location of third-party structure locations shall be performed before any excavation by

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4.2 MATERIALS
4.2.1 Anodes
Type, size, and number of anodes shall conform to (Appendix 5).
4.2.2 Lead cable
Lead cable type, size, and length shall conform to (Appendix 5). Also, the lead cable shall
be continuous from the anode to the shunt box without splices.
4.2.3 Positive header and negative cables
1. Positive header and negative cable shall be AWG stranded copper conductor with
HMWPE, Kynar® or Halar® insulation (or Principal-approved equivalent) and of
adequate size to carry the current from the entire anode bed.
2. Type, size, and length of cable shall conform to (Appendix 5).
4.2.4 Coke breeze
Type and quantity of coke breeze shall conform to (Appendix 5).
4.2.5 Junction box
Junction box shall conform to (Appendix 5).
4.2.6 Electrical connection
1. Unless otherwise specified, electrical connection of the negative cable to the structure
shall be made by Thermite welding.
2. Materials required for Thermite welding and coating of the welds shall conform to
(11.3).
4.2.7 Warning tape
Warning tape shall be yellow, 75 mm (3 in.) wide, and shall be labelled “Cathodic Protection
4.3 INSTALLATION OF ANODE BED

All installation requirements in this DEP shall be followed. (Appendix 9) includes a checklist
for impressed current surface groundbed installation.
4.3.1 Excavation of cable trenches
1. Prior to excavation of cable trenches, drawings and maps shall be reviewed and trench
route shall be surveyed with pipe and cable locators to determine location of
underground piping, cables, or other objects.
2. Location of underground objects crossing the trenches shall be flagged and dug out by
hand.
3. Trenches shall conform to the requirements of the location and this DEP.
4. Trenches shall be excavated to allow a minimum clearance of 300 mm (12 in.) between
the cable and other buried structures.
5. Unless otherwise specified, depth of trenches shall be 0.6 m (2 ft.)
6. Trenches shall be free of objects that may damage the cable such as sharp rocks.
7. Unless otherwise specified, required notifications prior to crossing a foreign pipeline or
cable are not the responsibility of the Installation Contractor.
8. If an unknown pipeline or cable is encountered, the Principal shall be notified
immediately.

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4.3.2 Installation of cable

4.3.2.1 General
Unless otherwise specified, cable “moles”, or other mechanical laying devices, shall not be
used.
4.3.2.2 AC cable
Unless otherwise specified, laying of AC cable from the disconnect switch (breaker) to the
rectifier shall be the responsibility of the Contractor installing the rectifier.
4.3.2.3 DC cable
1. DC cable shall be installed so that it is not twisted and with sufficient slack to allow for
future shifting of the soil.
2. Cables installed underground shall be suitable for direct burial. The cable between the
rectifier and the junction box may be installed in conduit.
3. If required by local plant regulations, the cable conduit shall be encased in concrete.
4. Cable shall be inspected to ensure that it is free of cuts, nicks, gouges, and other
defects.
5. Direct-buried cable shall have a plastic warning tape installed directly above the cable,
b. Tape shall be yellow, 75 mm (3 in.) wide, and shall be labelled “Cathodic
Protection Cable Buried Below.”
6. Above-ground cables shall be installed in conduit as directed by the Principal, in
accordance to API RP500. Conduit shall be free of burrs or other foreign material.
7. Header cables shall be laid in the trench in a layer of soft sand in order to mitigate
possible damage to insulation during backfill. To mitigate possible damage due to the
acidic environment in the vicinity of active anodes, header cables shall not be laid
above anodes.
8. If a central distribution box is used, the anode cable tails shall be terminated in the
distribution box, numbered sequentially, and shown on corresponding as-built
drawings.
9. Cable warning tape or cable protection tiles shall be used. Sufficient slack shall exist in
the anode cables to avoid strain.
10. On completion of the groundbed the resistivity of the groundbed and, if possible, the
individual anodes shall be measured to remote earth using a low resistance earth
Megger. If the groundbed resistivity is outside usable limits for operation within the
design parameters, the Principal and the Contractor shall investigate the cause and
take remedial actions.
11. Cable connections to the rectifier from both the anodes and the structure shall be
mechanically secure and electrically conductive. Before the power source is energized,
verification should be made that (1) the negative [-] conductor is connected to the
structure to be protected, and (2) the positive [+] conductor is connected to the anodes,
and (3) the system is free of short circuits.
12. The location of the groundbed shall be indicated by groundbed marker posts located at
both extremities of the groundbed.
the cable reel shall be supported so that cable may be pulled from the reel without

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15. The cables shall be installed at the specified depth in sand padding. Cable warning
4.3.3 Anode holes/trenches
4.3.3.1 Vertical holes
1. Unless otherwise specified, anodes shall be installed in vertical holes and have a
diameter and depth according to the project specification. Vertical holes shall conform
to Detail “A” in DEP Standard Drawing 41.012.
2. Holes shall be excavated so that they have a straight and uniform wall without cavities.
If there is major deformation of the wall, the hole shall be filled and packed with moist
dirt and excavated again.
3. In dry environments, holes shall be excavated with a power auger. Excavation with a
hollow stem auger is permitted only if soil conditions do not allow the use of a power
auger or backfill with coke breeze around the anode is not possible. In which case, pre-
packaged canister anodes shall be used. Holes for canister anodes shall conform to
Detail “B” in DEP Standard Drawing 41.012.
4. In marsh environments or areas in which the permanent water table is above the anode
depth, water jetting may be used. Water jetting shall not be used in dry environments
for installing anodes due to the high shrinkage of the borehole around the anode.
4.3.3.2 Horizontal trenches
1. If vertical holes are impractical, anodes may be installed in horizontal trenches.
2. A proposal for horizontal anode trenches shall be submitted to the Principal for
approval.
3. Trenches shall conform to Detail “C” in DEP Standard Drawing 41.012.
4.3.4 Installation of anodes
4.3.4.1 General
1. Anode hole shall be free of debris and foreign material.
2. Anodes shall be installed in accordance with the following DEP Standard Drawings:
a. 41.010
b. 41.011
c. 41.012
d. 41.014
e. 41.015
3. Depth of anodes shall conform to (Appendix 5).
4. If holes are excavated with a hollow stem auger, anodes shall be pre-packaged with
coke breeze in metal canisters. Native backfill shall be installed in 150 mm (6 in.) lifts.

September 2011
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Each lift shall be tamped to ensure full contact between the pre-packaged anode and
soil. Refer to Detail “B” in DEP Standard Drawing 41.012.
5. Anodes and associated components shall be subject to inspection prior to installation.
Damaged and/or defective components shall be rejected.
6. Unless otherwise specified, anodes installed in an operating unit shall be located a
minimum of 1.8 m (6 ft.) away from all structures. Exceptions to this requirement shall
be submitted to the Principal for approval.
4.3.4.2 Lead cables
1. Lead cables shall be of sufficient length to reach the anode shunt box terminals without
splices. Cables shall be checked for proper length prior to installation of anodes.
2. Lead cables shall not be twisted or damaged during installation. If a cable is damaged,
the entire cable, including the connection to the anode, shall be replaced. Splicing or
patching of cables is prohibited.
3. Each anode cable shall be tagged with a unique number or code showing at what
depth the anode was set at. This identification shall also be made within the anode
shunt box.
4. Anodes shall not be handled, lifted, or lowered using the anode cable, unless
specifically allowed by the Manufacturer in the installation instructions, e.g., stringed
anodes.
5. The location of the groundbed shall be indicated, e.g., by groundbed marker posts
located at both extremities of the groundbed.
the cable reel shall be supported so that cable may be pulled from the reel without
4.3.5 Installation of coke breeze
1. Vertical anode holes shall be completely backfilled with coke breeze to depth of the
cable trench.
2. Unless otherwise specified, coal coke breeze shall be used. Refer to (Appendix 5).
Petroleum coke breeze shall be used in canister anode assemblies.
3. Coke breeze shall be installed by pouring,
4. Coke breeze clean and free of rocks, dirt, and other foreign material.
5. Coke breeze installed in 150 mm (6 in.) lifts. Each lift shall be tamped to ensure full
contact between the anode, soil, and coke breeze.
6. Tamping of coke breeze shall be carried out with a tamping tool of proper size.

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7. Anode hole above coke breeze column may be filled with native soil, washed gravel, or
crushed stone.
4.4 INSTALLATION OF ANODE SHUNT BOXES

1. Shunts and their cable connections shall be housed in a shunt box and installed in
accordance with DEP Standard Drawing 41.013.
2. Unless otherwise specified, each anode shall have a current measuring shunt.
3. Each positive cable from the anode shunt boxes shall terminate in a positive junction
box as shown in DEP Standard Drawing 41.009.
4. A single positive cable shall be installed from the positive junction box to the rectifier.
5. Each anode cable within the shunt box shall be tagged with a unique number or code
showing at what depth the anode was set.
4.5 INSTALLATION OF RECTIFIERS

4.5.1 Air-cooled, pole-mounted
Air-cooled, pole-mounted rectifiers shall be installed in accordance with (9).
4.5.2 Oil-immersed, pad-mounted
Oil-immersed, pad-mounted rectifiers shall be installed in accordance with (10).

4.6.1 General
1. Principal retains the right to inspect equipment and materials prior to, and during,
installation.
2. Determination of deficiencies in the installation of anodes shall be made by the
Principal.
3. Installation Contractor shall correct all deficiencies in the anode installations.
1. Anodes, anode lead wires and cables shall be visually inspected prior to installation.
2. Anode lead wires and cable shall be free of breaks, kinks, and insulation flaws.
At the request of the Principal, an anode shall be cut open to allow inspection of the lead
cable connection to the anode core. Cost of the anode shall be borne by the Principal.
1. At the request of the Principal, all positive circuit cable, including anode lead cables,
shall be subjected to an electrical inspection of the insulation.
inspection.
4.7 ENERGIZING THE SYSTEM

4.7.1 General
1. If required by the Principal, the system shall be energized and tested as specified in
this DEP.
2. Adequate level of corrosion protection shall be determined in accordance with
NACE SP0169 and SP0572.

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4.7.2 Pre-energizing requirements

1. All temporary cathodic protection, bonds with foreign structures, and grounding facilities
that could affect CP, shall be disconnected.
disconnected to allow the natural potential of the carrier pipe and the open circuit
potential of the anodes to be measured.
3. Prior to energizing the deep anode bed system, native structure-to-soil potentials for
the structure(s) to be protected, and any other structure in the vicinity that may be
affected by the deep anode bed system, shall be recorded at designated test points.
4. Recorded potentials shall be submitted to the Principal.
4.7.3 Energizing
1. The system shall initially be energized on low tap settings to verify/determine the
following:
a. Rectifier(s), shunt boxes, and cables are operational.
d. Requirement for any remedial measures such as installation of additional test
stations.
2. After initial energizing, the rectifier shall be set at an operating output as instructed by
the Principal. Individual anode outputs shall be measured and recorded. If resistors
have been provided in individual anode circuits, the outputs of the anodes shall be
balanced within the design capacity. Resultant voltage and current outputs shall be
recorded.
3. If more than one structure is protected by the same power source, the current to each
structure shall be adjusted by changing the resistor value in each drain cable.
4. After polarisation is complete, structure-to-soil ON/OFF potentials shall be measured at
all test facilities. The measurements shall be carried out by interrupting the power
source at a duration cycle as instructed by the Principal. The permissible duration of
the interruption depends on the rate of depolarisation, which is determined by local
conditions.
NOTE: For uncoated structures and for structures with aged coatings, full polarisation may require from
several days up to several months. Where highly resistive soil environments exist, as in sand,
interruption cycles shall not be more than one second per minute.
5. If grounding facilities/polarisation cells have been installed to mitigate induced AC

voltages, AC potentials shall be recorded prior to, and after, the connection of the
grounding.
6. The insulating effectiveness of isolating joints and isolating flanges shall be checked in
accordance with the procedure in (13).
connected and the potential of the carrier pipe and the current output of the sacrificial
anode shall be measured and recorded. The current measurement shall be done
performed using a shunt.
8. Interference testing on all foreign structures/pipelines crossing or in close proximity to
the object shall be carried out. If bonds exist, adjustments shall be made to the resistive
bonds so that interference between the structures/pipelines remains within acceptable
limits.
9. If automatic potential controlled power sources are used, ON/OFF potential
measurements shall be performed with the potential control circuit switched off and the
unit adjusted manually to the required potential. Once testing is complete, the potential

September 2011
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setting shall be adjusted to the required drain point potential and the potential control
switched on.
10. If voltage and/or current limiting circuits have been installed, the settings of these
circuits shall be adjusted to a value approximately 10% higher than the recorded
voltage and current output. Such a setting prevents overprotection in case of failure of
the potential control circuit, while allowing sufficient swing in case of a change in
current demand.
4.8 DATA AND DOCUMENTATION

4.8.1 General
1. A material list shall be prepared for the anode bed system using form in (Appendix 2).
2. The material list shall contain the following:
a. Size, type, and number of anodes.
b. Type and amount of coke breeze.
c. Size, type, and length of positive and negative cables.
d. Size, type, and number of shunt and junction boxes.
e. Current output from each of the anodes.
4.8.2 Manual
1. A manual shall be prepared for the anode bed system.
2. Manual shall contain:
a. Location of the system.
b. Rectifier data.
c. Inspection, testing, and energizing data.
4.8.3 Plot plan
1. A plot plan of the as-built anode bed system shall be prepared.
2. The plot plan shall show:
a. Exact location of the various components of the system including rectifiers, ground
beds, bond boxes, cross bonds, test points and insulating devices with reference to
the structures being protected.
b. Foreign lines and foreign flanges in the protected area.

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5. INSTALLATION OF HORIZONTAL IMPRESSED CURRENT ANODE SYSTEMS FOR

NEW AND REPLACEMENT TANK BOTTOMS

1. Cathodic protection systems shall be installed by a Contractor that has been engaged
in this type of work for a period of not less than five years. Documentation of Contractor
qualifications shall be available upon request.
2. Cathodic protection systems shall be installed under the supervision of a NACE-
certified cathodic protection or corrosion specialist.
3. Electrical portion of the cathodic protection systems shall be installed in accordance
with applicable local codes, the National Electrical Code, and API RP500.
4. Cathodic protection systems shall be installed in accordance with NACE SP0169 and
RP0193 and API RP 651.
qualified by education, training, and experience to fulfill the requirements of this DEP.
work.
5.1.6 Drawings
system installation. Details shall include types, models, and locations of the rectifiers,
anodes, junction boxes, cables, and connections to tanks.
5.1.7 Permits
5.1.8 Safety

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5.2 MATERIALS
5.2.1 General
Polyvinyl chloride (PVC) pipe and pipe fittings shall conform to NEMA TC2.
5.2.2 Anodes
1. Anodes shall be titanium wire that conforms to ASTM B 265, Grade I.
2. Wire shall be 1.6 mm (0.062 in.) diameter, coated with iridium based TIR 2000 mixed
metal oxide, as supplied by Corrpro Companies, Inc. or approved equal.
5.2.3 Anode pipe
1. Anode pipe shall conform to NEMA TC2.
2. Anode pipe shall be polyvinyl chloride (PVC) schedule 80, nominal DN 100 (NPS 4)
diameter belled end pipe.
3. Joints of pipe shall have one end with male threads and one end with female threads.
4. Threaded ends shall be manufactured so that made-up joints have a flush outside
surface. Slots on pipe shall conform to DEP Standard Drawing 41.032.
5.2.4 Anode vent pipe
Anode vent pipe shall be slotted PVC schedule 40, nominal DN 20 (NPS ¾) diameter.
5.2.5 Monitoring pipe
1. Monitoring pipe shall be slotted PVC schedule 80, nominal DN 65 (NPS 2-½) diameter,
with modified acme threaded joints.
2. Slots on pipe shall conform to DEP Standard Drawing 41.067.
Threaded ends shall be manufactured so that made-up joints have a flush outside
surface.
5.2.6 Pipe fittings
1. Pipe fittings shall be PVC.
2. Exposed ends of the anode and monitoring pipes shall have PVC caps.
3. If specified for visual leak detection, PVC caps on the monitoring pipe shall have 6 mm
(¼ in.) diameter holes drilled at the 12 and 6 o’clock positions.
5.2.7 Cables
Anode header cable shall be #8 AWG stranded copper conductor with Duralar®/Halar®
insulation or Principal-approved equivalent.
5.2.8 Junction boxes
1. Junction boxes shall be made of aluminum, galvanized steel, or reinforced plastic,
2. Junction boxes shall conform to NEMA 4X requirements, and
3. Junction boxes shall have wire terminals to accommodate the following:
a. Lead wire for corrosion coupon or probe with cathodic protection.
b. Lead wire for corrosion coupon or probe without cathodic protection.
c. Reference electrodes lead wires.
d. Tank lead wire.
5.2.9 Permanent reference electrodes
1. Permanent reference electrodes shall be zinc or copper/copper sulphate, as indicated
on the project drawings.

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2. Zinc electrodes shall be 35 mm x 35 mm x 230 mm (1.4 in. x 1.4 in. x 9 in.), pre-
packaged in quick wetting backfill.
a. Zinc alloy shall conform to ASTM B-418-80, Type II.
b. Electrodes shall be Cathodic Protection Services Model AZR5AC or Principal-
approved equivalent.
3. Copper/copper sulfate electrodes shall:
a. have a design life of 30 years and a stability of ±5 millivolts under a 3.0 microamp
load.
b. have an ion trap to prevent contamination
c. be shipped in a cloth sack with special backfill.
d. be Electrochemical Devices, Inc. Model UL-CUG-LW or Principal-approved
equivalent.
4. Permanent reference electrodes shall be equipped with a number 14 AWG, standard
copper lead wire with red high molecular weight polyethylene insulation.
5. Lead wires shall be of sufficient length to extend to the junction box without splicing.
5.2.10 Coupons
1. Coupons shall be bare, cold-rolled steel with a surface area of 865 mm² (1.34 sq. in.)
and have two No. 12 AWG stranded wires.
a. Wires shall be silver soldered.
b. Wires shall be of sufficient length to extend to the junction box without splicing.
2. Coupons shall be M. C. Miller Co.® IR-Free Coupon, Model No. COU100 or Principal-
5.3 INSTALLATION
5.3.1 General
1. Anode system shall not be installed until after the tank ring wall foundation has been
constructed.
2. If the tank is to have secondary containment, the anode system shall not be installed
until the secondary containment liner and a compacted single lift of sand is in place
3. If the tank is to have double bottom, the anode system shall not be installed until the
HDPE liner is installed and 25 mm (1 in.) of sand is placed on the liner.
4. General system configuration of the anode system shall conform to DEP Standard
Drawing 41.071.
5.3.2 Ringwall penetration
1. The ringwall shall be core drilled for access to the soil directly below the tank bottom.
2. The drilled core hole shall be of adequate size for the anode system piping.
5.3.3 Assembly of PVC pipes
1. All PVC pipe joints except end caps and threaded joints shall be glued with
commercially available cement.
2. Joints to be glued shall be first cleaned with a commercially available solvent cleaner.
3. Cement shall not be applied until cleaner has dried.
5.3.4 Anode and monitoring pipes
1. Anode and monitoring pipes shall be installed as shown on DEP Standard
Drawing 41.071.

September 2011
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2. Anode pipe installed under the tank within the ring wall shall be one continuous length
of pipe.
3. Anode pipe that extends from the inside of the ring wall or rim to the termination point
shall be solid (no slots).
4. Monitoring pipe installed under the tank shall be one continuous length of pipe.
5. Monitoring pipe that extends from the inside of the ring wall or rim to the termination
point shall be solid (no slots).
6. After the anode and monitoring pipes are installed, the annular space between the
pipes and the ringwall shall be epoxy grouted to produce a liquid-tight seal.
5.3.5 Anode assemblies
1. Anodes and associated lead cables, anode centralizers, and vent pipe shall be installed
inside the anode pipe as an assembly.
2. Anode assembly shall be made by clamping the centralizers to the vent pipe at 2.1 m
(7 ft.) to 2.4 m (8 ft.) intervals.
3. Vent pipe shall be long enough to extend along the entire length of the anode wire.
4. Centralizers shall consist of rigid metallic frames, 230 mm (9 in.) to 300 mm (12 in.)
long. Centralizers shall be designed so that there is an annular clearance between the
centralizers and the inside of the anode pipe of approximately 3 mm (1/8 in.).
5. Anode assembly shall be pulled into the anode pipe with a rope. Pulling operation shall
be done in a manner that does not damage the anode assembly. Anodes shall be
positioned as shown on DEP Standard Drawing 41.032.
6. A flexible tremie pipe to be used for installation of the coke breeze shall be fed with the
anode assembly.
7. Centralizers shall keep the anode centered in the anode pipe during anode installation
and pumping of coke breeze. Refer to DEP Standard Drawing 41.032.
8. Anode lead cable shall be continuous (no splices) from the anode assembly to the main
header cable.
9. Anode header cable shall be connected to the anode using a copper crimp.
Connection shall be epoxy sealed.
5.3.6 Coke breeze
1. Backfill installed in the anode pipe shall be calcined-petroleum coke with the following
composition:
Moisture 0.05%
Volatiles 0.7% max
Ash 0.6% max
Carbon Remainder
Bulk Density 1185 kg/m3 (74 lbs/ft3)
2. Coke breeze shall be installed in a slurry form.

3. After the anode assemblies are in place, the coke breeze slurry shall be pumped into
the anode tube using the tremie pipe.
4. Tremie pipe shall be pulled back slowly as the coke breeze is pumped into the anode
tube. This minimizes the possibility of voids in the anode tube.

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5.3.7 Cable termination

1. Anode lead cables shall be spliced to the header cable and the header cable shall be
run to the rectifier as shown on the project drawings.
2. Negative cable shall be connected to the tank in accordance with (11.3).
1. Permanent reference electrodes shall be installed in accordance with the drawings.
2. Electrodes shall be installed with the following procedure:
a. Soak the cloth sack containing the electrode in a container of water for 15 to 20
minutes.
b. Dig a hole in the sand for placement of the electrode.
c. Place the electrode in the hole.
d. Backfill the hole with sand. Compact the sand around the electrode by hand.
e. Route the electrode lead wires to the conduit penetration in the ring wall.
5.3.9 Coupons
1. Coupons shall be polished to remove all corrosion before the coupons are inserted.
2. Edges of coupons shall be sealed so that their sides and back do not contact the soil.
3. Coupons shall be electrically isolated from each other.
4. Coupons shall be installed:
a. 50 mm (2 in.) below the surface of the compacted sand pad with the carbon steel
element facing down.
b. As close as possible to the center of the tank.
c. With the aid of a PVC push pipe.
5. Coupon lead cables shall be routed to the junction box and one lead cable shall be
connected to one of the tank test wires.
6. Coupons to be bonded to the tank will be designated by the Principal. Coupons shall
be bonded using a connector as shown in the drawings.
5.3.10 Junction box
1. All reference electrode, coupon, and tank leads shall be terminated in the junction box.
2. Junction box shall be mounted near the ring wall.
3. Lead cables shall be terminated on the numbered, insulated terminal block.
Identification number for each electrode and each coupon shall be recorded on the as-
built drawing.
4. If a metallic junction box is used, a ground conductor shall be connected between a
tank ground connection and the ground lug in the junction box.
5.3.11 Backfilling
1. Backfilling operation within the ring wall shall be performed by the Tank Construction
Contractor.
2. It shall be conducted in a manner that avoids damage to the anode system.
3. Backfilling operation shall be suspended if damage to the anode system is indicated by
tests. See (5.4.3).

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5.4 INSPECTION
5.4.1 General
1. Equipment and materials used for the cathodic protection system are subject to
inspection and acceptance by the Principal.
2. Unless otherwise specified, installation work shall be inspected by the Principal.
1. Anodes, reference electrodes, and cables shall be visually inspected prior to
installation.
2. Wire and cable shall be free of breaks, kinks, and insulation flaws.
5.4.3 Resistance/potential considerations
1. Resistance and/or potential of the anode system shall be monitored during backfill
operations.
2. Abrupt increases/changes in resistance/potential may indicate damage to the system
components.
3. Backfilling shall cease for investigation/repair.
5.4.4 Installation deficiencies
1. Determination of system deficiencies shall be made by the Principal.
2. Deficiencies shall be corrected by the Installation Contractor.
5.5 COMMISSIONING
1. The cathodic protection system shall be commissioned with the following procedure:
a. Ensure that access pipes are free of obstructions.
b. Record native potential measurements at eight points around the tank shell and on
1.5 m (5 ft.) centers within the monitoring pipe installed under the tank.
c. Energize rectifiers on low tap settings to verify/determine the following:
- Rectifier, shunt boxes, and other components are operational
- Polarity of the cables is correct
- Interference from stray currents is not present
- Requirement for any remedial measures
d. Adjust rectifier output as necessary and record potential measurements.
e. Allow rectifiers to operate continuously for a minimum of seven days.
f. Repeat potential measurements with current applied (on) and interrupted (instant
off). Use an interruption cycle of 30 seconds “on”, 3 seconds “off.”
g. Make adjustments until all points meet the NACE –850 millivolt CSE (copper
sulphate electrode) polarized potential criterion or the 100 millivolt polarization shift
criterion as directed by Shell.
2. A commissioning report along with the as-built drawings shall be submitted to Shell
including all the data gathered, findings and recommendations.

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6. INSTALLATION OF HORIZONTALLY BORED IMPRESSED CURRENT ANODE

SYSTEMS UNDER EXISTING TANKS

1. Cathodic protection systems shall be installed by a Contractor that has been engaged
in this type of work for a period of not less than five years. Documentation of Contractor
qualifications shall be available upon request.
2. Cathodic protection systems shall be installed under the supervision of a NACE-
certified cathodic protection or corrosion specialist.
3. Electrical portion of the cathodic protection systems shall be installed in accordance
with applicable local codes, the National Electrical Code, and API RP500.
4. Cathodic protection systems shall be installed in accordance with NACE SP0169 and
RP0193 and API RP 651.
work.
6.1.6 Drawings
system installation. Details shall include types, models, and locations of the rectifiers,
anodes, junction boxes, cables, and connections to tanks.
6.1.7 Permits
6.1.8 Safety

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6.2 MATERIALS
6.2.1 Anodes
1. Anodes shall be titanium wire that conforms to ASTM B265, Grade I.
2. Wire shall be 1.6 mm (0.062 in.) diameter, coated with iridium based TIR 2000 mixed
metal oxide, as supplied by Corrpro Companies, Inc. or approved equal.
6.2.2 Anode pipe
1. Anode pipe shall conform to NEMA TC2.
2. Anode pipe shall be polyvinyl chloride (PVC), Schedule 80, nominal DN 100 (NPS 4)
diameter belled-end pipe.
surface.
6.2.3 Anode vent pipe
Anode vent pipe shall be slotted PVC, Schedule 40, nominal DN 20 (NPS ¾) diameter.
6.2.4 Monitoring pipe
1. Monitoring pipe shall be slotted PVC, Schedule 80, nominal DN 65 (NPS 2½) diameter,
with modified acme threaded joints.
surface.
6.2.5 Pipe fittings
1. Pipe fittings shall be PVC.
2. Ends of anode and monitoring pipes shall have PVC caps.
3. If specified for visual leak detection, the PVC caps on the monitoring pipe shall have
6 mm (¼ in.) diameter holes drilled at the 12 and 6 o’clock positions.
6.2.6 Cables
Anode header cable shall be #8 AWG stranded copper conductor with Duralar®/Halar®
insulation or Principal-approved equivalent.
6.3 INSTALLATION EQUIPMENT

6.3.1 Boring equipment
1. Boring equipment shall be a directional, horizontal, extended range, fluid-assisted
boring system, suitable for trenchless installation in a variety of soil conditions.
2. Equipment shall not be of the water jet type due to possible wash outs and voids in the
soil under the tank foundation.
3. Equipment shall be capable of being operated from a surface launch position that
eliminates the need for a pit.
4. Equipment shall have an electronic location and wire line transmitter or sonde unit in
the boring tool. Transmitter shall be used to obtain location and guidance information.
Transmitter shall be able to be detected at all times.
6.3.2 Locating equipment
1. Locating equipment shall be a magnetometer/accelerometer guidance wire line type
system. A radio beacon/receiver, "walk over" guidance system is unacceptable.

September 2011
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2. Locating equipment shall be able to be monitored at a display console by the

directional drill operator from the operator workstation.
6.3.3 Computer tracking system
1. Data from the locating equipment shall be fed into a computer tracking system.
2. Computer tracking system shall monitor and display the depth of the tool, length of the
bore, and time of day in real time.
3. Recorded data shall be submitted to Principal on request.
6.3.4 Electrical strike system
1. Boring equipment frame shall be equipped with an electrical strike system.
2. Electrical strike system shall be capable of indicating an electrical strike through both
current and voltage sensing devices. The system shall include warning strobes on both
drill frame and power unit.
3. Grounding mats for both the operator and helper shall be supplied. The mat for helper
shall be positioned so that stepping off the mat is not required while performing his
duties.
4. The electrical strike system shall be connected to the trailer so that the trailer is at the
same potential as the system.
5. Standard safety cones for barricading the job site and three pairs of certified 20kV
boots and gloves shall be available.
6.4 INSTALLATION
6.4.1 Underground utilities
After the position of the anode tube is determined, all underground utilities shall be located
prior to any excavation or boring.
6.4.2 Fluid pit excavation
1. A fluid pit shall be excavated to contain all drilling fluids required for the horizontal
boring.
2. Drilling fluids used shall be environmentally benign.
3. Drilling fluids shall remain on site unless otherwise specified by the Principal.
6.4.3 Ringwall penetration
1. Tank ringwall shall be core drilled for access to the soil directly below the tank bottom.
2. The drilled core hole shall be of adequate size for the anode system piping.
6.4.4 Performing bore
1. Horizontal bore equipment shall be set into place and anchored.
2. The boring process shall include monitoring and logging of the head elevation at all
times to ensure that the bore does not come closer than 0.6 m (2 ft.) from the tank
bottom. The boring process shall be stopped if the elevation of the head cannot be
determined.
3. Boring shall be performed so that no voids are created in the soil foundation.
4. Bore hole shall traverse the entire distance under the tank and exit as shown on the
project drawings.
6.4.5 Assembly of PVC pipes
1. All PVC pipe joints, except end caps and threaded joints, shall be glued with
commercially available cement.
2. Joints to be glued shall be cleaned first with a commercially available solvent cleaner.

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3. Cement shall not be applied until cleaner has dried.

6.4.6 Anode and monitoring pipes
1. Anode and monitoring pipes shall be installed using the boring equipment.
2. Each pipe shall be attached to the drill stem and pulled back through the borehole.
Operator shall continuously monitor the thrust pullback to ensure the pipes are not
damaged during installation.
3. If required, the borehole diameter may be enlarged using a back reamer drill.
4. Anode pipe installed under the tank shall be one continuous length.
5. Anode pipe that extends from the inside of the ring wall or rim to the termination point
shall be solid (no slots). Pipe shall be terminated as shown on DEP Standard Drawing
41.031.
6. Monitoring pipe installed under the tank shall be one continuous length.
7. Monitoring pipe that extends from the inside of the ring wall or rim to the termination
point shall be solid (no slots). Pipe shall be terminated as shown on DEP Standard
Drawing 41.031. After the anode and monitoring pipes are installed, the annular space
between the pipes and the ringwall hole shall be epoxy-grouted to produce a liquid
seal.
6.4.7 Anode assemblies
1. Anodes and associated lead cables, anode centralizers, and vent pipe shall be installed
inside the anode pipe as an assembly.
2. Anode assembly shall be made by clamping the centralizers to the vent pipe at 2.1 m
(7 ft.) to 2.4 m (8 ft.) intervals.
3. Vent pipe shall be long enough to extend along the entire length of the anode wire.
4. Centralizers shall consist of rigid metallic frames, 230 mm (9 in.) to 300 mm (12 in.)
long. Centralizers shall be designed so that there is an annular clearance between the
centralizers and the inside of the anode pipe of approximately 3 mm (1/8 in.).
5. Anode assembly shall be pulled into the anode pipe with a rope. Pulling operation shall
be done in a manner that does not damage the anode assembly. Anodes shall be
positioned as shown on DEP Standard Drawing 41.032.
6. A flexible tremie pipe to be used for installation of the coke breeze shall be fed with the
anode assembly.
7. Centralizers shall keep the anode centered in the anode pipe during anode installation
and pumping of coke breeze. Refer to DEP Standard Drawing 41.032.
8. Anode header cable shall be continuous (no splices) from the anode assembly to the
main system header cable.
9. Anode header cable shall be connected to the anode using a copper crimp.
Connection shall be epoxy sealed.
6.4.8 Cables
1. The location of all groundbed cables shall be indicated e.g., by groundbed marker
posts located at both extremities of the groundbed.

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4. All trenched in cables shall be installed at the specified depth in sand padding. Cable
warning tape and/or cable tiles shall be used.
6.4.9 Coke breeze
1. Backfill installed in the anode pipe shall be calcined petroleum coke with the following
composition:
Moisture 0.05%
Volatiles 0.7% max.
Ash 0.6% max.
Carbon Remainder
Bulk Density 1185 kg/m3 (74 lbs/ft.3)
2. Coke breeze shall be installed in a slurry form.

3. After the anode assemblies are in place, the coke breeze slurry shall be pumped into
the anode tube using the tremie pipe.
4. Tremie pipe shall be pulled back slowly as the coke breeze is pumped into the anode
tube. This minimizes the possibility of voids in the anode tube.
6.4.10 Cable termination
1. Anode header cables shall be spliced to the main header cable. The header cable shall
be run to the rectifier as shown on the project drawings.
2. Negative cable shall be connected to the tank in accordance with (11.3) of this DEP.
6.5 INSPECTION
6.5.1 General
1. Anodes and cables shall be visually inspected prior to installation.
2. Wire and cable shall be free of breaks, kinks and insulation flaws.
1. Determination of deficiencies shall be made by the Principal.
2. Installation deficiencies as determined by the Principal shall be corrected by the
Installation Contractor.
6.6 COMMISSIONING
Impressed current cathodic protection system shall be commissioned with the following
procedure:

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1. Prior to energizing the rectifier, with the tank filled to a minimum of 1.5 m (5 ft.) of water
or product, native state potential measurements between the tank bottom and each
reference electrode shall be measured and recorded. Potential measurements shall be
made using a calibrated voltmeter with minimum 10 megohm input impedance.
2. Ensure that access pipes are free of obstructions.
3. Record native potential measurements at eight points around the tank shell and on
1.5 m (5 ft.) centers within the monitoring tube installed under the tank.
4. Energize rectifiers on low tap settings to verify/determine the following:
a. Rectifier, shunt boxes, and other components are operational.
d. Requirement for any remedial measures.
5. The rectifier output shall then be increased sequentially until design current is supplied
to the tank. Individual power feed circuits will be checked and the rectifier will be
allowed to operate for a minimum of 4 hours before further potential testing is
conducted.
6. After the rectifier has been in continuous operation for a minimum of 4 hours, "On" and
"Instant Off" (polarized) potentials shall be measured at all permanent reference
electrodes and in eight evenly spaced locations around the tank perimeter. An
interruption cycle ratio of no less than 10:1 shall be used.
7. Final adjustments to the system shall be made after sufficient time is allowed for
polarization (minimum of seven days). For ambient temperature tank fluid, the
polarization criteria shall be a potential shift of at least 100 millivolts more negative than
native state potentials or an “Instant Off” (polarized) potential of –0.85 volt vs.
copper/copper sulfate reference electrode. For elevated temperature tank fluid, criteria
shall be provided by Shell.
8. A commissioning report shall be submitted by the Contractor with “As-Built” drawings,
all data, an analysis of the data, and recommendations for operation and maintenance
of the system.
6.7 SUBMITTALS
6.7.1 Proposals
1. Proposals shall provide a lump sum price for performing work as defined in this
specification.
2. A detailed listing of all services and materials to be provided shall be provided.
3. Design calculations shall be provided indicating current density, system design life,
anode spacing, total current required, and the rating of the rectifier to be provided.
4. Any exceptions to this specification and associated typical detail drawings shall be
clearly documented and supported with technical justification.
5. Any work assumed to be performed by others within the scope of this specification,
including, but not limited to, trenching, concrete placement, installation of structures or
foundations, provision of power, installation of electrical wiring or conduit, shall be
clearly defined.
6. A listing of the personnel to be used on the project and their qualifications and training
shall be provided. All personnel shall have required safety training.
7. Timing to perform all work shall be provided.

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6.7.2 Project documentation

Upon receipt of a Purchase Order from the Principal, submittals shall be provided and
include the following:
1. An Introduction detailing the work to be performed
2. A Bill of Materials showing all materials to be used on the project
3. All Design Calculations indicating current density, system design life, anode spacing,
total current required and rectifier rating
4. A Project Data Book providing Manufacturer’s product data sheets and technical
literature for all materials listed in the Bill of Materials, including, but not limited to:
a. Anodes
b. Cables and wire
c. Coke breeze
d. Junction box and all related hardware and appurtenances
5. Technical literature shall include the Manufacturer’s name and specifications verifying
that the material meets the requirements of this DEP. If more than one item or catalog
number appears on a technical brochure, the proposed item shall be clearly identified.
6. Site specific Project Drawings in the format provided in this specification under (7.8).
7. An “Exception section” listing any variances to this specification, including revised
drawings.
8. Equipment instruction manuals, parts lists, installation details and associated drawings.

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7. INSTALLATION OF IMPRESSED CURRENT GRID SYSTEMS FOR ON GRADE

STORAGE TANK BOTTOMS

7.1.1 Application
This section covers requirements for installation of cathodic protection impressed current
systems beneath new on-grade storage tank bottoms using mixed metal oxide titanium
ribbon anode.
This technical specification shall apply to the design, furnishing of materials, and installation
of an impressed current cathodic protection grid system directly under on-grade storage
tank bottoms. This specification is applicable to the following tank bottom configurations:
(1) new on-grade storage tanks with or without a secondary containment liner, (2) existing
on-grade storage tanks with double steel bottoms and a liner over the old tank bottom and
(3) existing on-grade storage tanks with the old bottom removed and equipped with or
without a secondary containment liner beneath the new steel tank bottom.
This specification shall not apply to tank configurations where the tank foundation consists
of concrete underlain by piers or pilings. In these cases, cathodic protection shall not be
employed, but instead will utilize an above grade asphalt or bitumen/sand pad in contact
with the tank bottom to mitigate corrosion.
7.1.2 References
Applicable requirements in the following referenced standards shall be considered an
integral part of this DEP. Unless otherwise specified, the latest edition/revision of the
referenced standards is applicable.
1. API RP 500
2. API RP 651
3. ASTM B265
4. ASTM B418
5. ASTM C144
6. ASTM C778
7. ASTM D512
8. ASTM D516
9. ASTM G51
10. ASTM G57
11. NACE RP0193
12. NEMA Standard 250 (Type 4X and 3R Enclosures)
13. NFPA NEC 70
This section covers requirements for installation of cathodic protection impressed current
systems beneath new on-grade storage tank bottoms using mixed metal oxide titanium
ribbon anode.
1. This technical specification shall apply to the design, furnishing of materials, and
installation of an impressed current cathodic protection grid system directly under on-
grade storage tank bottoms. This specification is applicable to the following tank
bottom configurations:
a. new on-grade storage tanks with or without a secondary containment liner,
b. existing on-grade storage tanks with double steel bottoms and a liner over the old
tank bottom and

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c. existing on-grade storage tanks with the old bottom removed and equipped with or
without a secondary containment liner beneath the new steel tank bottom.
2. This specification shall not apply to tank configurations where the tank foundation
consists of concrete underlain by piers or pilings. In these cases, cathodic protection
shall not be employed, but instead will utilize an above grade asphalt or bitumen/sand
pad in contact with the tank bottom to mitigate corrosion.
3. All cathodic protection design, materials and technical services shall be supplied by a
qualified Cathodic Protection Contractor who has a minimum of 5 years of experience
in cathodic protection of on-grade storage tank bottoms. Tank bottom cathodic
protection systems shall be installed by a Contractor that has been engaged in this type
of work for a period of not less than five years. Documentation of qualifications shall be
available upon request.
4. Installation of cathodic protection systems shall be carried out under the supervision of
a NACE-certified cathodic protection or corrosion specialist.
5. Electrical portion of the cathodic protection system shall be installed in accordance with
6. Cathodic protection systems shall be installed in accordance with the latest revision of
NACE RP0193 and API RP 651.
7. Design Criteria: The cathodic protection system shall be designed by a Cathodic
Protection Specialist or registered Professional Engineer and shall be site specific
based on the following:
a. Current density of 2 mA per 929 cm² (1 ft2) for tanks operated at ambient
temperature and 4 mA per 929 cm² (1 ft2) [minimum] for tanks operated at
elevated temperatures.
b. Cathodic protection system shall have a minimum design life expectancy of 40
years.
c. Ribbon anode spacing for tanks with or without a secondary containment liner
shall be 1 m (3 ft.) separation between adjacent ribbon anodes and
450 mm (1½ ft.) from the tank ringwall for anode-to-tank bottom distances of at
least 230 mm (9 in.) The ribbon anode spacing will decrease for anode-to-tank
bottom distances less than 230 mm (9 in.).
d. Conductor bar spacing shall be a maximum of 4.6 m (15 ft.) separation between
adjacent conductor bars and a maximum of 2.3 m (7½ ft.) from the ringwall.
8. Criteria for Protection: The criteria for cathodic protection shall be as set forth in
NACE RP0193 and shall be either -100 millivolts of polarization or an IR free voltage of
-0.85 volts DC vs. a copper/copper sulfate reference electrode.
1. Personnel engaged in installing cathodic protection systems shall be qualified by
education, training, and experience to fulfill requirements of this specification.
1. Equipment, tools, and materials used to install the cathodic protection systems shall be
proper and adequate for the job.
7.1.6 Permits

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7.1.7 Safety
7.1.8 Drawings
Installation Contractor shall provide as-built drawings with details of the installation of the
cathodic protection systems. Details shall include locations of rectifiers, anodes, junction
boxes, permanent reference electrodes and cables.
7.2 MATERIALS
7.2.1 Anode ribbon
1. Anode ribbon shall be titanium that conforms to ASTM B 265, Grade I.
2. Anode ribbon shall be at least 6 mm (0.25 in.) in width by 0.6 mm (0.025 in.) thick.
3. Anode ribbon shall be coated with iridium based TIR 2000 mixed metal oxide, and be
as supplied by Corrpro Companies, Inc. or approved equal.
7.2.2 Conductor bar
1. Conductor bar shall be ASTM 265 titanium, grade 1.
2. Conductor bar shall be at least 12.7 mm (0.50 in.) width by 1 mm (0.04 in.) thick.
7.2.3 Power feed cables
1. Power feed cables shall be shop fabricated, no field splices are permitted.
2. Power feed cables shall be a number 8 AWG (minimum) stranded copper with HMWPE
(high molecular weight polyethylene) insulation, or, where chlorides are present in the
soil, HALAR® insulation or Principal-approved equivalent.
3. Power feed cables shall be of sufficient length to extend from the point of connection on
the conductor bar to the junction box; no splices are permitted.
4. The copper cable conductor shall be connected to a titanium rod which is then
connected to a strip of 12.7 mm (0.5 in.) wide by 1 mm (0.04 in.) thick titanium
conductor bar with a minimum length of 250 mm (10 in.).
1. Permanent reference electrodes installed under the tank shall consist of copper/copper
sulfate and/or zinc reference electrode. A minimum of three (3) reference electrodes
shall be required for tanks less than 24.4 m (80 ft.) in diameter. A minimum of five (5)
reference electrodes shall be used for tanks 24.4 m (80 ft.) but less than 55 m (180 ft.)
in diameter. A minimum of nine (9) reference electrodes shall be used for tanks 55 m
(180 ft.) or greater in diameter.
2. Copper/copper sulfate reference electrodes shall have a minimum service life of
25 years and a stability of ±5 millivolts under a 3.0 microamp load.
3. Lead wires for the reference electrodes shall be minimum No. 14 AWG stranded
copper conductor with HMWPE insulation. Lead wires shall be of sufficient length to
extend to the junction box without splicing.
4. Copper/copper sulfate reference electrodes shall be Permacell Plus or an approved
equal.
5. Zinc electrodes shall be 35 mm (1.4 in.) x 35 mm (1.4 in.) x 230 mm (9 in.),
prepackaged in quick wetting backfill and shall conform to ASTM B-418-80, Type II.

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6. Lead wires shall be a minimum of #12 AWG stranded copper conductor with THHN
insulation, white in color. Lead wires shall of sufficient length to extend to the junction
box without splicing.
7.2.5 Slotted PVC reference cell monitoring tubes
1. A 50 mm (2 in.) diameter, slotted, PVC reference, cell monitoring tube shall be installed
across the diameter of the tank and extend at least 150 mm (6 in.) beyond the concrete
ringwall or tank shell. Both ends of the tube shall be fitted with threaded end caps. For
tanks larger than 29 m (95 ft.) in diameter, a second reference electrode access tube
shall be installed and spaced so that the tubes divide the tank bottom into three
equidistant lengths.
2. The slotted PVC reference cell monitoring tube shall allow ionic contact with the tank
foundation sand for monitoring cathodic protection levels with an external portable
reference electrode. The tubes shall be nominal DN 50 (NPS 2) diameter schedule 40
PVC and radially slotted. Slots shall be no greater than 0.5 mm (0.02 in.) in width.
There shall be two rows of slots and the slots shall be spaced 6 mm (¼ in.) apart
longitudinally. The tubes shall be as supplied by National Well Supplies, Inc., Atlantic
Screen & Mfg., Inc. or approved equal. The portion of the reference cell monitoring tube
through the ringwall and external extension shall be non-perforated (solid wall)
schedule 40 PVC. A geotextile fabric sock shall cover the exterior of the access tube to
minimize sand entry into the tube.
7.2.6 Junction boxes
3. All wiring from under the tank shall be terminated in a junction box to be located
adjacent to the tank. Actual location will be project specific. If a non-explosion proof
junction box is used, it will be located a minimum of 3 m (10 ft.) from the tank. All wiring
from under the tank shall be routed to the junction box in rigid galvanized steel (RGS)
conduit.
4. Non-explosion proof junction box enclosures shall be NEMA 4X stainless steel,
galvanized steel, or fiberglass. Explosion proof rated, NEMA 7 junction boxes shall be
provided where specified.
5. The junction box shall be equipped with an insulated (phenolic) terminal panel. A
copper bus bar shall be installed with properly sized Holloway Type SW shunts
between the copper bus bar and each anode power feed cable. A properly sized
Holloway Type SW shunt between the copper bus bar and common terminal shall be
provided for connection to the rectifier's positive terminal.
6. Separate individual brass bolts shall be provided for terminating each reference
electrode lead wire.
7. Terminations for the tank negative connection and the rectifier's negative terminal cable
shall be mounted on a common copper bus bar mounted on the terminal board.
8. All wiring connections shall be clearly identified by silk screen or engraved white
lettering or numbers on the terminal board.
7.2.7 Rectifiers
1. Unless agreed to in advance, a rectifier shall be furnished for each tank's cathodic
protection system. If supplied, the rectifier shall meet requirements defined in this DEP
as applicable.
2. Rectifier requirements are site specific and the configuration shall be coordinated with
the Principal’s representative. The following parameters shall be considered:
a. Manufacturer: JA Electronics (or approved equivalent) as specified by Tank Owner.
b. Cooling: Air or Oil Cooled (Site Specific)
c. Enclosure: Site Specific
d. Rectification: Silicon diodes, bridge type with surge protection

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e. AC Input Rating: Site Specific

f. DC Current Rating: 125% of minimum design current
g. DC Voltage Rating: Site Specific
h. Tap adjustment: Site specific, 24 taps minimum (4 Coarse – 6 Fine) unless a
constant current rectifier is specified.
7.2.8 Miscellaneous cables and conduit
1. A minimum No. 4 AWG stranded, insulated single conductor copper cable capable of
carrying 125% of rectifier rated current shall be used as DC power leads from the
rectifier. The DC voltage drop shall be considered on longer runs. For direct burial
service, the cable shall be HMWPE cathodic protection cable, or, where chlorides are
present in the soil, HALAR® insulated cable or Principal-approved equivalent.
2. All above grade wiring shall be installed in rigid galvanized steel conduit. All below
grade wiring shall be installed in rigid galvanized steel conduit unless specifically
permitted to use direct burial cable.
7.2.9 Ringwall penetrations for cables and reference cell tubes
1. New tanks with ringwall and HDPE Liner:
a. HDPE pipe penetrations DN 50 (NPS 2) diameter through the tank ringwall and
fused to the liner shall be used for grid system cables and reference cell tubes.
b. PVC pipe penetrations DN 20 (NPS ¾) diameter shall be used for spare power
feed cables to be connected to the two main conductor bars.
c. A total of three DN 50 (NPS 2) diameter and four DN 20 (NPS ¾) diameter PVC
pipe penetrations will be required for tanks less than or equal to 29 m (95 ft.) in
diameter.
d. For tanks greater than 29 m (95 ft.) in diameter, five DN 50 (NPS 2) diameter and
four 19 mm (¾ in.) PVC pipe penetrations will be required.
2. New tanks with ringwall and no HDPE Liner:
a. PVC pipe penetrations DN 50 (NPS 2) diameter through the tank ringwall shall be
used for grid system cables and reference cell tubes.
b. PVC pipe penetrations DN 20 (NPS ¾) diameter shall be used for spare power
feed cables to be connected to the two main conductor bars.
c. A total of three DN 50 (NPS 2) diameter and four DN 20 (NPS ¾) diameter PVC
pipe penetrations will be required for tanks less than or equal to 29 m (95 ft.) in
diameter.
d. For tanks greater than 29 m (95 ft.) in diameter, five DN 50 (NPS 2) diameter and
four DN 20 (NPS ¾) diameter PVC pipe penetrations will be required.
3. The Foundation Contractor shall ensure all piping used for ringwall penetrations will
have threads (male or female) at the exit point on the exterior of the ringwall.
7.3 INSTALLATION
7.3.1 General requirements
1. The titanium ribbon anode system shall not be installed until after the tank ring wall
foundation has been constructed. If the tank is to have secondary containment, the
anode system shall not be installed until the secondary containment liner and a
compacted single lift of sand is in place.
2. If the tank is to have double bottom, the anode system shall not be installed until the
HDPE liner is installed and a minimum of 25 mm (1 in.) of sand is placed on the liner.

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3. General configuration of the ribbon anode, conductor bars, power feed cables,
permanent reference electrodes and slotted PVC reference cell monitoring tubes shall
conform to the typical drawings included as part of this DEP.
4. Location of the junction box and rectifier will be project specific and will be determined
by the tank owner.
5. Ringwall penetrations will be the responsibility of the Tank Foundation Contractor. The
ringwall penetrations for reference cell monitoring tubes should be located so they will
be easily accessible for future testing. The ringwall penetration for the powerfeed
cables and reference electrode lead wires should be located as near as possible to the
location where the junction box will be installed.
6. The cathodic protection grid system shall be installed in clean sand cushion approved
by the Principal. See (7.9) for sand pad requirements.
7.3.2 Anode system
The anode grid system installation consists of the titanium ribbon anode, titanium conductor
bars, power feed cables, permanent reference electrodes and slotted PVC
1. A minimum of 50 mm (2 in.) of compacted sand backfill shall be installed before
installation of the anode grid system. Prior to any equipment being operated over the
anode grid system, a minimum of 150 mm (6 in.) of compacted sand shall cover the
anode grid system. A minimum of 230 mm (9 in.) of final compacted sand shall cover
the anode grid system.
2. The anodes shall be unrolled from the spools and installed at the specified anode
spacing.
3. On existing tanks where the cushion sand/soil under the annular/sketch plate has not
or cannot been removed, a ribbon anode below and alongside the annular sketch plate
shall be installed.
4. The conductor bars shall be uncoiled and installed at the spacing indicated on the
project drawings. Conductor bar spacing shall be a maximum of 4.6 m (15 ft.)
separation between adjacent conductor bars and a maximum of 2.3 m (7½ ft.) from the
ringwall.
5. Spare power feed cables shall be connected to both ends of the two main conductor
bars and shall extend through the ringwall or double-bottom tank shell and be
terminated in a fiberglass junction box.
6. Each intersection of the anode ribbon and conductor bar shall be resistance-welded.
Each weld shall be checked to ensure that it is secure.
7. The prefabricated power feed cables shall be connected to the two main conductor
bars at the locations shown on the project drawings. The connection of the power feed
titanium strip to the conductor bar shall be made by resistance welding at a minimum of
six locations along each power feed titanium strip.
8. The power feed cables shall be routed through the conduit penetration of the ringwall or
double-bottom tank shell and be terminated in the junction box to be installed adjacent
to the tank after tank construction has been completed.
9. When the possibility of the ribbon anode or conductor bar making contact with the tank
bottom (causing an electrical short) is high such as having less than 150 mm (6 in.) of
sand between the ribbon anode and the tank bottom, a minimum of 100 mm (4 in.)
wide polyethylene mesh (rockshield) shall be used to cover the ribbon anode and
conductor bar. The mesh shall extend a minimum of 100 mm (4 in.) past the ends of
the ribbon anode and conductor bar. The mesh shall be attached to the ribbon anode
and conductor bar using nylon tie wraps or other Principal-approved fasteners.
7.3.3 Cables
1. The location of all groundbed cables shall be indicated e.g., by groundbed cable
marker posts located around the tank.

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1. Each reference electrode shall be soaked in fresh water for a minimum of 10 minutes
prior to installation or as specified in the Manufacturer’s instructions. Dig a hole in the
sand and place the reference electrode in the hole. Backfill the hole with sand and
compact the sand around the reference electrode by hand.
2. The reference electrodes shall be placed at the positions shown on the project
drawings. The electrodes shall be centered between adjacent anodes and adjacent
conductor bar. The electrode shall be aligned paralleled to the anode ribbons. Each
reference electrode lead wire shall be labelled as to tank installation location.
3. Each electrode's lead wire shall be routed through the conduit penetration of the
ringwall or double-bottom tank shell and be terminated in the junction box. The
identification for each reference electrode and the location where it is installed shall be
recorded on the as-built drawings.
7.3.5 Slotted PVC reference cell monitoring tubes
1. A slotted PVC reference cell monitoring tube shall be installed for performing potential
profile surveys using an external portable reference electrode. The tubes shall be
radially slotted. Longitudinal slots shall be no greater than 0.5 mm (0.02 in.) in width.
There shall be two rows of slots and the slots shall be spaced 6 mm (¼ in.) apart
longitudinally. The tubes shall be as supplied by National Well Supplies, Inc, Atlantic
Screen & Mfg., Inc. or approved equal.
2. The slotted PVC reference cell monitoring tube shall extend the entire diameter of the
tank. Both ends of the tube shall be attached to the conduit through the ringwall or
double-bottom tank shell. The portion of the tube through the ringwall and
150 mm (6 in.) outside the ringwall shall be solid wall (no perforations). The slotted
portion of the reference cell monitoring tube under the tank shall be covered with a
geotextile fabric sock to minimize sand entry into the tube.
3. The outside ends of the reference cell monitoring tube shall be fitted with easily
removable threaded end caps for future cathodic protection surveys.
4. For tank greater than 29 m (95 ft.) in diameter, a second reference cell monitoring tube
across the tank diameter shall be installed perpendicular to the main access tube
at/near tank center and shall also extend through the ringwall or double-bottom tank
shell. The portion of the tube through the ringwall and 150 mm (6 in.) outside the
ringwall shall be solid wall (no perforations). The perforated portion of the access tube
under the tank shall be covered with a geotextile fabric sock to minimize sand entry into
the tube.

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5. All PVC pipe joints except end caps and threaded joints shall be glued with
commercially available PVC cement. Joints to be glued shall be first cleaned with a
commercially available PVC solvent cleaner. Cement shall not be applied until cleaner
has dried.
7.3.6 Junction box
All power feed cables and reference electrode lead wires shall be terminated in the junction
box.
1. The junction box shall be located adjacent to the tank at a location approved by Tank
Owner. For locations where a non-explosion proof type junction box is used, it will be
located a minimum of 3 m (10 ft.) from the tank. For junction boxes not installed at the
tank ringwall, the installation of four 75 mm (3 in.) diameter steel bollards will be
required to provide physical protection for the junction box.
2. The reference electrode lead wires shall be terminated on the individual brass bolts
mounted on the junction box phenolic panel board.
3. The power feed cables shall be terminated on the shunts connected to the copper bus
bar. The identification for each power feed and the location where it is connected to the
conductor bar shall be recorded on the as-built drawing.
7.3.7 Rectifier
1. The rectifier shall be located as required by the Tank Owner and shall be easily
accessible for routine monitoring. If practical, the rectifier shall be located in an
unclassified area where an air-cooled rectifier can be used. Depending on the location,
the installation of 75 mm (3 in.) diameter steel bollards may be required to provide
protection for the rectifier.
2. The negative cable from the rectifier shall be exothermically welded to the tank chime
or mechanically connected to the tank chime or shell ground clip.
3. The positive cable from the rectifier to the junction box shall be connected to the
positive bus bar in the junction box through a totalizing shunt.
7.3.8 Miscellaneous
The installation of sand backfill within the tank ringwall can be performed using rubber-
tired/rubber track equipment when there is at least 150 mm (6 in.) of sand between the
cathodic protection system and the equipment.
7.4 INSPECTION
7.4.1 General
1. Ribbon anodes, conductor bars, permanent reference electrodes, rectifiers, junction
boxes and cables shall be visually inspected prior to installation.
2. Wire and cable shall be free of breaks, kinks, and insulation flaws.
1. Determination of system deficiencies shall be made by the Principal.
2. Deficiencies shall be corrected by the Installation Contractor.

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7.5 TESTING AND COMMISSIONING

7.5.1 Testing
1. All testing shall be performed by an experienced corrosion technician working under
the supervision of a NACE Level 4 Cathodic Protection Specialist or Registered
Professional Corrosion Engineer.
2. Resistance measurements between the power feed cables shall be measured after
installation of the anode grid system and prior to placement of the tank bottom. On
existing tanks, these measurements may be supplemented by additional resistance
and/or potential readings between the reference cells, power feed cables, and tank
shell.
Subsequent resistance tests during the tank construction can be made by Tank Owner.
Any abrupt change in these measurements may indicate damage to the system and
should be investigated and repaired prior to placing the tank bottom.
3. Rectifier-sizing test will not be required provided the Cathodic Protection Contractor
incurs the cost of replacing and installing the rectifier with one of proper size should the
original rectifier be determined improperly sized (i.e., rectifier cannot provide adequate
current as required or current increments are too large for proper adjustment).
7.5.2 Commissioning
1. Prior to energizing the rectifier, with the tank filled to a minimum of 1.5 m (5 ft.) of water
or product, native state potential measurements between the tank bottom and each
reference electrode shall be measured and recorded. Potential measurements shall be
made using a calibrated voltmeter with minimum 10 megohm input impedance.
2. Ensure that access pipes are free of obstructions.
3. Record native potential measurements at eight points around the tank shell and on
1.5 m (5 ft.) centers within the monitoring tube(s) installed under the tank.
4. Energize rectifiers on low tap settings to verify/determine the following:
a. Rectifier, shunt boxes, and other components are operational.
d. Requirement for any remedial measures.
5. The rectifier output shall then be increased sequentially until design current is supplied
to the tank. Individual power feed circuits will be checked and the rectifier will be
allowed to operate for a minimum of 4 hours before further potential testing is
conducted.
6. After the rectifier has been in continuous operation for a minimum of 4 hours, "On" and
"Instant Off" (polarized) potentials shall be measured at all permanent reference
electrodes and in eight evenly spaced locations around the tank perimeter. An
interruption cycle ratio of no less than 10:1 shall be used.
7. Final adjustments to the system will be made after sufficient time is allowed for
polarization (minimum of seven days). For ambient temperature tank fluid, the
polarization criteria shall be a potential shift of at least 100 millivolts more negative than
native state potentials or an “Instant Off” (polarized) potential of –0.85 volt vs.
copper/copper sulfate reference electrode. For elevated temperature tank fluid, criteria
will be provided by Shell.
8. A commissioning report shall be submitted by the Contractor with “As-Built” drawings,
all data, an analysis of the data, and recommendations for operation and maintenance
of the system.

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7.6 SUBMITTALS
7.6.1 Proposals
1. Proposals shall provide a lump sum price for performing work as defined in this
specification.
2. A detailed listing of all services and materials to be provided shall be provided.
3. Design calculations shall be provided indicating current density, system design life,
anode spacing, total current required, and the rating of the rectifier to be provided.
4. Any exceptions to this specification and associated typical detail drawings shall be
clearly documented and supported with technical justification.
5. Any work assumed to be performed by others within the scope of this specification,
including, but not limited to, trenching, concrete placement, installation of structures or
foundations, provision of power, installation of electrical wiring or conduit, shall be
clearly defined.
6. A listing of the personnel to be used on the project and their qualifications and training
shall be provided. All personnel shall have required safety training.
7. Timing to perform all work shall be provided.
7.6.2 Project documentation
Upon receipt of a Purchase Order from the Principal, submittals shall be provided and
include the following:
1. An Introduction detailing the work to be performed
2. A Bill of Materials showing all materials to be used on the project
3. All Design Calculations indicating current density, system design life, anode spacing,
total current required and rectifier rating
4. A Project Data Book providing Manufacturer’s product data sheets and technical
literature for all materials listed in the Bill of Materials, including, but not limited to:
a. Anode Ribbon
b. Conductor Bar
c. Power Feed Cable
d. Permanent Reference Electrodes
e. Rectifier
f. DC Wire and Cable
5. Technical literature shall include the Manufacturer’s name and specifications verifying
that the material meets the requirements of this DEP. If more than one item or catalog
number appears on a technical brochure, the proposed item shall be clearly identified.
6. Site-specific Project Drawings in the format provided in this specification under (7.8).
7. An “Exception section" listing any variances to this specification including revised
drawings.
8. Equipment instruction manuals, parts lists, installation details and associated drawings.
7.7 WARRANTY REQUIREMENTS

The vendor shall warrant all components furnished pursuant to this DEP to be new,
undamaged, free from defects in material and workmanship, and in conformity with the
Purchase Order, specification and drawings in all respects.

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7.8 DRAWINGS – TYPICAL DRAWING LIST

The following typical DEP Standard Drawings shall be utilized in the design and
construction of the cathodic protection Grid system for on-grade storage tank bottoms. The
drawings shall be revised as required to comply with project specific requirements such as
tank diameter, number of reference electrodes, number of power feeds, etc.
1. 41.081
2. 41.082
3. 41.083
4. 41.084
5. 41.085
6. 41.086
7. 41.087
7.9 SAND PAD MATERIAL REQUIREMENTS

7.9.1 Sand sample analysis
1. Samples shall be obtained from the proposed sand sources prior to installation for
laboratory analysis to ensure the requirements listed below are satisfied.
2. Additional samples of the actual sand material being installed shall be provided as
shipments arrive for laboratory and/or on site analysis to ensure compliance with the
requirements listed below. Sand samples shall be tested on site at least twice per day
to ensure all sieve, chloride, sulfate, and pH specifications are met.
3. Every shipment will be visually inspected as it is unloaded and spread for each lift. The
sand pad material shall be clean, free of clay balls of any size, vegetation, stones and
lumps of earth. Note that raw pit sand usually has some level of clay. Mason sand that
has been washed and graded has proven to be a clay free product. Clay balls, even
6 mm (¼ in.) diameter can cause corrosion on the soil side of the tank bottom.
4. The sand pad material shall also be free of corrosive materials such as salt in beach
sand or sulfur in crushed slag.
5. Sand pad material shall have a maximum chloride content of 300 ppm (parts per
million). Chloride content shall be determined in accordance with ASTM D516.
6. Sand pad material shall have a maximum sulfate content of 200 ppm. Sulfate content
shall be determined in accordance with ASTM D512.
7. Sand pad material shall have a pH between 6.5 and 8.5. The pH shall be determined in
accordance with ASTM G51.
8. Resistivity of the sand pad material from proposed sources shall be determined in
accordance with ASTM G57 and provided to the Contractor designing the cathodic
protection system.
7.9.2 Additional requirements
1. Sand pad material shall be mechanically washed sand that conforms to any of the
following, in order of preference: (1) ASTM C778, type “20-30 Sand”, (2) ASTM C778
“Graded Sand” or (3) ASTM C144.
2. The sand pad material shall be clean, free of clay balls, vegetation, stones and lumps
of earth. The sand pad material shall also be free of corrosive materials such as salt in
beach sand or sulfur in crushed slag.
3. Oiled sand pads shall not be installed under tank bottoms that have cathodic protection
systems installed.
4. Sand pad material shall meet other requirements as provided by the tank owner.

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7.10 SAND PAD INSTALLATION REQUIREMENTS

Sand pad installation will typically be performed by a Contractor other than the CP
Contractor. The installation procedures are as follows:
1. Prior to installing the first sand lift the native base shall be graded smooth and all loose
native materials should be removed from within the ring wall area. The inside ring of the
ring wall and the top of the ring wall should be cleaned of native materials to minimize
contamination of the sand pad.
2. As required by Principal, install a rock entryway to each tank to provide ingress/egress
to the tank ring wall area.
3. Stockpile rock and install a small layer of over roadway right before sand installation to
insure a clean environment for sand truck.
4. At the beginning of each day, all trucks and loading equipment to be used for sand
delivery shall be inspected prior to loading to ensure the beds are clean and free of
possible contaminants. As each load is delivered, the sand shall be sampled and tested
for chlorides, sulfates, and pH.
5. Sand truck will back up to the ring wall to dump sand into the ring wall area. The sand
truck shall not enter the ring wall area; this is to eliminate the possibility of any dirt and
clay contamination from the truck.
6. Sand will be brought to grade using a skid steer unit on tracks. Machine and tracks will
be pressure washed before entry into the ring wall to eliminate any contamination. As
sand is spread it should be inspected for clay content. Any streaking in the surface of
the sand as it is spread is a likely indication of contamination by clay or some other
organic material.
7. Personnel footwear (rubber boots) shall be pressure washed as necessary before entry
into the ring wall to eliminate any contamination. Alternatively, separate footwear may
used by personnel entering the ring wall area where conditions warrant.
8. Pressure washing should be with water only; no soap or cleaner shall be used. Avoid
getting any more water than necessary on the sand inside the ringwall.
9. The first load of sand should be dumped just inside the ringwall and spread in 150 mm
(6 in.) lifts working away from the ringwall. The first 150 mm (6 in.) lift should be graded
to allow an even surface for the grid installation. Once the grid is placed, care should
be taken to dump the sand in a manner that will not disturb the grid installation. The
grid should not be driven over with less than 150 mm (6 in.) of sand coverage. The final
lift(s) should be placed to a height of 300 mm (12 in.) in order to protect the grid and
provide optimal current distribution.
10. Once all layers of sand are installed, the entire sand pad shall be covered with .15 mm
(6-mil) polyethylene. 40 mm x 90 mm (2 in. x 4 in.) lads will be laid over the top of the
covering. Sand bags will then be placed on top of the 2 x 4 ‘s to secure the cover.
11. The pad covering will stay in place until the start of bottom plate construction.
12. If required, a motor grader will be used to dress-up sand to correct elevation. All
cleanliness standards defined above shall apply.
7.11 PLATE INSTALLATION

7.11.1 Cleanliness
1. The same cleanliness standards used for the sand installation defined above shall be
used for plate installation. That is, the tracks/tires of all equipment and personnel
footwear used inside the ringwall will be pressure washed before entering.
2. Any mud, dirt, etc. on the soil side of the tank bottom plate shall be pressure washed
before it is laid to ensure a clean surface on which the possibility for galvanic corrosion
due to differential aeration will be minimized.

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7.11.2 Damage to CP system

Extreme care should be taken by the Tank Contractor to prevent damage to the underlying
cathodic protection system (anode grid, cables, PVC piping, etc.). The Tank Contractor
should not lower or drag the tank plates edgewise over any of the cathodic protection
system. Protective mats should be used wherever necessary to prevent damage to the
buried cathodic protection system.
Any damage shall be the responsibility of the respective Contractor to repair. The Principal
inspector shall manage this aspect, including determination of damage by conducting
continuity testing between the tank bottom and CP system components.
7.12 MISCELLANEOUS
After installation, power feed cables and reference electrode leads, that extend through
penetrations, shall be rolled up and tied neatly and shall be protected during the remainder
of tank construction by installing steel ½ soles at all penetrations on the exterior of the
ringwall. Split DN 900 (NPS 36) diameter pipe shall be used for header cable and DN 300
(NPS 12) diameter pipe used for spares, all 1.5 m (5 ft.) long.

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8. INSTALLATION OF GALVANIC ANODE BED SYSTEMS

8.1.1 Installation requirements
1. Galvanic anode systems shall be installed in accordance with applicable government
regulations, local requirements, NACE SP0169 and this DEP.
2. Electrical portion of the galvanic anode systems shall be installed in accordance with
1. Installation of galvanic anode systems shall be carried out under the supervision of a
2. Personnel engaged in installing galvanic anode systems shall be qualified by
education, training, and experience to fulfill requirements of this DEP.
1. Equipment, tools, and materials used to install galvanic anodes shall be proper and
1. Manufacturer’s technical literature shall be provided for each item required in
(Appendix 6) of this DEP.
All equipment, materials, fabrications, and installations are subject to inspection, testing,
and approval by the Principal.
8.1.6 Drawings
Installation Contractor shall provide as-built drawings with details of the galvanic anode
installation. Details shall include types, locations, and number of anodes and details of the
connections to protected structures.
8.1.7 Permits
8.1.8 Safety

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8.2 INSTALLATION OF GALVANIC ANODE SYSTEMS IN SOIL

8.2.1 Anode holes and trenches
1. The location in relation to the object to be protected and the installation depth of the
anode shall be verified against the design. The checklist for recording the installation
and commissioning test results (Appendix 11) should be used.
2. Unless otherwise specified, anode holes shall be drilled vertically with a power auger.
a. Horizontal trenches may be used in lieu of vertical holes, if vertical holes are
impractical.
b. Proposal for use of horizontal trenches shall be submitted to the Principal for
approval prior to installation.
3. Depth of the vertical hole shall be governed by soil resistivity and moisture content, but
shall be sufficiently deep for the top of the anode to be below the bottom of the pipe as
a minimum.
4. Preferably, holes shall be located in low resistivity wet soil.
5. Diameter of vertical hole shall be a minimum of 100 mm (4 in.) larger than the diameter
of the prepackaged anode.
6. All anodes shall be centered in the hole before backfilling.
7. Care shall be exercised to avoid damaging anodes and leads during handling and
installation.
8.2.2 Anodes
1. Plastic shipment bag and/or paper wrapper shall be removed from the prepackaged
anode prior to placement in ground. Cotton bag that contains the anode and the
special backfill material shall not be removed.
2. Type of anode shall be as specified in (Appendix 6).
3. Anodes shall not be soaked prior to installation.
4. Anodes shall be handled carefully to avoid damage to the anodes, anode leads, and
lead connections.
5. Installation of a single anode shall conform to DEP Standard Drawings 41.020 and
41.021.
6. Installation of multiple anodes shall conform to DEP Standard Drawing 41.022.
Prepackaged anodes shall be lowered into the holes and the holes shall be backfilled.
a. Backfill material shall be firmly tamped around the anodes in 150 mm (6 in.) lifts so
that the material is in intimate contact with the anode bags.
b. For soil with resistivity less than 10,000 ohm-cm (3937 ohm-in.), (backfill material
shall be native soil.
c. For soil with resistivity greater than 10,000 ohm-cm (3937 ohm-in.), backfill material
shall be bentonite drilling mud. Thickness of mud around the anodes shall be a
minimum of 50 mm (2 in.) in all directions.
8.2.3 Anode leads and cables
1. Anode leads for installations with one or two anodes shall be No.12 AWG, single
conductor, stranded copper wire with TW or THW yellow insulation.
2. Anode leads for installations with three or more anodes shall be No.8 AWG, single
conductor, stranded copper cable with HMWPE insulation.
3. Insulation on all structure leads shall be black.
4. Leads shall be installed with adequate slack to allow for differential settlement of
structure and anode(s).

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5. Cables shall be inspected for defects in insulation during installation

6. The location of the groundbed shall be indicated e.g., by groundbed marker posts
located at both extremities of the groundbed.
8.2.4 Connections to structures
1. Lead connections to protected structures shall conform to (11) of this DEP.
2. Coating repairs on structures shall be made with a coating compatible with the existing
structure coating.
8.2.5 Test stations
1. Test stations shall conform to (11) of this DEP.
a. Test stations for single anode installations shall be Crouse-Hinds E37 Closed End
Condulets™, or approved equal.
b. Test stations for multiple anode installations shall be Cott Big Fink® test stations, or
approved equal.
2. Each anode lead shall have a dedicated current shunt.
3. Unless otherwise specified, each individual anode installation shall have a test station.
4. For short sections of drain or vent piping, or if the ground surface is paved above the
structure, anodes may be directly connected to the protected structure without the use
of a test station.
8.2.6 Guy anchor protection
Installation of galvanic anode system for protection of guy anchors shall conform to DEP
Standard Drawing 41.023.

8.3.1 General
1. Principal retains the right to inspect equipment and materials used for the galvanic
anode installations prior to, and during installation.
3. Determination of deficiencies in the installation of the anodes shall be made by the
Principal.
4. Installation Contractor shall correct any deficiencies in the anode installations.

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1. Prior to the installation, anodes shall be inspected for defects, conformance with the
anode specification, and size and length of anode cable tails. Anode leads shall be
free of breaks, kinks, and insulation flaws.
2. Electrical continuity between the anode and lead wire should be tested without
compromising the integrity of the package.
3. When new anode Manufacturers provide the anodes, Installation Contractor shall notify
the Principal so that a representative can inspect the manufacturing process.
8.3.3 Radiography
At request of the Principal, anode lead connections to the anode cores shall be
radiographed. Cost of radiography will be borne by the Principal.
At request of the Principal, an anode shall be cut open to allow inspection of the anode lead
connection to the anode core. Cost of the anode shall be borne by the Principal.
1. At request of the Principal, all cable, including anode leads, shall be subjected to an
electrical inspection of the insulation.
2. Insulation voltage shall be 150 volts per mil (0.001 inch or 0.025 mm) of insulation
inspection.
8.4 COMMISSIONING
8.4.1 Sacrificial anodes in soil
Commissioning tests of sacrificial anodes in soil shall include the following:
1. Before connection of the sacrificial anodes, the natural potential of the structure and the
open circuit potential of the sacrificial anode shall be measured and recorded at all test
stations, including the “unprotected” side of isolating joints/flanges.
2. After connection of the anodes, the structure potential and the current at each anode
shall be measured and recorded. The current measurement shall be performed using a
shunt.
3. The structure shall be allowed to polarise for at least 24 hours, after which the
structure-to-soil potential shall be measured and recorded at all test stations. All
potential values shall comply with the design protection criteria.
4. The structure to soil potential at the “unprotected” side of the isolating joints/flanges
shall be measured and recorded. If a polarisation of more than 20 mV from the natural
potential is measured in either polarity direction, the isolating joint/flange shall be
checked.
8.4.2 Sacrificial anodes in water
Commissioning tests of sacrificial anodes in water shall include the following:
Although welded or clamped anodes operate automatically when immersed in water, the
functioning of the system shall be checked upon completion or immersion of the system.
Commissioning tests consist of the measurement of the structure-to-electrolyte potential at
all test stations. All results shall be recorded for future comparison.

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9. DESIGN, MANUFACTURE, AND INSTALLATION OF AIR COOLED CATHODIC

PROTECTION RECTIFERS
9.1 GENERAL
9.1.1 References
• NFPA - NEC 70
• UL506
• IEC 60146
1. Personnel engaged in designing, manufacturing, and installation of cathodic protection
rectifiers shall be qualified by education, training, and experience to fulfill requirements
of this DEP.
2. Documentation of qualifications shall be available to the Principal upon request.
3. Manufacturing facility and all equipment, tools, electrical components, and materials
used to manufacture and install rectifiers shall be proper and adequate for the job.
9.1.3 Manufacturing and installation documents and as-built drawings
1. Manufacturing documents pertaining to the design and manufacture of rectifiers shall
be provided.
2. Documents shall include the Manufacturer’s name and shall provide sufficient
information to show that the items meet the requirements in this document.
3. Installation Contractor shall provide as-built drawings with details of the rectifier
installation. Details shall include types, locations, and number of rectifiers and details
of the connections to electric power and protected structures.
9.1.4 Drawings
The following DEP Standard Drawings shall be followed. Exceptions shall be approved by
the Principal:
1. 41.006
2. 41.007
3. 41.009
4. 41.068
9.1.5 Permits
Installation Contractor shall obtain the required safety and work permits, including “hot
work” permits, before proceeding with any work.
9.1.6 Safety

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9.2 DESIGN
9.2.1 General
1. Rectifiers shall be designed to deliver continuous DC output at 110% of DC voltage and
current ratings.
2. Rectifiers shall be designed to operate at rated DC output at an ambient temperature of
45°C (113 ºF).
3. Rectifiers will not be located in Class I, Division 1 or Class I, Division 2 areas and do
not need to be provided with “explosion proof” features or equipment.
4. Rectifiers shall have a dual AC input rating of 120/240 volts and shall be operated at
240 volts when possible.
5. Additional design features and optional equipment shall be as specified on the Rectifier
Data Sheet.
9.2.2 AC breaker
1. Rectifiers shall have a circuit breaker in the AC electric power supply circuit.
2. Breaker shall be:
a. Sized in accordance with the National Electrical Code as a minimum and
additionally sized for the AC input current and voltage required by the rectifier.
b. Fully magnetic.
c. Located on the front of the rectifier panel and easily accessible.
d. Capable of being manually switched on and off.
9.2.3 Transformers
1. Transformers shall meet UL 506 specifications.
2. Transformers shall have separate windings for each electrical input phase supplied to
the transformers.
3. Transformers shall have separate primary and secondary windings with the primary
and secondary windings electrically isolated from one another.
4. Transformers shall have an electrostatic shield between the primary and secondary
windings. Shield shall be electrically connected to the rectifier chassis.
5. Transformer materials and construction shall be rated for Class "H" operation [180°C
(356ºF)]. Insulation materials shall be further enhanced by being dipped in
thermosetting varnish and baked.
6. Transformers shall be rated for a minimum dielectric strength of 2,250 volts AC applied
for one minute between each of the windings and the core.
7. For rectifiers with DC output ratings less than or equal to 40 volts DC, the secondary
windings shall be adjustable by taps in increments of up to 5% of the rated DC voltage
over the full DC output range. For rectifiers with DC output ratings greater than 40 volts
DC, the transformer shall have five coarse and ten fine output tap settings for a total of
fifty step adjustments. Taps shall be located on the front panel of the rectifier and be
easily accessible for adjustments.
8. Transformer shall have a separate 110-volt winding to power 115 VAC outlet and/or
aerial warning indicator system. Winding shall deliver 115 VAC regardless of input
voltage (120/240) to the rectifier.
9.2.4 Rectification elements
1. Rectification elements shall have full-wave silicon diode modular construction.
2. Diode bridges shall be rated at a minimum of 400 volts DC for rectifiers with outputs
equal to, or less than, 100 volts DC and 800 volts DC for rectifiers with outputs greater

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than 100 volts DC. Each individual diode shall be rated for a minimum peak inverse
voltage (PIV) of 1,000 volts.
3. Diodes shall be rated for a minimum of 125% over the maximum DC amperage rating
of the rectifier.
4. Heat sinks shall be sized to prevent diode junction temperatures from exceeding 100°C
(212 ºF) at rated output and maximum ambient temperature.
5. Diodes shall be overload protected by means of high speed semi-conductor fuses
located in one leg of the AC secondary and on the DC negative output leg.
a. Fuses shall be mounted physically on the front of the rectifier panel or other
convenient location for easy access.
b. Fuses shall be “blade/bolt-in” type, such as Gould A25X-4™, or equivalent.
c. Diodes shall be provided with supplemental surge protection using metal oxide
varistors (MOVs) installed across the diodes. MOVs shall be sized to provide
protection against secondary over-voltage surges.
9.2.5 DC output meters
1. Rectifiers shall have separate meters for display of DC voltage and current outputs.
Use of dual display meters is prohibited.
2. Meter circuits shall not contain switches of any type.
3. Meters shall be mounted inside the rectifier cabinet on the panel.
4. Meters shall be a minimum of 89 mm (3-1/2 in.) x 89 mm (3-1/2 in.) in overall
dimensions with minimum scale dimensions of 72 mm (2-7/8 in.) x 72 mm (2-7/8 in.).
5. Meters shall be 0-50 millivolt full-scale deflection, taut-banded movement with a four-to-
one dampening ratio. Internal meter resistance shall be comprised of 25% winding
resistance and 75% fully temperature compensated dropping resistor for wide
temperature range performance.
6. Meter accuracy shall be ±2% full-scale deflection at 25°C (77ºF) and temperature
compensated to 0.085% per degree C (F).
7. Meters shall be scaled to have rated output not less than 70% and not greater than
85% of full-scale deflection.
8. Ammeters shall include an external 50-mV shunt with an accuracy of ±2% at full current
rating.
9. Shunts shall be physically located on the panel of the rectifier to facilitate access and
calibration of the meter. Panels shall have the wording “Meter Shunt” permanently
labelled near the shunts.
Shunts shall be electrically located in the positive (+) DC output circuit.
9.2.6 Cable terminals and connections
1. Cable terminals shall be crimped and soldered to the cables.
2. Bolted connections shall have double nuts with cable terminals soldered to the bolts
and nuts.
3. Bolted connections that penetrate non-metallic material, such as phenolic panels, shall
have double nuts on both sides of the non-metallic material so that physical security of
the connections is not dependent on the non-metallic materials.
4. Negative and positive DC output terminal connectors shall be of adequate size to
accommodate cable sized for maximum rectifier output. Each DC output terminal shall
be labelled with proper polarity in accordance with Table 310 of NFPA/NEC 70.

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9.2.7 Cabinet and chassis

1. Cabinet shall be sized for proper cooling of electrical components by natural air
convection.
2. Cabinet shall be weather-proofed to a degree of protection of at least IP 54 in
accordance with IEC 529.
3. Cabinet shall be manufactured from sheet steel or from 5052-H 32 aluminum, as
specified on the rectifier data sheet.
4. Large surface areas of cabinet shall be reinforced to prevent distortion.
5. Thickness of sheet steel for steel cabinet shall be 11-gauge minimum.
6. Thickness of aluminum for aluminum cabinet shall be 3 mm (0.125 in.) minimum.
7. Steel cabinet shall be hot dip galvanized after fabrication.
8. Aluminum cabinet shall be anodized and sealed with a TGIC “Dry Powder” clear
coating.
9. Doors shall have heavy-duty hinges and lockable hasps.
10. Lockable hasps shall be sized to accommodate padlocks with shanks of
10 mm (3/8 in.) diameter.
11. Cooling screens shall be manufactured from stainless steel or 5052-H 32 aluminum.
Perforations on screens shall be 3 mm (1/8 in.) diameter or smaller.
12. Cabinet shall have three openings on the bottom panel; two for 25 mm (1 in.) diameter
DC conduits and one for 25 mm (1 in.) diameter AC conduit.
13. Component chassis shall be manufactured from angle steel. Chassis shall be gold
phosphatized or chromated after fabrication.
14. Chassis shall be manufactured in a manner that allows removal of electrical
components for servicing by one person.
a. Chassis for rectifiers with relatively lightweight components shall have slide-out or
tilt-out configuration.
b. Chassis for rectifiers with heavy components shall have split-slide-out
configuration.
15. Chassis shall be manufactured and/or mounted in the cabinets in a manner that
ensures that the chassis are electrically connected to the cabinets.
9.2.8 Accessories
9.2.8.1 DC failure warning system
1. Rectifiers shall have a DC failure warning system if so specified in the rectifier data
sheet.
2. DC failure warning system shall be the “spinning plate” type if specified in the rectifier
data sheet.
3. DC failure warning system shall conform to DEP Standard Drawing 41.068.
4. Provisions for the installation of a Holloway SW 50-mV=5 (or Principal-approved
equivalent) to 50 amp shunt shall be made for the operation of the warning system.
a. Provisions shall be located directly above meter shunt.
b. Provisions shall be wired in series with meter shunt.
c. Panel shall have a permanent label that reads “Auxiliary Shunt” near the shunt.
9.2.8.2 Efficiency filter
1. Single phase rectifiers shall have a properly sized efficiency filter (choke). Three phase
rectifiers shall not have efficiency filters.

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2. Efficiency filter shall be sized for 100% of rated DC output.

3. Efficiency filter shall be designed to increase the overall efficiency of the rectifier by a
minimum of 10% at full rated DC output.
4. Efficiency filter shall be designed with a life expectancy equal to that of the
transformers.
5. Efficiency filter shall be installed in the DC negative leg.
9.2.8.3 Convenience outlets
1. Rectifiers shall have a convenience outlet.
2. Convenience outlet shall be rated for 120 volt and 15 ampere AC service, and shall
have “ground fault circuit interrupt” (GFCI) protection.
3. Convenience outlet shall be mounted on the rectifier panel near the AC circuit breaker.
4. Convenience outlet circuits shall be sized for 0.5 KVA (approximately 4 amperes at 120
volts) and shall be protected by an “inline” 5.0 ampere fuse. Fuse shall be accessible
from front panel, next to 120 Volts AC+GFCI outlet.
9.2.8.4 Lightning arrestors
1. Lightning arrestors shall be provided for both the AC input and the DC output of the
rectifier.
2. Lightning arrestor shall be Delta model LA 104 rated at 60,000 amps or approved
equal.
9.2.8.5 Potential control unit
Rectifiers used to provide cathodic protection to internal surfaces of tanks shall be of the
potential control type with the following features:
1. DC current output shall be automatically controlled and varied by control units to
maintain a preset structure-to-electrolyte potential as measured to a permanent
reference electrode.
2. Control units shall have a minimum of two electrode channels with a selector switch to
allow operator selection of the controlling electrode.
3. Rectifier output shall be determined by potential(s) measured by a minimum of two
reference electrodes that are separated by a maximum of 15 m (50 ft.) More than two
reference electrodes may be used as back-up electrodes.
4. Control units shall be capable of maintaining a structure-to-electrolyte potential with an
accuracy of ±5 millivolts DC from any operator set potential within a range from -800
millivolts to -1100 millivolts with respect to a copper-copper sulfate reference electrode.
5. Control units shall measure potentials in a manner so that the potentials are "IR drop
free.”
6. Control units shall have a current limiting mode that limits the amount of current
produced by the rectifier in the event a failure occurs with potential control.
7. Current limiting mode shall not engage unless a failure occurs in the potential
measurement circuit (failures of electrodes, leads wires, etc.).
8. Current limiting mode shall be capable of being manually set at any current output level
greater than 10% of operating output up to rated output.
9.3 MANUFACTURE
9.3.1 General
1. Materials and workmanship used in the manufacture of rectifiers shall be of good
quality and free from defects.

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2. Welds, sharp edges, and corners of cabinet and chassis components shall be ground
smooth prior to application of coating.
9.3.2 Manufacturing data
The following data shall be furnished with the rectifier.
1. Manufacturer and model number.
2. Type of rectifying stack and its product code.
3. Description and Manufacturer of DC meters.
4. Description and Manufacturer of AC breaker.
5. Overall conversion efficiency at rated output.
6. Rectifier shop test data.
7. Schematic diagram of rectifier and all electrical circuits.
8. Two copies of drawings showing mounting, wiring and general dimensions.
9. Complete parts list.
10. Problems, if any, encountered during inspection and testing.
11. Exceptions, if any, to this DEP and reasons for exceptions.
9.3.3 Unit number tags
1. Rectifiers shall have a stainless steel or aluminum tag similar to the Manufacturer’s
nameplate attached to the outside cabinet door.
2. Tag shall be engraved with the unit number furnished by the Principal in the Rectifier
Data Sheet. Lettering shall be approximately 13 mm (½ in.) in height.
9.3.4 Certification
If required by local code, rectifiers shall be certified by an appropriate certification body.
Documentation of certification shall be provided with the rectifiers.
9.4 INSTALLATION
9.4.1 Materials
9.4.1.1 Rectifiers
Specific electrical requirements, such as AC supply voltage, DC outputs, and optional
features shall conform to (Appendix 8). The installation checklist for the transformer
rectifiers stations (Appendix 7) should be used.
9.4.1.2 Junction boxes
Junction boxes, if required, shall conform to (Appendix 8) and DEP Standard
Drawing 41.009.
9.4.1.3 Miscellaneous materials
Mounting poles, mounting hardware, meter loops, and grounding materials shall conform to
(Appendix 8) and DEP Standard Drawing 41.006 for installation with overhead electric
power or DEP Standard Drawing 41.007 for installation with underground electric power.
9.4.2 Unpacking
1. Promptly upon receipt at the installation site, the rectifier shall be unpacked and
thoroughly inspected. If damage is evident, the Rectifier Manufacturer and/or the
freight company shall be promptly notified, and corrective action shall be taken.
2. Rectifier components and connections shall be cleaned, tightened, and adjusted as
required to ensure satisfactory installation and operation.

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3. If required, rectifier shall be function tested in accordance with the Manufacturer's

recommendations.
4. If the rectifier is not to be installed immediately after receipt, it shall be stored in a
protective manner until it is installed.
5. Reference (Appendix 7), installation checklist for rectifiers, for onsite inspection form.
9.4.3 Locating and mounting rectifiers
1. Rectifiers shall not be located in Class I, Division 1 areas. The rectifiers shall meet the
requirements of the area classification in which they are to be installed.
2. Rectifiers shall be installed in accordance with the Manufacturer's recommendations
and applicable local codes and regulations. Additionally, all external AC and DC cables
shall be run in separate conduit
3. All rectifiers shall be installed so that they have sufficient ventilation.
4. Sufficient room shall be provided around the rectifiers to allow full opening of all doors
and panels, and to provide access for reading meters and carry out visual inspection,
adjustments, and repairs.
5. Rectifiers shall be mounted in accordance with DEP Standard Drawing 41.006 or DEP
Standard Drawing 41.007. Floor and pole mounted rectifiers shall be installed on a
concrete foundation. Wall-mounted rectifiers shall be adequately supported and bolted
to the wall.
6. Security shall be provided by using lockable cabinets and main circuit breakers to
minimise the possibility of damage or vandalism. When designated, rectifiers may
require installation in a fenced-in area.
9.4.4 Electrical system
9.4.4.1 General
1. Electric and grounding systems installation and connection shall conform to the
DEP 33.64.10.10-Gen., applicable local electrical codes and regulations, and to site-
specific Principal requirements.
2. Rectifiers shall be provided with an external disconnect switch in the AC wiring.
3. Lead wire connections to the rectifier shall be mechanically secure and electrically
conductive. Before the power supply is energized, it shall be verified that the negative
lead is connected to the structure to be protected and that the positive lead is
connected to the anodes.
4. Onsite functional testing of the transformer/rectifier unit shall be done with the
secondary DC cables disconnected from the structure to be protected. Dummy load
resistors or circuits shall be used for such testing.
5. Upon completion of the installation, rectifiers shall be left de-energised. Main circuit
breakers shall be locked open and/or the primary or secondary fuses shall be removed
and stored separately from the rectifiers until final commissioning.
9.4.4.2 Grounding system
1. Unless otherwise specified, rectifier case and chassis shall be electrically grounded
with one 19 mm (¾ in.) diameter by 3 m (10 ft.) long copperweld ground rod.
a. Resistance of the ground rod to ground shall not exceed 5 ohms.
b. If one ground rod does not meet above resistance requirement, additional
grounding shall be provided as specified by the Principal.
2. Ground wire shall be No. 2 AWG single conductor, stranded copper wire bare or with
THW insulation. If wire is supplied with insulation, color shall be green.
3. Individual ground wires shall not have any splices or damage to the insulation.

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4. Ground wire shall be connected to the rectifier case using the grounding lug on the
rectifier case and to the ground rod by a Thermite weld or by a standard ground rod
clamp.
5. Ground wire shall not be connected to the structure being provided with cathodic
protection.
9.4.4.3 DC cables
1. DC cables shall be electrically insulated from one another and from metallic structures
during installation of the rectifier.
2. DC cables shall be properly routed into the rectifier.
3. Only one structure (negative) DC cable and one anode bed (positive) DC cable shall
terminate inside of the rectifier case.
a. Cables shall terminate at the respective rectifier DC output terminals.
b. Anode bed cable shall be connected to the positive terminal of the rectifier and the
structure cable shall be connected to the negative terminal of the rectifier.
4. DC cables shall be permanently marked with metallic tags attached to the cable to
indicate the anode bed (positive) cable and the structure (negative) cable.
5. DC cables shall not be connected to the DC output terminals of the rectifier until after
the rectifier is energized and tested by the Principal. Rectifier shall be turned off while
making the DC cable connections to the rectifier.
1. Manufacture and installation of junction boxes shall conform to DEP Standard
Drawing 41.009. If the cathodic protection system requires more than one negative DC
cable or more than one positive DC cable, the cables shall be terminated in a junction
box outside of the rectifier case.
2. Separate junction boxes shall be used for negative and positive cables.
3. A single negative and a single positive cable shall be used to connect the junction box
to the rectifier output terminals.
4. Junction box with negative cables shall be located on the rectifier mounting pole in
accordance with DEP Standard Drawing 41.006.
5. Junction box with positive cables shall be located in accordance with the anode bed
installation specification.
9.5 SOLAR POWERED GENERATOR STATIONS

1. Solar generator stations shall be supplied complete with supporting framework.
2. Location of the generators shall not have any obstructions that could block light
sources to the solar panels, such as buildings, trees, etc.
3. The generators shall be placed on suitable foundations, able to support, generator,
batteries, and regulators according to the Generator Manufacturer's written
recommendations.
a. A foundation shall be able to withstand the maximum prevailing winds on the solar
panel structure.
b. A solar panel structure shall be oriented so that the installed solar panel faces the
direction of maximum insulation.
c. Sufficient room shall be provided around the solar panels to provide access for
maintenance and cleaning of the panels and control equipment.
4. Battery containers or supports shall have an acid resistant container that can hold
spillage of the full content of one battery unit.

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5. Security shall be provided by using lockable cabinets or buildings and/or by

constructing a security fence around the solar generator station.
6. All functional testing of the generators shall be done with the secondary cables
disconnected from the structure to be protected. Dummy load resistors or circuits shall
be used for such testing and may be left in place until final commissioning.
7. Upon completion of the installation, the generators may be left energised to keep the
batteries charged. Secondary fuses shall be removed and stored separately from the
generators until final commissioning.
9.6 COMMISSIONING
9.6.1 General
1. Commissioning involves the testing of cathodic protection equipment, accessories, and
systems to ensure that the pipeline or structure is protected in accordance with the
design parameters.
2. Principal shall have access to inspect rectifiers at any time during manufacture and
testing.
3. Materials used in the manufacture of rectifiers are subject to inspection and approval by
the Principal.
4. Principal shall have access to inspect all phases of rectifier installation at any time.
9.6.2 Manufacturing deficiencies
1. Determination of manufacturing deficiencies shall be made by the Principal.
2. Rectifier Manufacturer shall correct all manufacturing deficiencies detected by the
Principal during inspection and testing.
9.6.3 Transformer rectifiers
Pre-commissioning tests for transformer rectifier stations shall be done in accordance with
Manufacturer's written recommendations. The tests shall include the following as a
minimum:
1. Check the tightness of screws and nuts.
2. Verify that accessories are securely mounted.
3. Verify the correct functioning of the unidirectional devise (diode).
4. Measure the insulation resistance to ground [minimum shall be 10 ohms at
30 ºC (86 ºF)].
5. Measure the electrical resistance of earth connections.
6. Verify the full-range current output that can be obtained.
7. Verify the correct polarity of pipeline and groundbed cables.
8. Verify the AC power supply and grounding connections.
9. Verify the correct installation of oil, silica gel breathers, etc.
10. Energise and test without load for one hour.
11. Test at 50% capacity for two hours with dummy load connect to the DC side.
12. Test at 100% capacity for two hours with dummy load connected to the DC side.
13. Calibrate the unit’s meters.
14. De-energise and connect DC cables to the appropriate terminals.
If an electronic component of the rectifier needs to be replaced during the pre-
commissioning tests, e.g., due to rectifier malfunction or failure of the unit to fulfill the
performance requirements, then the pre-commissioning test shall be repeated.

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9.6.4 Solar generators

Pre-commissioning tests for solar generator stations shall be done in accordance with
Manufacturer's written recommendations.
The tests shall include, as a minimum, functioning of the equipment throughout its working
range with a dummy load connected to the DC side.
On completion of the tests the generators shall be switched off and the DC cables shall be
connected to the appropriate terminals.

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10. DESIGN, MANUFACTURE, AND INSTALLATION OF OIL COOLED CATHODIC

PROTECTION RECTIFIERS
10.1 GENERAL
10.1.1 References
• ASME Section VIII
• NFPA - NEC 70
• UL 506
1. Personnel engaged in designing, manufacturing, and installation of cathodic protection
rectifiers shall be qualified by education, training, and experience to fulfill requirements
of this DEP.
2. Documentation of qualifications shall be available to the Principal upon request.
3. Manufacturing facility and all equipment, tools, electrical components, and materials
used to manufacture and install rectifiers shall be proper and adequate for the job.
10.1.3 Manufacturing and installation documents and as-built drawings
1. Manufacturing documents pertaining to the design and manufacture of rectifiers shall
be provided.
2. Documents shall include the Manufacturer’s name and shall provide sufficient
information to show that the items meet the requirements in this document.
3. Installation Contractor shall provide as-built drawings with details of the rectifier
installation. Details shall include types, locations, and number of rectifiers and details
of the connections to electric power and protected structures.
10.1.4 Drawings
The following DEP Standard Drawings shall be followed. Exceptions shall be approved by
the Principal:
1. 41.008
2. 41.009
3. 41.068
10.1.5 Permits
Installation Contractor shall obtain the required safety and work permits, including “hot
work” permits, before proceeding with any work.
10.1.6 Safety
10.2 DESIGN
10.2.1 General
1. Rectifiers shall be designed to deliver continuous DC output at 110% of DC voltage and
current ratings.

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2. Rectifiers shall be designed to operate at rated DC output at an ambient temperature of

45°C (113ºF).
3. Rectifiers shall not be located in Class I, Division 1 areas.
4. Rectifiers located in Class I, Division 2 areas shall be provided with auxiliary equipment
adequate for these areas.
5. Rectifiers located outside of Class I, Division 1 or Class I, Division 2 areas do not need
to be provided with “explosion proof” features or equipment.
6. Additional design features and optional equipment shall be as specified on the rectifier
data sheet.
10.2.2 AC breaker
1. Rectifiers shall have a circuit breaker in the AC electric power supply circuit.
2. Circuit breaker shall be:
a. Sized in accordance with the NEC as a minimum and additionally sized for the AC
input current and voltage required by the rectifier.
b. Fully magnetic.
c. Located on the front of the rectifier panel and easily accessible.
d. Capable of being manually switched on and off.
10.2.3 Transformers
1. Transformers shall meet UL 506 specifications.
2. Transformers shall have separate windings for each electrical input phase supplied to
the transformers.
3. Transformers shall have separate primary and secondary windings with the primary
and secondary windings electrically isolated from one another.
4. Transformers shall have an electrostatic shield between the primary and secondary
windings. Shield shall be electrically connected to the rectifier chassis.
5. Transformer materials and construction shall be rated for Class "H" operation [180°C
(356ºF)]. Insulation materials shall be further enhanced by being dipped in
thermosetting varnish and baked.
6. Transformers shall be rated for a minimum dielectric strength of 2,250 volts AC applied
for one minute between each of the windings and the core.
7. For rectifiers with DC output ratings less than, or equal to, 40 volts DC, the transformer
secondary winding shall be adjustable by taps in increments of up to 5% of the rated
DC voltage over the full DC output range.
8. For rectifiers with DC output ratings greater than 40 volts DC, the transformer
secondary winding shall have five coarse and ten fine output tap settings.
9. Taps shall be located on the front panel of the rectifier and be easily accessible for
adjustments.
10. Transformer shall have a separate 115-volt winding to power 115 VAC outlet and/or
aerial warning indicator system. Winding shall deliver 115 VAC regardless of input
voltage to the rectifier.
11. Transformers for single-phase rectifiers shall have connection provisions to allow for
two AC input voltages; such as “120 and 240 volts” or “240 and 480 volts.”
10.2.4 Rectification elements
1. Rectification elements shall have full-wave silicon diode modular construction.
2. Diode bridges shall be rated at a minimum of 400 volts DC for rectifiers with outputs
equal to, or less than, 100 volts DC and 800 volts DC for rectifiers with outputs greater

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than 100 volts DC. Each individual diode shall be rated for a minimum peak inverse
voltage (PIV) of 1,000 volts.
3. Diodes shall be rated for a minimum of 120% over the maximum DC amperage rating
of the rectifier.
4. Heat sinks shall be sized to prevent diode junction temperatures from exceeding 100°C
(212ºF) at rated output and maximum ambient temperature.
5. Diodes shall be overload protected by means of high speed semi-conductor fuses
located in one leg of the AC secondary and on the DC negative output leg.
a. Fuses shall be mounted physically on the panel inside the oil cabinet or other
convenient location for easy access.
b. Fuses shall be “blade/bolt-in” type, such as Gould A25X_-4, or equivalent.
6. Diodes shall be provided with supplemental surge protection using metal oxide
varistors (MOVs installed across the diodes. MOVs shall be sized to provide protection
against secondary over-voltage surges.
10.2.5 DC output meters
1. Rectifiers shall have separate meters for display of DC voltage and current outputs.
Use of dual display meters is prohibited.
2. Meter circuits shall not contain switches of any type.
3. Meters shall be mounted inside the rectifier cabinet on the panel.
4. Meters shall be a minimum of 88 mm (3-1/2 in.) x 88 mm (3-1/2 in. in overall
dimensions with minimum scale dimensions of 77 mm (2-7/8 in.) x 77 mm (2-7/8 in.).
5. Meters shall be 0-50 millivolt full-scale deflection, taut-banded movement with a four-to-
one dampening ratio. Internal meter resistance shall be comprised of 25% winding
resistance and 75% fully temperature compensated dropping resistor for wide
temperature range performance.
6. Meter accuracy shall be ± 2% full-scale deflection at 25°C (77ºF) and temperature
compensated to 0.085% per degree C (F).
7. Meters shall be scaled to have rated output not less than 70% and not greater than
85% of full-scale deflection.
8. Ammeters shall include an external 50-mV shunt with an accuracy of ± 2% at full
current rating.
9. Shunts shall be physically located on the panel of the rectifier to facilitate access and
calibration of the meter. Panels shall have the wording “Meter Shunt” permanently
labelled near the shunts.
10. Shunts shall be electrically located in the positive (+) DC output circuit.
10.2.6 Cable terminals and connections
1. Cable terminals shall be crimped and soldered to the cables.
2. Bolted connections shall have double nuts with cable terminals soldered to the bolts
and nuts.
3. Bolted connections that penetrate non-metallic material, such as phenolic panels, shall
have double nuts on both sides of the non-metallic material so that physical security of
the connections is not dependent on the non-metallic materials.
4. Negative and positive DC output terminal connectors shall be of adequate size to
accommodate cable sized for maximum rectifier output. Each DC output terminal shall
be labelled with proper polarity in accordance with Table 310 of NFPA/NEC 70.

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10.2.7 Cabinets and chassis

10.2.7.1 General
1. Rectifier shall have an oil cabinet and a meter cabinet. Oil cabinet shall contain the
transformer, transformer secondary taps, rectification element, and associated
components. Meter cabinet shall contain the AC circuit breaker, DC output meters,
shunts, relays, and associated components.
2. Cabinets shall be manufactured from sheet steel or from 5052-H 32 aluminum, as
specified on the rectifier data sheet.
3. Large surface areas of cabinet shall have reinforcements to prevent distortion.
4. Thickness of sheet steel for steel cabinets shall be 11-gauge minimum.
5. Thickness of aluminum for aluminum cabinets shall be 3 mm (0.125 in.) minimum.
6. Steel cabinets shall be hot dip galvanized after fabrication.
7. Aluminum cabinets shall be aledyned and sealed with a TGIC “Dry Powder” ASA 70
gray coating.
10.2.7.2 Oil cabinet
1. Oil cabinet shall be sized so that the bottom panel and the portions of the side panels
immersed in oil provide a minimum area of 25.8 cm² (4 in.2) per watt of heat required to
be dissipated with the rectifier operating at full rated output.
2. Minimum and maximum oil levels shall be clearly labelled on the inside of the oil
cabinet.
3. Oil cabinet shall have an opening on top for access. Opening shall have a lid.
a. Lid shall be attached to tank with heavy-duty hinges. Bolt-on lids are prohibited.
b. Lid shall have rubber gasket seals that prevent ingress of air and moisture.
c. Lid shall be lockable with padlocks with 10 mm (3/8 in.) diameter shanks.
4. Oil cabinet shall have drain openings that allow complete draining of oil from the
cabinet. Openings shall have removable screw plugs.
5. Silica gel breathers shall be installed. The content of the breathers shall be dry as
indicated by blue crystals. Moisture contaminated silica gel, indicated by pink or white
crystals.
6. Electrical conductors that emerge from oil shall be manufactured in a manner that
prevents oil wicking or siphoning. This may be accomplished by removing a segment
of insulation from the wire or by using copper bus bars that extend a minimum of
50 mm (2 in.) above the maximum oil level.
10.2.7.3 Meter cabinet
1. Meter cabinet shall be permanently attached to one side or end of the oil cabinet.
2. Meter cabinet shall be sized to properly cool electrical components by heat conduction
to the cabinet or by natural air convection.
3. Meter cabinet shall have a door that allows full access to the cabinet. Door shall have
heavy-duty hinges and latches.
4. Meter cabinet shall have three openings on the bottom panel; two for 25 mm (1 in.)
diameter DC conduits, and one for a 25 mm (1 in.) diameter AC conduit.
10.2.7.4 Chassis
1. Component chassis shall be fabricated from angle steel. Chassis shall be hot-dip
galvanized after fabrication.
2. Chassis shall be manufactured in a manner that allows the chassis to be removed from
the oil cabinet.

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3. Chassis shall be manufactured and/or mounted on the cabinets in a manner that

ensures that the chassis is electrically connected to the cabinets.
4. Rectifier components located inside the oil cabinet shall be mounted on the chassis in
positions that fully immerse the components in the oil. Components shall be arranged
so that all connections are accessible for testing and maintenance without removal of
the chassis from the cabinet.
10.2.8 Accessories
10.2.8.1 DC failure warning system
1. Rectifiers shall have a DC failure warning system if specified in the rectifier data sheet.
2. DC failure warning system shall be the “spinning plate” type.
3. DC failure warning system shall conform to DEP Standard Drawing 41.068.
4. Rectifier shall have provisions for the installation of a Holloway SW 50 mV = 5 to 50
amp shunt for the operation of the warning system.
a. Provisions shall be located directly above the meter shunt.
b. Provisions shall be wired in series with the meter shunt.
c. Panel shall have a permanent label that reads “Auxiliary Shunt” near the shunt.
d. A cooper bus bar shall be installed in place of the shunt at the factory.
10.2.8.2 Efficiency filter
1. Single phase rectifiers shall have a properly sized efficiency filter (choke). Three phase
rectifiers shall not have an efficiency filter.
2. Efficiency filter shall be sized for 100% of rated DC output.
3. Efficiency filter shall be designed to increase the overall efficiency of the rectifier by a
minimum of 10% at full rated DC output.
4. Efficiency filter shall be designed with a life expectancy equal to that of the
transformers.
5. Efficiency filter shall be installed in the DC negative leg.
10.2.8.3 Convenience outlets
1. Rectifiers shall have a convenience outlet.
2. Convenience outlet shall be rated for 120 volt and 15 ampere AC service, and shall
have “ground fault circuit interrupt” (GFCI) protection.
3. Convenience outlet shall be mounted on the rectifier panel near the AC circuit breaker.
4. Convenience outlet circuits shall be sized for 0.5 KVA (approximately 4 amperes at 120
volts) and shall be protected by an “inline” 5.0 ampere fuse. Fuse shall be accessible
from front panel, next to 120 VAC+GFCI outlet.
10.2.8.4 Lightning arrestors
1. Rectifier shall have lightning arrestors for both the AC input and the DC output of the
rectifier.
2. Lightning arrestor shall be Delta model LA 104 rated at 60,000 amps or equal.
10.2.9 Potential control unit
Rectifiers used to provide cathodic protection to internal surfaces of tanks shall be of the
potential control type with the following features:
1. DC current output shall be automatically controlled and varied by control units to
maintain a preset structure-to-electrolyte potential as measured to a permanent
reference electrode.

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2. Control units shall have a minimum of two electrode channels with a selector switch to
allow operator selection of the controlling electrode.
3. Rectifier output shall be determined by potential(s) measured by a minimum of two
reference electrodes that are separated by a maximum of 15 m (50 ft.) More than two
reference electrodes may be used as back-up electrodes.
4. Control units shall be capable of maintaining a structure-to-electrolyte potential with an
accuracy of ±5 millivolts DC from any operator set potential within a range from -800
millivolts to -1100 millivolts with respect to a copper-copper sulfate reference electrode.
5. Control units shall measure potentials in a manner so that the potentials are “IR drop
free”.
6. Control units shall have a current limiting mode that limits the amount of current
produced by the rectifier in the event a failure occurs with potential control.
7. Current limiting mode shall not engage unless a failure occurs in the potential
measurement circuit (failures of electrodes, leads wires, etc.).
8. Current limiting mode shall be capable of being manually set at any current output level
greater than 10% of operating output up to rated output.
10.3 MANUFACTURE
10.3.1 General
1. Materials and workmanship used in the manufacture of rectifiers shall be of good
quality and free from defects.
2. Welds, sharp edges, and corners of cabinet and chassis components shall be ground
smooth prior to application of coating.
3. Oil cabinets shall be tested for leaks prior to galvanizing using the dye-penetrant test as
specified in ASME Code Section VIII.
10.3.2 Manufacturing data
The following manufacturing data shall be furnished with the rectifier.
1. Manufacturer and model number.
2. Type of rectifying stack and its product code.
3. Description and Manufacturer of DC meters.
4. Description and Manufacturer of AC breaker.
5. Volume and type of oil required.
6. Overall conversion efficiency at rated output.
7. Rectifier shop test data.
8. Schematic diagram of rectifier and all electrical circuits.
9. Two copies of drawings showing mounting, wiring and general dimensions.
10. Complete parts list.
11. Problems, if any, encountered during inspection and testing.
12. Exceptions, if any, to this DEP and reasons for exceptions.
10.3.3 Unit number tags
1. Rectifiers shall have a stainless steel or aluminum tag similar to the Manufacturer’s
nameplate attached to the outside cabinet door.
2. Tag shall be engraved with the unit number furnished by the Principal in the rectifier
data sheet. Lettering shall be approximately 13 mm (1/2 in.) in height.

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10.3.4 Certification
If required by local code, rectifiers shall be certified by an appropriate certification body.
Documentation of certification shall be provided with the rectifiers.
10.3.5 Inspection and testing
10.3.5.1 General
Manufactured rectifiers, manufacturing facility, and all equipment, tools, electrical
components, fabrications, and other materials used to manufacture the rectifiers are subject
to inspection and testing by the Principal.
10.3.5.2 Manufacturing deficiencies
10.4 INSTALLATION
10.4.1 Materials
10.4.1.1 Rectifiers
Specific electrical requirements, such as AC supply voltage, DC outputs, and optional
features shall conform to (Appendix 8).
10.4.1.2 Mounting pads, mounting hardware and grounding
Mounting pads, mounting hardware and grounding materials shall conform to (Appendix 1)
and DEP Standard Drawing 41.008.
Junction boxes, if required, shall conform to the Material Requirement Sheet in
(Appendix 8) and DEP Standard Drawing 41.009.
10.4.1.4 Transformer oil
1. Oil shall be provided and installed with the rectifier to the indicated level, leaving
sufficient room for expansion after energising the unit. If a rectifier is supplied oil-filled,
the level shall be checked and adjusted if necessary.
2. Oil shall be as recommended by the Rectifier Manufacturer.
3. Oil shall be a petroleum-based electrical insulating oil. The oil shall not contain
inhibitors, detergent or polychlorinated biphenyls (PCBs).
4. Manufacturer’s technical literature and a material safety data sheet (MSDS) for the oil
to be installed shall be provided to Shell or its designated representative prior to the oil
being transported to the installation site.
10.4.2 Unpacking and making rectifier ready
1. Promptly upon receipt at the installation site, the rectifier shall be unpacked and
thoroughly inspected. If damage is evident, the Rectifier Manufacturer and/or the
freight company shall be promptly notified, and corrective action shall be taken.
2. Rectifier components and connections shall be cleaned, tightened, and adjusted as
required to ensure satisfactory installation and operation.
3. If required, rectifier shall be function tested in accordance with the Manufacturer's
recommendations.
4. If the rectifier is not to be installed immediately after receipt, it shall be stored in a
protective manner until it is installed.
10.4.3 Locating and mounting rectifiers
1. Rectifiers shall not be located in Class I, Division 1 areas.

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2. Rectifiers shall be mounted in accordance with the Manufacturer's recommendations

and local codes.
3. Rectifiers shall be mounted in accordance with DEP Standard Drawing 41.008.
10.4.4 Electrical system
10.4.4.1 General
1. Electric and grounding systems installation and connection shall conform to the
DEP 33.64.10.10-Gen., applicable local electrical codes and regulations, and to site-
specific Principal requirements.
2. Rectifiers shall be provided with an external disconnect switch in the AC wiring.
3. Lead wire connections to the rectifier shall be mechanically secure and electrically
conductive. Before the power supply is energized, it shall be verified that the negative
lead is connected to the structure to be protected and that the positive lead is
connected to the anodes.
4. Onsite functional testing of the transformer/rectifier unit shall be done with the
secondary DC cables disconnected from the structure to be protected. Dummy load
resistors or circuits shall be used for such testing.
5. Upon completion of the installation, rectifiers shall be left de-energised. Main circuit
breakers shall be locked open and/or the primary or secondary fuses shall be removed
and stored separately from the rectifiers until final commissioning.
10.4.4.2 Grounding system
1. Unless otherwise specified, rectifier case and chassis shall be electrically grounded
with one 19 mm (3/4 in.) diameter by 3 mm (10 ft.) long copperweld ground rod.
a. Resistance of the ground rod to ground shall not exceed 5 ohms.
b. If one ground rod does not meet above resistance requirement, additional
grounding shall be provided as specified by the Principal.
2. Ground wire shall be No. 2 AWG single conductor, stranded copper wire bare or with
THW green insulation.
3. Individual ground wires shall not have any splices or damage to the insulation.
4. Ground wire shall be connected to the rectifier case using the grounding lug on the
rectifier case and to the ground rod by a Thermite weld or by a standard ground rod
clamp.
5. Ground wire shall not be connected to the structure being provided with cathodic
protection.
10.4.4.3 DC cables
1. DC cables shall be electrically insulated from one another and from metallic structures
during installation of the rectifier.
2. DC cables shall be properly routed into the rectifier.
3. Only one structure (negative) DC cable and one anode bed (positive) DC cable shall
terminate inside of the rectifier case.
a. Cables shall terminate at the respective rectifier DC output terminals.
b. Anode bed cable shall be connected to the positive terminal of the rectifier and the
structure cable shall be connected to the negative terminal of the rectifier.
4. DC cables shall be permanently marked with metallic tags attached to the cable to
indicate the anode bed (positive) cable and the structure (negative) cable.
5. Rectifier shall be turned off while making the DC cable connections to the rectifier.

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1. Manufacture and installation of junction boxes shall conform to DEP Standard
Drawing 41.009.
2. If the cathodic protection system requires more than one negative DC cable or more
than one positive DC cable, the cables shall be terminated in a junction box outside of
the rectifier case.
3. Separate junction boxes shall be used for negative and positive cables.
4. A single negative and a single positive cable shall be used to connect the junction box
to the rectifier output terminals.
5. Negative junction boxes for rectifiers shall be located on or immediately adjacent to the
concrete rectifier-mounting pad at the end of the rectifier opposite the AC and DC
connections cabinet.
6. Positive junction boxes shall be located as required in the anode bed installation
specification.
10.4.4.5 Transformer oil
1. Transformer oil shall not be installed until after Shell or its designated representative
has been given a reasonable opportunity to inspect the rectifier installation.
2. Rectifier oil cabinet shall be thoroughly cleaned and dried immediately before the oil is
installed.
3. Rectifier oil cabinet shall be filled with oil to the proper level as indicated by the fill lines
marked inside of the oil cabinet.
4. Oil shall not be spilled on the mounting pad or ground around the rectifier during the
filling process.
5. Rectifier and the mounting pad shall be inspected for signs of oil leaks approximately
24 hours after the oil is installed. If leaks are discovered, the causes of the leaks shall
be corrected, the oil replenished to the proper level, and the leaked oil cleaned up.
6. Empty oil containers and related debris shall be removed from the installation site and
disposed of properly.
10.5 COMMISSIONING
10.5.1 General
1. Commissioning involves the testing of all cathodic protection equipment, accessories,
and systems to ensure that the structure is protected in accordance with the design
parameters.
2. Principal shall have access to inspect rectifiers at any time during manufacture and
testing.
3. Materials used in the manufacture of rectifiers are subject to inspection and approval by
the Principal.
4. Principal shall have access to inspect all phases of rectifier installation at any time.
10.5.2 Manufacturing deficiencies
10.5.3 Transformer rectifiers
Pre-commissioning tests for transformer rectifier stations shall be done in accordance with
Manufacturer's written recommendations. The tests shall include the following as a
minimum:

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1. Check the tightness of screws and nuts.

2. Verify that accessories are securely mounted.
3. Verify the correct functioning of the unidirectional devise [diode].
4. Measure the insulation resistance to ground [minimum shall be 10 ohms at 30 C
(86 ºF)].
5. Measure the electrical resistance of earth connections.
6. Verify the full-range current output that can be obtained.
7. Verify the correct polarity of pipeline and groundbed cables.
8. Verify the AC power supply and grounding connections.
9. Verify the correct installation of oil, silica gel breathers, etc. See (10.4.1.4) and
(10.4.4.5).
10. Energise and test without load for one hour.
11. Test at 50% capacity for two hours with dummy load connect to the DC side.
12. Test at 100% capacity for two hours with dummy load connected to the DC side.
13. Calibrate the unit’s meters.
14. De-energise and connect DC cables to the appropriate terminals.
If an electronic component of the rectifier needs to be replaced during the pre-
commissioning tests, e.g., due to rectifier malfunction or failure of the unit to fulfill the
performance requirements, then the pre-commissioning test shall be repeated.
On completion of the tests the generators shall be switched off and the DC cables shall be
connected to the appropriate terminals.

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11. TEST STATIONS

11.1.1 General installation and testing requirements
1. Test stations shall be installed by a Contractor that has been engaged in this type of
work for a period of not less than five years.
2. Note carefully the standard color-coding required for the test leads.
a. Regardless of whether the color-codes in existing test stations are the same or
different than that designated on the DEP Standard Drawings, each test lead shall
be permanently labelled.
b. Where several pipelines or numerous test leads come into one box, a drawing
should also be prepared and maintained by the technician showing where the test
leads are attached to the various lines, their color and a schematic of the test lead
panel in the box.
3. The drawings contained in this section are intended for illustration purposes and are to
be adhered to regarding the number, size and color-coding of test leads. Other
equivalent terminal boxes may be used (e.g., M.C. Miller®, Condulets) provided that
silicon-bronze or stainless steel bolts, nuts and washers are used for all electrical
connections.
4. Test lead additions shall be documented in record keeping software (CPDM) and on
the appropriate alignment drawing, and route map. If the line is uncovered to install the
test lead, a DEP Standard Form 30.10.73.80 shall be completed also. An SAP
notification shall also be written.
1. Installation of cathodic protection systems shall be carried out under the supervision of
a NACE-certified cathodic protection or corrosion specialist.
2. Personnel engaged in this installation shall be qualified by education, training, and
experience to fulfill requirements of this DEP.
1. Equipment, tools, and materials used in this installation shall be proper and adequate
for the job.
Items required are those designated by the Principal in this DEP.
All equipment, materials, fabrications, and installations are subject to inspection and testing
by the Principal.
11.1.6 Permits

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11.1.7 Safety
Location of third-party structure locations shall be performed before any excavation by
11.2 INSTALLATION GUIDELINES FOR ALL TEST STATION CONFIGURATIONS

11.2.1 General
1. Drawings and maps shall be reviewed and the area shall be surveyed with pipe and
cable locators to determine location of underground piping, cables, or other objects.
2. Test leads shall be installed:
a. with sufficient slack to prevent undue stress during backfill so that it will remain
mechanically secure and electrically conductive
b. in such a way as to prevent the test lead attachments from causing stress
concentrations on the pipe
c. so that they are suitably insulated from the conduits and junction boxes, and
d. with a suitable coating on the bared area compatible with the pipe coating and
cable insulation.
3. At foreign pipeline crossing test stations, the owner of the pipeline shall be notified.
Owner’s permission shall be obtained before the test leads are connected to their
pipeline.
4. Installation Contractor shall not proceed with connection to foreign pipeline unless the
pipeline owner has a representative present.
11.2.2 Test station locations
1. Test stations shall be installed:
a. At all metallic underground pipeline crossings.
b. At all cased crossings and tunnels (both ends).
c. At all underground isolation flanges.
d. At galvanic anode locations. Refer to DEP Standard Drawings 41.021 and 41.022
for typical details.
e. At all rectifier locations.
f. At all other locations shown on the Principal drawings, generally at spacings no
more than 0.6 miles (1 Km).
2. Test stations shall be located as close as possible to directly over the pipe.
3. For a pipeline under a road, test stations shall be located at the curb for easy access.
4. Test stations shall be located adjacent to a permanent structure (e.g., a fence, power
pole), if available, for physical protection.
11.2.3 Test station materials
11.2.3.1 General
1. Test station lead cable shall be No. 12 AWG, single conductor, stranded copper wire
with TW, THW or THHN insulation.
2. Color of insulation shall depend on which cable lead the insulation is connected, and
shall be as follows:
a. Principal structure or piping - Black
b. Foreign structure or piping - Red

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c. Steel casing - White

d. Sacrificial anodes - Yellow
3. Silicon-bronze hardware is preferred for use because it is very corrosion resistant, and
since it is slightly softer than stainless steel, develops very tight and somewhat
self-locking connections. Stainless steel is acceptable, but only when lock washers are
used for all connections.
11.2.3.2 Above-ground test station heads
11.2.3.2.1Standard two-terminal test station
Standard two-terminal test station shall consist of the following as shown in DEP Standard
Drawing 41.001:
1. One 25 mm (1 in.) Crouse-Hinds E37 galvanized condulet, or approved equal
2. One 25 mm (1 in.) blank composition condulet cover with gasket and two terminals
3. One 25 mm (1 in.) galvanized conduit, 1.5 m (5 ft.) long
4. One 100 mm (4 in.) x 100 mm (4 in.) x 1.8 m (6 ft.) (min.) treated timber post
11.2.3.2.2Big Fink® test station
1. Test station shall be a five terminal Big Fink® as shown in DEP Standard Drawing
41.065 and manufactured by Cott Manufacturing, Corrpro Companies, Inc., or
approved equal.
2. Conduit shall be 1.5 m (5 ft.) long and 75 mm (3 in.) diameter complete with
UV-resistant plastic with a 250 mm (10 in.) long anchor.
3. Color of the test station head shall be yellow.
4. Color of the conduit shall be white.
11.2.3.3 Flush mount test stations
1. Flush mount test stations shall be installed as shown in DEP Standard Drawing 41.005.
2. Terminal box shall be a five terminal Street Fink® or Flush Fink® as manufactured by
Cott or approved equal.
3. In heavy traffic areas, a 216 mm (8-5/8 in.) diameter I-RT concrete box, complete with a
cast iron cover marked “CP Test”, shall be utilized. The concrete box shall be supplied
by Brooks Products, Inc., or approved equal.
11.2.3.4 Permanent reference electrodes
1. Permanent reference electrodes shall be copper/copper sulfate Permacell, Model
IHRP-802 as manufactured by Corrpro Companies Inc., or Principal approved
equivalent.
2. Electrodes shall have a design life of 15 years and a stability of 5 millivolts under a 3.0
microamp load.
3. Electrodes shall have No. 14 AWG stranded copper wire with black HMWPE insulation
of suitable length to attach to the terminal board of the test station.
Electrodes shall be installed approximately 300 mm (12 in.) from the pipeline.
1. Backfill immediately around the electrodes shall be native soil compacted by hand.
The rest of the backfill shall be select granular material.
2. Backfilled electrodes shall be saturated with 19 L (5 gal.) of water.
11.2.4 Excavation
3. Depth of the pipeline shall be determined.
4. Installation Contractor shall not start excavating until it has been notified by the
Principal that the One-Call system has been notified.

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5. Excavation by mechanical devices, such as backhoes, shall not be done closer than
300 mm (12 in.) from the pipeline. Remaining cover shall be excavated by hand.
6. Excavation shall be carried out in accordance with OSHA and the Principal’s safety
requirements.
11.2.5 Backfill of excavation
1. Lead cable slack shall be coiled beneath the test station to allow for soil settlement and
to prevent damage to the cable during backfilling.
2. On flush mounted test stations, lead cable shall have a minimum of 300 mm (12 in.) of
additional slack to allow for withdrawal of the terminal board above the top of the test
station.
3. Backfilling requirements at each individual location shall be reviewed and followed.
4. Soil used for backfill shall not have any rocks or trash.
5. Direct-buried cable shall have a plastic warning tape installed directly above the cable
b. Tape shall be yellow, 75 mm (3 in.) wide, and shall be labelled “Cathodic Protection
6. After backfilling, the finished grade over holes/trenches shall blend in with existing
undisturbed terrain and not be detectable.
7. Excess backfill soil shall be distributed in a manner that maintains the site's
appearance. If required, excess backfill soil shall be removed from the job site.
8. Debris shall be disposed of in an approved manner.
11.2.6 Inspection and testing
11.2.6.1 General
1. Principal retains the right to inspect equipment and materials used for the test stations
prior to, and during, installation.
3. Determination of deficiencies in the installation of test stations shall be made by the
Principal.
4. Installation Contractor shall correct any deficiencies in the test station installations.
11.2.6.2 Visual inspection
Cables and test station equipment shall be visually inspected prior to their installation.
11.2.6.3 Electrical inspection
1. At the request of the Principal, test station cables shall be subjected to an electrical
inspection of the insulation.
thickness for dry inspection and 70 volts for wet sponge inspection.
11.3 CABLE-TO-STRUCTURE CONNECTIONS

11.3.1 Thermite welded connections
11.3.1.1 General
1. All wire/cable connections to piping shall be made with Thermite welding, unless
specific situations dictate that this is not permitted or is not feasible. In situations where
exothermic welds are not permitted or feasible, a strong permanent magnet or
mechanical clamp may be used, if approved by Principal.

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2. Wire/cable connections to structures other than piping, such as tanks and flanges, shall
be made using a mechanical connection as shown on DEP Standard Drawing 41.004.
3. All connections shall conform to this DEP and DEP Standard Drawings 41.002 and
41.003, as applicable.
4. Welding equipment and tools shall be Cadweld® as manufactured by Erico Electrical
Products Company or Thermoweld® as manufactured by Continental Industries, Inc. or
equivalent, where approved by the Principal.
5. Thermite welding equipment and materials shall conform to DEP Standard Drawings
41.002 and 41.003.
6. Use of Thermite welding equipment and materials shall conform to the Manufacturer’s
instructions. Only the correct Thermite welding charges and molds shall be used.
7. Thermite welding equipment and tools used for a specific installation shall be as
specified by the Thermite welding Material Manufacturer.
8. Only the proper size graphite molds should be used when making horizontal or vertical
connections (refer to Manufacturer's recommendations). The copper oxide and
aluminum charges shall be the F-33 alloy for connections to steel pipe. Charges shall
be restricted to the 15-gram size (e.g., CA 15) to avoid overheating of the pipe.
9. Thermite welding shall not be used on in-service ethylene pipelines. The Principal’s
Safety Procedures Manual and Section 3.10 in the Pipeline Inspection and
Maintenance Manual shall be reviewed for additional requirements when Thermite
welding connections connects to other types of pipelines.
10. Thermite welding shall not be used if it is deleterious to a structure such as a stress-
relieved pipe.
11. Cable-to-structure connections shall be coated in accordance with this section.
11.3.1.2 Connection location/geometry
1. Connections of No. 6 AWG wire and smaller, that can be made with one Thermite weld
shall be made at the 12 o’clock position of the pipe.
2. Connections of No. 4 AWG wire and larger, that require more than one Thermite weld
shall be made in a “crowfoot” pattern, centered at the 12 o’clock position of the pipe as
shown on DEP Standard Drawing 41.003.
11.3.1.3 Pipe wall thickness considerations
Review requirements of the Principal’s Safety Procedures Manual and Section 3.10 in the
Pipeline Inspection and Maintenance Manual. Within Section 3.10, there is an overview on
Thermite Welding and Table 3.10-9, a welding chart that outlines pressure and temperature
restrictions. Additional restrictions on wall thickness, flow rate, and pressure as a function
of maximum allowable operating pressure (MAOP) are also addressed in Note (2) at the
bottom of Table 3.10-9. Thermite (CAD) welding on in-service pipelines may be done using
the following flow and pressure restrictions based on measured pipe wall thickness:
a. Wall thickness 6.4 mm (0.250 in.) and greater → flow is not required and pressure
reductions are not required.*
b. Wall thickness 3 mm (0.125 in.) to 6 mm (0.250 in.) → flow is required and
pressure shall not exceed 50% of maximum operating pressure at the Thermite
welding location.*
c. Wall thickness less than 3 mm (0.125 in.) → Thermite welding is not allowed.*
*Source: SPLC Pipeline I&M Manual, Table 3.10-8, Note (2).
11.3.1.4 Pipe preparation
1. All grease, dirt, and other debris shall be removed from the cleaned area, using
solvents if necessary.

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2. Surfaces to be Thermite welded shall be cleaned to base metal prior to welding using
an MBX® Bristle Blaster (or Principal-approved equivalent) over a 75 mm (3 in.) x 75
mm (3 in.) area for each connection.
3. Cleaned area shall be dried by towel or heat immediately prior to Thermite welding.
11.3.1.5 Pre welding requirements
1. Historically, Shell has had no instances of burn-through during Thermite welding.
However, as a measure of precaution, areas for Thermite welding shall be inspected
for low wall thickness and laminations. The scanning shall be carried out using an
ultrasonic digital thickness gauge that utilizes a dual element transducer probe. Dual
element transducers are used to enhance the detectability of the instrument to low wall
thickness. Standard digital thickness gauges may not be able to discern between areas
of low wall thickness and laminations; both features will show up as lowered wall
thickness readings.
2. No welding shall be performed in an area where the inspection identifies wall loss or
laminations that do not conform to the requirements in (11.3.1.3) above.
11.3.1.6 Wire preparation
1. Wires to be connected to the pipe shall have 25 mm (1 in.) to 50 mm (2 in.) of
insulation removed from the ends to be connected.
2. Exposed copper conductors shall be clean and free of oxide immediately prior to
welding.
11.3.1.7 Wire size considerations
1. No. 6 AWG, and smaller, wire shall be Thermite welded as a single bundle with one
single weld charge.
2. No. 12 AWG, and smaller, wire shall have a copper welding sleeve crimped in place on
the exposed copper conductor prior to welding.
3. No. 4 AWG, and larger, wire shall be Thermite welded as three (minimum) separate
bundles using one single weld charge for each bundle.
11.3.1.8 Making welds
1. Exposed conductor shall be placed on the prepared pipe surface and the welder shall
be positioned properly and firmly against the conductor and pipe.
2. Weld charge shall be loaded into the welder mold by placing the metal retainer disk in
the mold, pouring the weld charge from its container into the mold and on top of the
metal disk, and applying the ignition powder to the top of the weld charge.
NOTE: The ignition powder is tightly packed in the bottom of the weld charge container. It can be dislodged
from the container by squeezing the sides of the container.
3. After the weld charge is loaded into the welder, the mold cover shall be closed.
4. Precautions shall be taken to protect eyes, hands, and arms when igniting the weld
charge and while welding.
5. All extraneous flammable materials shall be removed from the immediate area prior to
welding.
6. Weld charge shall be ignited using an igniter (flint gun) provided with the welder.
7. Welder shall be held firmly in place while welding.
11.3.1.9 Post welding requirements
11.3.1.9.1 General
1. After the weld has partially cooled, the welder shall be removed from the connection by
lightly tapping the sides of the welder mold with a hammer.

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2. Weld slag shall be removed from the connection by lightly striking the connection with a
hammer and by brushing with a wire brush.
3. Weld spatter, sharp edges, and burs shall be removed with metal file.
11.3.1.9.2Testing welds
1. Strength of the welds shall be tested by lightly striking the sides of the weld with a
hammer and by lightly pulling on the conductor.
2. If the connection is not secure, it shall be removed from the pipe and the entire welding
process shall be repeated a minimum of 75 mm (3 in.) away from the unsuccessful
weld location.
3. At the unsuccessful weld location, the pipe shall be cleaned to bright metal and coated
using Kop-Coat® coating material.
11.3.1.9.3Cleaning and protection of welds
1. Completed and cooled connections and surrounding bare pipe surface shall be cleaned
with a wire brush.
2. Exposed metal surfaces shall be coated with Kop-Coat® material as manufactured by
Carboline Company. Other coating materials may be used, with prior approval of the
Principal.
3. Coated connections shall be covered with plastic weld caps.
11.3.2 Mechanical connections
1. Mechanical cable-to-structure connections may be used if Thermite welded
connections are prohibited.
2. Bonding clamps, magnets, or conductive epoxy may be used for the connections if
approved by the Principal.
3. Mechanical connections shall conform to DEP Standard Drawing 41.004.
11.3.3 Pin Brazing
1. Pin brazing using the Easybond® system is an acceptable substitute for Thermite
welding (in places where Thermite welding would be allowed) provided that the
Manufacturer’s recommended procedures are followed. Other pin brazing systems may
be used if they provide a similar quality of connection with similar heat characteristics.
2. The brazed connection shall leave a similar size and shape connection on the pipe as a
Thermite connection, and shall not have any threaded connections or bolts protruding
from the pipe surface.
3. All other precautions and relevant procedures as required for Thermite connections
shall be followed.
11.3.4 Connections to aboveground structures
1. Above-ground structures, such as valves, hydrants, and tank rims shall be used as test
points.
2. A 50 mm (2 in.) length of solid No. 12 AWG copper wire, with the insulation removed,
may be brazed or Thermite welded to the structure to prevent damage to the structure’s
paint or coating system.
11.4 PIPE-TO-SOIL POTENTIAL STATION CONFIGURATION

1. Pipe-to-soil potential test stations should be installed as shown on (Figure 1) and in
accordance with this section.
2. Along well-coated pipeline systems, it is desirable but not mandatory to have test
stations located at approximate two-mile (three Km) intervals. For bare and
poorly-coated pipelines, the number of test stations generally should be increased and
the spacing decreased.

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3. The spacing and location of test leads shall allow the measurements to indicate the
adequacy of cathodic protection and should be based at least on the following criteria:
a. coating condition
b. historical increase in rectifier current
c. uniformity of soil conditions
d. corrosion history
e. reconditioning history
f. cathodic protection practices on parallel and intersecting pipelines
g. likelihood of disturbance by others (farming, construction, utilities, etc.)
h. low potential areas indicated by close interval surveys, and
i. the impact of a release on the environment
GALVANIZED DEAD-END
CONDULET
BLANK COMPOSITION
CONDULET COVER WITH
GASKET
SILICON BRONZE MACHINE

SCREW, NUTS, AND WASHERS
#12 AWG BLACK

TEST LEADS
TO PIPE
GALVANIZED CONDUIT STRAPS

2' SPACED AT 2' INTERVALS
MIN. WITH 1/4"x1 3/4" GALV.
LAG SCREWS
NOTE: IN MARSHED OR OTHER WET AREAS.

GRADE CONDUIT & CONDULET SHALL BE P.V.C.
STRAPS, NAILS, ETC. SHALL BE MONEL
OR STAINLESS STEEL.
5' LENGTH OF 1"

GALVANIZED CONDUIT
4"x4" TREATED POST
REAM TO
REMOVE
BURRS
Figure 1 - Potential Test Station

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4. On bare lines with spot reconditioning, test leads on coated sections shall not reflect
pipe to soil potential levels of bare sections. The bare sections will generally be at a
lower potential. Wherever feasible, at the intersection of bare and coated piping, a test
station should be placed at the point of transition from bare to coated, with another
placed on the bare pipeline approximately 150 to 300 m (500 to 1000 ft.) from the
transition (or a long lead used to reach this point).
5. Test leads should also be added or relocated, as necessary, to properly monitor
sections of pipeline with marginal potentials. These areas are most often detected
when close interval, pipe-to-soil potential surveys are performed.
6. On bare or poorly-coated pipelines, there are times when adjacent rectifier units are in
close proximity of each other. In all cases, a minimum of one test station or other
means of cathodic protection monitoring is required between rectifiers to ensure the
ability to effectively monitor the level of cathodic protection at or near the point of
current overlap between the two systems.
7. There are circumstances where it may be impractical to install a test station at the
specific location of interest. When this is the case, one of the following options should
be employed:
a. Establish test lead(s) at the site of lowest potential.
b. Use a long lead during each survey to reach the low potential area from the nearest
test lead.
c. Install IR leads on the pipe at convenient locations and document the current
demand for this section to achieve an adequate pipe-to-soil potential throughout
the low potential area, or
d. Establish and document the difference in potential between the area of concern
and the two adjacent test leads. From these differences, determine the minimum
potential required at the existing test leads to maintain the required potential
throughout the low area.
NOTE: When Option c or d is used, the relevant data shall be maintained in CPDM and SAP. Notes and
sketches of the testing should also be maintained in personal files. A note should also be added in the
remarks section in CPDM. The documentation should indicate the minimum conditions (potential or
current) necessary at the monitored test point to have for adequate CP at the unmonitored remote
point and how this was determined. The location of the critical point should also be indicated.
11.5 FOREIGN LINE CROSSING STATION CONFIGURATION

1. Test stations at foreign line crossings should be installed as shown on (Figure 2).
2. These test facilities should be installed at the crossing of all cathodically protected
foreign lines in order to facilitate interference testing and bonding. Consideration should
also be given to installation of foreign line test stations at other major utility crossings
(e.g., steel reinforced concrete water lines).

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1” GALV. STL.
CONDUIT
TEST STATION TERMINAL BOARD
Figure 2 - Foreign Line Test Station

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11.6 ELECTRICAL ISOLATION STATION CONFIGURATION

1. Installation and repair of an electrical isolation device (insulating flange or fitting) should
be documented in CPDM and on the appropriate alignment sheet and route map or
station drawing (new installation). DEP Standard Form 30.10.73.80 should also be
used if the line is uncovered for the work.
2. (Figure 3) illustrates the standard test station installation at a buried electrical isolation
device (e.g., flange insulator).
3. Electrical isolation devices shall be installed in accordance with (13) of this DEP.
4. All buried electrical isolators should be provided with a test station.
5. Where flange isolators are installed with a bond for propagating cathodic protection
current, a shunt should be provided for measuring current flow. (A clip-on DC ammeter
may be used instead of installing a shunt.)
a. Flat shunts at aboveground electrical isolators may be installed directly across the
flange, but this is not preferred. Wire-type shunts are discouraged, except in very
low current situations.
b. The physical integrity of these shunts is critical to maintaining proper cathodic
protection levels and preventing possible interference situations if the shunt is
broken.
c. Except in very arid regions, shunt integrity can be improved by installing them in an
enclosure.
6. For all isolation devices, it is important to provide isolation fittings in all conduits and/or
instrument lines that could bypass the isolator and short the system.
7. For jurisdictional gas pipelines and liquid pipelines, electrical isolation devices shall not
be installed in a Class I, Division I area, unless they:
a. have current measurement bonding cables across them, or
b. are fitted with a device to prevent arcing (e.g., Dairyland Industries, zinc grounding
cells, polarization cells, etc.).
8. For isolation devices installed on jurisdictional gas or liquid pipelines where there is an
unusual risk of lightning, or where the device is near a HVAC or HVDC power line
right-of-way, prevention of arcing across the pipeline isolator shall be provided by the
use of Dairyland Industries devices, zinc grounding cells, polarization cells, or similar
protective devices.

September 2011
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Figure 3 - Isolator Test Station
11.7 CASED CROSSING STATION CONFIGURATION

1. The standard test station installation at a cased crossing is shown on (Figure 4).
2. All cased crossings shall be provided with test stations on the carrier pipe and the
casing or other means provided to test for a shorted casing.
3. Where casings are longer than 45.7 m (150 ft.) in length, a test station should be
installed on the pipe at both ends of the casing. Test leads are recommended on both
ends of all casings.
4. On a bare or poorly coated line, a much shorter distance may be necessary to detect a
shorted casing.
5. Pipe inside of casings may be evaluated using In-line Inspection (ILI) data when it is
available.

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CASING VENT
CONDULET
STRAPS
2'
MIN. 1" GALV. STL. CONDUIT
GRADE
4"x4" TREATED POST
5'
#12 AWG, SOLID COPPER,

SINGLE CONDUCTOR TEST LEADS
BLACK TW INSULATION WHITE TW INSULATION
END CASING
PIPELINE
SEAL
THERMITE BRAZED CONNECTION

COATED WITH COMPATABLE COATING.
(TYPICAL 4 PLCS.)
CONDULET
BLACK LEADS
TO PIPELINE WHITE LEADS
TO CASING
1" GALV.
CONDUIT
Figure 4 - Casing Test Station
11.8 SACRIFICIAL ANODE STATION CONFIGURATION

1. Sacrificial anodes are sometimes used to provide additional protective current to
supplement impressed current cathodic protection systems. This may be necessary in
areas where AC power is not available or in areas where current from the impressed
current system is shielded from reaching the pipe.
2. Sacrificial anodes may also be used, at times, for hot spot protection or for mitigating
interference effects through auxiliary drainage.
3. Sacrificial anodes (usually magnesium) may be installed singularly or in groups (banks)
connected to a header cable. (Figure 5) illustrates the standard test station installation
with a single sacrificial anode.

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4. When sacrificial anodes are used to supplement rectifier systems or to provide auxiliary
drainage, the anode(s) should always be connected to the pipe at an aboveground test
station. A shunt should be installed always for measuring anode current output and to
allow interruption during on/off CP surveys.
11.9 COUPON TEST STATION CONFIGURATION

1. Coupon tests stations should be designed, and installed in accordance with this DEP.
2. Coupon test stations are often useful for evaluating the instant-off potential and
polarization status of a pipe segment. The basic installation consists of:
a. one or two steel coupons buried in the earth, typically within 300 mm (12 in.) of the
pipe,
b. test leads from the coupons and pipe which are brought up to an aboveground
junction box,
c. a soil-filled PVC or other non-metallic tube between the coupons and the ground
surface. This is used to insert a reference cell for potential measurements of the
coupons in a fashion that greatly reduces or in some designs, eliminates the soil IR
drop from the coupon readings, and
d. other hardware, such as shunts, switches, cables, etc., in the aboveground junction
box are needed to facilitate the desired measurements.
3. These test stations are particularly useful where:
a. there are significant seasonal variations in On and Instant-Off potential,
b. 100 mV polarization criteria is used,
c. stray current occurs, and
d. areas with variable coating condition or for other reasons frequent polarized
potentials are desired.

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Figure 5 - Sacrificial Anode Test Station

September 2011
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4. Generally, there will be two coupons installed at a given test point, with one coupon
connected to the pipe to receive cathodic protection and the other one is left to freely
corrode. This one is used to estimate the free corrosion potential of the pipe while the
other one is used to estimate the polarized potential of the pipe at a coating holiday of
similar size.
5. In stray current (interference) situations, coupons can also be used to determine the
direction of current, either to or from a particular pipeline.
6. Careful attention to the initial conditioning of the coupons is necessary to assure proper
operation. Typically, coupons are allowed to freely corrode for several weeks or months
until a stable free corrosion potential is reached before they are connected to the
pipeline.
7. Recording coupon data (Contact your corrosion support for further information if
needed):
a. When coupon test stations are used, annual testing is required. Testing should be
performed during the CPSS (Cathodic Protection System Survey) annual survey
and recorded in CPDM as follows.
b. Coupon shall be listed as a separate test point, given the RT (read type) of S
(Simulated holiday). If the coupon is added to an existing test point site, then the
new coupon test point should be created just downstream of the existing test point
in CPDM.
c. Measure the potential of the coupon that is connected to the pipe or structure and
record the data in the Structure P/S field in CPDM. While the meter is still
connected remove the bond to the pipeline and measure the instant off potential.
This data will be recorded in the Structure IRF field. Connect the meter to the other
non-connected coupon and record the data in the native P/S field. Reconnect the
first coupon back to the pipe or structure and verify that it returns to the original on
potential.
11.10 IR DROP STATION CONFIGURATION

1. IR drop test stations are used to measure current flowing on the pipe. They are
particularly useful for stray current testing, coating resistance tests, monitoring the
routine current requirements of sections of pipe and especially for measuring line
currents during on/off close interval surveys.
2. IR drop test stations are recommended for installation at the following locations:
a. new rectifier installations
b. new crossings of cathodically protected pipelines
c. to monitor CP current demand and fluctuations of a particular section(s) of pipe
d. at five to ten mile intervals along the pipeline to monitor line currents during on/off
potential surveys
NOTE: These are used to verify that current is off during instant off surveys. They should be installed on
existing lines where experience indicates, due to stray currents or other influences, there is difficulty in
verifying that current is off during on/off surveys. Using existing bonded insulating flanges for this
purpose is also acceptable.
3. Where it is felt they are needed but do not now exist at existing rectifiers and foreign
crossings, IR drop test stations should be installed in conjunction with other work and
as schedules permit.
4. IR drop test points, with two color-coded wires at each end of a current measuring span
[recommended span length 30 m (100 ft.) or more], are best equipped for current
measurements because each such span may be calibrated accurately, as indicated on
(Figure 6).

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NOTE:
2 - STANDARD TW O W IRE TEST LEAD
ASSEMBLIES INSTALLED BACK TO BACK.
DETAIL "A"
Figure 6 - Typical I.R. Drop Lead Installation
5. Color-coded and labelled wires in a common terminal box is an acceptable alternative

to the colors shown in (Figure 6). Using different colors for each wire makes installation
easier.
6. Four-wire IR drop test stations, configured as shown on Figure 7, IR Drop Test Station
Calibration should be calibrated using the procedure described below. The calibration
procedure is as follows:
a. Measure and record the Normal voltage (IR) drop between the inner leads in the
test station (Terminals 2 and 3), in millivolts. The positive terminal of the digital
voltmeter should be on the upstream terminal in terms of current flow direction.
This will produce a positive (+) polarity on the value indicated by the meter.
b. Apply a known amount of current from an external source, between the outer leads
of the test station (Terminals 1 and 4) in the same direction as the current

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measured in Step 1 above. Record: 1) the applied current from the external source,
in amps, and 2) the total voltage (IR) drop between Terminals 2 and 3, in millivolts.
c. Subtract the Normal IR drop (Step 1) from the Total IR drop (Step 2) to determine
the Resulting IR Drop.
d. Reverse the leads from Step 2. Repeat Steps 1 and 2, using the same applied
current as before, but in the opposite direction. Record the Reverse values of:
• Normal IR Drop, in millivolts
• applied current from the external source, in amps
• total voltage (IR) drop between Terminals 2 and 3, in millivolts.
e. This time, ADD the Normal IR drop to the Total IR drop (both determined in Step 4)
to determine the Reverse Resulting IR Drop.
f. Compute the average of the Resulting IR Drops determined in Steps 3 and 5 by
adding the two values and dividing by two.
g. Determine the IR Drop Calibration Factor by dividing the applied external current
(From Steps 2 and 4) by the Average Resulting IR Drop (From Step 7).
Example
1. The Normal IR Drop between test leads 2 and 3, is 2.0 mV. The positive meter lead
is on test lead number 2.
2. A truck battery is used for the source of external current. The positive terminal of
the battery is connected to test lead number 1 and the negative terminal is
connected to test lead number 4. From the shunt in the positive (or negative) lead,
we determine that a 10 amp external current is applied. The Total IR Drop between
test leads 2 and 3 is now 8.0 mV.
3. Subtract the Normal IR Drop from the Total IR Drop:
Total IR Drop - Normal IR Drop = Resulting IR Drop
8 mV - 2 mV = 6 mV
4. Reverse the leads for the external current and apply the same 10 amp between
test leads 4 and 1. The measured IR Drop between test leads 3 and 2 is now 6 mV.
5. ADD the Normal IR drop to the Total IR Drop to determine the Resulting IR Drop.
Total IR Drop + Normal IR Drop = Resulting IR Drop
6 mV + 2 mV = 8 mV
6. The average of the two Resulting IR Drops is:
Resulting IR Drop #1 + Resulting IR Drop #2 =

Total of the two IR Drops
6 mV + 8 mV = 14 mV
Average Resulting IR Drop = 7 mV
7. Divide the external applied current by the average resulting IR drop:
10 amps / 7 mV
= 1.43 Amps/mV

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CLOSE SWITCH FOR

STEPS 1 AND 2 ONLY
BATTERY
A
MV
STEP 1 ONLY
STEP 2 ONLY
TEST POINT
COLOR CODED TERMINALS (TYP.)
TEST POINT
LEADS
PIPELINE
Figure 7 – IR Drop Test Station Calibration
1. The resistance determined by that method may be compared with (Table 1a) and
(Table 1b), which should only be used for purposes of comparison as the calibrated
value should be reasonably close to that shown.
2. Differences may occur due to variations in wall thickness and unknown fittings and
repairs. If a calibration cannot be performed, then the resistance may be estimated
using the data in (Table 1a) and (Table 1b).

September 2011
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Table 1a - Steel Pipe Resistance 1 (SI)
Pipe Size Outside Wall Weight per Resistance 2 of

(mm) Diameter (mm) Thickness Meter one Meter
(mm) (kilograms) (microhms)
50 60 3.911 5.43 260
100 114 6.019 16.07 87.93
150 168 7.112 28.28 49.87
200 219 8.179 42.56 33.14
250 273 9.271 60.27 23.39
300 324 9.525 73.81 19.09
350 355 9.525 81.25 17.36
400 406 9.525 93.16 15.12
450 457 9.525 104.41 13.42
500 508 9.525 116.97 12.07
550 559 9.525 128.87 10.96
600 609 9.525 140.78 10.04
650 660 9.525 152.69 9.25
700 711 9.525 164.59 8.60
750 762 9.525 176.65 8.01
800 813 9.525 188.40 7.48
850 864 9.525 200.31 7.05
900 914 9.525 212.21 6.66
1000 1016 9.525 236.17 5.97
1 Based on steel density of 489 pounds per cubic foot and steel resistivity of 18 microhm-cm.
2 Resistance/Meter: R = 16.011 x Resistivity (Microhm-cm)
Weight per Meter (kg)
Table 1b - Steel Pipe Resistance 1 (USC)

(in) Diameter (in) Thickness (in) Foot one Foot
(pounds) (microhms)
2 2.375 0.154 3.65 79.20
4 4.500 0.237 10.8 26.80
6 6.625 0.280 19.0 15.20
8 8.625 0.322 28.6 10.10
10 10.750 0.365 40.5 7.13
12 12.750 0.375 49.6 5.82
14 14.000 0.375 54.6 5.29
16 16.000 0.375 62.6 4.61

September 2011
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(in) Diameter (in) Thickness (in) Foot one Foot
(pounds) (microhms)
18 18.000 0.375 70.6 4.09
20 20.000 0.375 78.6 3.68
22 22.000 0.375 86.6 3.34
24 24.000 0.375 94.6 3.06
26 26.000 0.375 102.6 2.82
28 28.000 0.375 110.6 2.62
30 30.000 0.375 118.7 2.44
32 32.000 0.375 126.6 2.28
34 34.000 0.375 134.6 2.15
36 36.000 0.375 142.6 2.03
40 40.000 0.375 158.7 1.82
1 Based on steel density of 489 pounds per cubic foot and steel resistivity of 18 microhm-cm.
2 Resistance/Ft: R = 16.011 x Resistivity (Microhm-cm)
Weight per Foot (pounds)
11.11 IR FREE COUPON STATION CONFIGURATION

11.11.1 General
1. Applications of coupon test stations include locations where future testing is anticipated
for the following reasons:
a. Testing to determine the effectiveness of the installed cathodic protection system
and to allow for startup adjustments.
b. Testing to determine interference effects from and on adjacent or crossing foreign
underground structures.
c. Testing to determine sources and magnitude of stray currents (AC or DC) and
required mitigating measures.
d. Periodic monitoring to determine status of existing cathodic protection systems,
stray current, and foreign line influence.
2. Coupon test stations may be used for:
a. Measuring structure-to-soil and coupon-to-soil “on” potentials
b. Coupon “instant off” potential
c. Current density of coupon
d. Polarization and depolarization rates of the coupon
11.11.2 Locating IR free coupon test stations
1. Test stations shall be located preferably on the side of the pipe 100 mm to 150 mm
(4 in. to 6 in.) away from the pipe and 50 mm to 150 mm (2 in. to 6 in.) above the
bottom line of the pipe as shown on DEP Standard Drawing 41.070.
2. Test stations shall be located adjacent to a permanent structure (e.g., a fence, power
pole), if available, for physical protection.
3. Test stations shall be located at:

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a. Anticipated or known trouble spots.

b. Locations where accurate off-potential readings are difficult to obtain.
c. All other locations shown on the Principal drawings.
11.11.3 Excavation for IR free coupon test station
1. The hole to expose the pipe shall not be used to install the coupon test station.
2. The coupon test station shall be installed in a 75 mm (3 in.) diameter hole.
3. Hole shall be augered to the desire depth. The augered hole minimizes disturbance to
the area where the coupons are placed.
4. 50 mm to 75 mm (2 in. to 3 in.) of loose soil removed from the bottom of the hole shall
be dropped in to the hole.
5. Packing material used to protect the coupons shall be removed. Coupons should stick
out at the bottom of the test station.
6. Coupon test station assembly shall be inserted into the hole. The two coupons should
be lined up along the longitudinal axis of the pipe.
7. Small amounts of soil shall be added to the inside of the tube and packed well before
adding additional soil. Soil shall be added to the inside of the tube to just below grade.
The pipeline/structure leads shall be routed into a drilled hole on the tube. Additional
soil shall be added until soil is even with grade. Care shall be taken to prevent damage
to the leads and coupons during packing. Packing of the soil is critical to a successful
installation.
8. If drying out of soil occurs, water may be added to the soil inside the tube. Do not over
wet the soil. The soil should have similar moisture content as the original soil.
11.11.4 IR free coupon test station connections
1. Coupons should typically remain disconnected from the structure and permitted to
corrode freely for a period of 3 months or more to allow coupon to reach a stable free
corrosion potential.
2. Periodic coupon-to-soil potentials may be recorded to determine when a free corrosion
potential has been reached.

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12. INSTALLATION OF CATHODIC PROTECTION BONDS ON FOREIGN STRUCTURES
12.1 GENERAL
1. Cathodic protection bonds shall be installed in accordance with NACE SP0169 and
RP0193.
2. Adjustments of cathodic protection bonds shall be performed by a cathodic protection
specialist.
3. Stray alternating currents shall be controlled with galvanic anodes or PCR decoupling
devices. Refer to (14) of this DEP.
4. If stray currents cannot be totally prevented, they shall be controlled with resistance
bonds to the affected structures or with galvanic anodes to drain the stray currents from
the affected structure to ground.
1. Installation of cathodic protection bonds shall be carried out under the supervision of a
2. Personnel engaged in installing cathodic protection bonds shall be qualified by
education, training, and experience to fulfill requirements of this DEP.
3. Documentation of qualifications shall be available to the Principal on request.
1. Equipment, tools, and materials used to install bonds shall be proper and adequate for
the job.
1. Manufacturer’s technical literature shall be provided for each item required in this DEP.
12.1.5 Drawings
1. Installation Contractor shall provide as-built drawings with details of the cathodic
protection bonds.
2. Details shall include types, locations, and number of bonds and details of the
connections to the affected structures.
12.1.6 Permits
12.1.7 Safety
1. Installation Contractor shall be familiar with applicable government regulations and the
Principal’s safety guidelines and requirements and shall adhere to them.
2. Location of third party structure locations shall be performed before any excavation by

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12.2 MATERIALS
12.2.1 Lead wires and bond cables
1. Test station lead wires shall be No. 12 AWG, single conductor, stranded copper wire
with TW, THW, or THHN insulation.
2. Bond cables shall be No 6 AWG, single conductor, stranded copper wire with THW or
THHN insulation.
3. Insulation shall be color-coded as follows based on the structure the wire/cable
connects to:
a. Shell structure or piping - black
b. Foreign structure or piping - red
c. Steel casing - white
d. Sacrificial anode - yellow
12.2.3 Bond station
1. The typical bond box shall be as shown on DEP Standard Drawing 41.075 and shall
consist of the following:
a. One (1) 300 mm x 300 mm x 150 mm (12 in. x 12 in. x 6 in.) fiberglass box.
b. Four (4) terminals. Two (2) for No. 12 AWG cables and two (2) for No. 6 AWG
cables.
c. One (1) shunt. Shunt to be rated, as required.
d. One (1) resistor. Resistor to be rated, as required.
e. Rigid galvanized conduit and hardware, as required.
2. For other types of test stations, refer to (11) of this DEP.
1. Permanent reference electrodes, if installed, shall be zinc or copper/copper sulfate as
indicated on the project drawings.
2. Zinc electrodes shall be 35 mm x 35 mm x 230 mm (1.4 in. x 1.4 in. x 9 in.),
prepackaged in quick wetting backfill.
a. Zinc alloy shall conform to ASTM B-418-80, Type II.
b. Electrodes shall be Cathodic Protection Services Model AZR5AC or Principal-
3. Copper/copper sulfate electrodes shall:
a. have a design life of 30 years and a stability of ±5 millivolts under a 3.0 microamp
load.
b. have an ion trap to prevent contamination.
c. be shipped in a cloth sack with special backfill.
d. be Electrochemical Devices, Inc. Model UL-CUG-xx or approved equal.
4. Permanent reference electrodes shall be equipped with a number 14 AWG, standard
copper lead wire with red high molecular weight polyethylene insulation.
5. Lead wires shall be of sufficient length to extend to the junction box without splicing.
12.2.5 Coupons
Coupon test station, if installed, shall be as per technical specification (11) of this DEP.

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12.3 INSTALLATION
12.3.1 General
1. Prior to doing any work on a foreign structure, its owner shall be notified.
2. Installation Contractor shall not proceed with installation of cathodic protection bonds
on foreign structures unless the owner’s permission has been obtained in writing and
the owner has a representative present.
3. For test station and wire/cable connections and installation procedures, refer to (11) of
this DEP.
12.3.2 Cross bonds
1. Structures being bonded shall be adequately connected with cross bonds that provide
proper propagation of the protective current and mitigate interference currents.
2. For above ground pipes in contact with a metal pipe rack, the rack shall not be
assumed to provide the cross bond.
3. Cross bonds shall include a shunt and a resistor or the proper length of resistance wire
to regulate the amount of current flow. Use of a diode in the circuit shall be considered.
Permanent reference electrodes shall be installed in accordance with the following
procedure:
a. Soak the cloth sack containing the electrode in a container of water for 15 to 20
minutes.
b. Dig a hole in the soil for placement of the electrode.
c. Place the electrode in the hole.
d. Backfill the hole with soil. Compact the soil around the electrode by hand.
e. Route the electrode lead wires to the test station.
12.3.4 Coupons
Coupons shall be installed in accordance with (11) of this DEP.
12.4 INSPECTION
1. Principal retains the right to inspect equipment and materials used for bonds prior to,
and during, installation.
3. Determination of deficiencies in the installation of bonds shall be made by the Principal.
4. Installation Contractor shall correct any deficiencies in the bond installations.

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13. INSTALLATION OF ELECTRICAL ISOLATION FOR CATHODIC PROTECTION
13.1 GENERAL
1. Facilities protected by cathodic protection shall be electrically isolated from common or
plant grounding systems to avoid a loss of current.
2. Electrical isolation systems shall be installed in accordance with NACE SP 0169,
SP 0177 and RP 0286.
3. Proper control of cathodic protection currents sometimes requires the installation of
electrical insulating devices (gaskets, unions, insulating joints). These devices are
normally used to isolate piping systems that enter or leave a location to prevent loss of
current and improve current distribution.
4. Electrical isolation shall be installed at all of the following locations unless modified on
approved project design documents that show different requirements:
a. Junction between the Principal and foreign piping systems (typically a valve or
scraper trap).
b. Junction between mainline piping and station or terminal piping (typically a valve or
scraper trap).
c. Block valves on major river crossings.
d. Instrumentation tubing where specified.
e. Both sides of aboveground turbine meter runs.
f. Offshore pipeline risers (typically at the scraper trap or valve on the working deck).
NOTE: See DEP Standard Drawing 41.080 for typical installations.
5. Electrical isolation devices shall be installed at aboveground locations unless

installation on buried piping is approved by the Principal. If electrical isolation fittings
are buried or submerged, properly sized cables shall be attached on both sides of the
insulating device for current measurement and control. Cables shall be routed into an
above ground junction box in accordance with (11) of this DEP.
6. Electrical isolation devices shall not be installed in the following areas unless approved
by Principal:
a. Class I, Division 1 locations as defined by API RP-500.
b. In close proximity to electrical transmission tower footings, ground cables or
counterpoise.
c. Other areas where it is reasonable to expect fault currents or unusual risk of
lighting.
7. If electrical insulating devices are installed in any area defined in Item 4 above,
polarization cells, grounding cells, surge suppressors, decoupling devices or other
means of preventing arcing shall be installed in order to protect personnel and
equipment against electrical shock hazards associated with lightning, induced AC and
AC fault currents.
NOTE: See DEP Standard Drawings 41.073 and 41.077 for typical installations.
8. Supply of materials shall conform to this DEP and the requirements noted on
(Appendix 12). Isolating couplings or flanges for pipelines shall be suitable for the
operating conditions, e.g., pressure and temperature, and the product.
1. Installation of cathodic protection electrical isolation systems shall be carried out under
the on-site supervision of a NACE-certified Cathodic Protection Technician or other
person meeting the Principal’s qualification requirements.

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2. Unless specified otherwise, a NACE-certified Cathodic Protection or Corrosion

Specialist shall provide project oversight.
3. Personnel engaged in installing cathodic protection electrical isolation systems shall be
1. Equipment, tools, and materials used in this installation shall be proper and adequate
for the job.
1. Manufacturer’s technical literature shall be provided for each item supplied under this
DEP.
proposed item to be installed shall be clearly identified.
13.1.5 Drawings
Installation Contractor shall provide as-built drawings with details of the installation. Details
shall include types, locations, and number of electrical isolations and details of the
connections to the affected structures.
13.1.6 Permits
13.1.7 Safety
13.2 MATERIALS
13.2.1 Flange insulating kits
1. Gaskets, sleeves and insulating washers should be made of glass-reinforced epoxy,
and shall comply with the requirements of NEMA LI-1, Grade G-10 or better. The
sealing ring material should be nitrile, viton, teflon or other material, depending on the
type of service. Substitutions with materials subject to cold flow or cracking should not
be allowed.
2. All gaskets shall be type F (inside bolt circle) unless full face is specifically required.
The use of type D (RTJ) insulating gaskets is not allowed. When ordering gaskets, the
ID of the gasket shall be specified to match the ID of the flange face.
NOTE: If the ID of the gasket is larger than the flange bore, a crevice is created that can collect debris
which could lead to internal corrosion of the flange face.

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3. In all cases, the insulating flange kit shall have double washer type insulation that
provides an insulating washer for both sides of the flange.
4. Products such as LPG, ethylene, carbon dioxide or chlorine may require special sealing
or insulating materials.
5. Replacement gasket kits should be obtained from PSI (Pipeline Seal and Insulator,
Inc.) Model “Linebacker®” or other approved vendor. See note below.
6. Gasket kits for new construction should be obtained from Pikotek, PSI or other
approved vendor as per the following table:
Table 2 – Insulating Flange Kits
Temperature Degrees ANSI Class 150 and 300 ANSI Class 600 to 2500
Celsius / Fahrenheit
Up to 150 ºC NEMA Standard LI-1, NEMA Standard LI-1,
(Up to 302 ºF) Grade G10 Grade G10
PSI model Linebacker or Pikotek Model VCS
Pikotek Model PGE
150 to 177 ºC NEMA Standard LI-1, NEMA Standard LI-1,
(302 to 350.6 ºF) Grade G11 Grade G11
PSI Model Linebacker or Pikotek Model VCS
Pikotek Model PGE
NOTE: The Pikotek gasket is recommended for new construction only because it is slightly thicker than most
gaskets and could present a problem when used as a replacement when trying to squeeze it in
between existing flange faces. If there is space available, the Pikotek gaskets can also be used as
replacement gaskets.
13.2.2 Insulating unions

1. Insulating unions shall meet the system pressure requirements.
2. Insulating unions shall be equipped with an octagon nut (hammer bar nuts are not
allowed).
3. The nut and body shall be made of forged steel.
13.2.3 Tubing insulators
1. Tubing Insulators shall meet the system pressure requirements.
2. Tubing insulators shall provide high dielectric strength over a wide range of operating
and climatic conditions.
3. Tubing insulators shall be made of 316 stainless steel.
4. Tubing insulators should be obtained from Swagelok or other approved vendor.
13.2.4 Insulating joints (monoblock fittings)
1. Insulating joints shall meet the system pressure requirements.
2. Insulating joints shall be designed as per the project requirements and shall be
electrically and hydrostatically tested to ensure that they meet the minimum
performance requirements.
3. Insulating joints should be used instead of insulating flanges in Class I, Division 1 areas
as defined in API RP-500 and where product leaks or electrical short circuits cannot be
tolerated.

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13.3 INSTALLATION
13.3.1 Insulation flange kits
13.3.1.1 General
1. For new construction, isolating flanges shall be assembled before being welded into the
pipeline or piping system to ensure correct alignment and to avoid stresses during
installation. Before installation, Contractor shall measure the electrical resistance with a
1000 V insulation tester. Resistance of the isolating joint shall be greater than 1 MΩ in
air.
2. If insulation is installed on existing flanges, it is essential for the bolt holes and flanges
to be exactly aligned to prevent damage to the insulating material. Oversized bolts or
dowel pins shall be fitted at equal spacing around the flange to maintain alignment
during installation.
3. If insulation is installed on existing flanges that are not exactly aligned, smaller
diameter bolts of a higher strength shall not be used, unless approved by the Principal.
4. Approved gaskets, designed for isolating flanges, shall be installed without the use of
graphite filled lubricants or greases. Information concerning the use and application of
gaskets can be found in DEP 30.10.73.10-Gen.
5. The insulating sleeves shall be inserted into the bolt holes and checked for length and
clearance. The bolts shall then be passed through a steel washer, an insulating
washer, and then the sleeve in the flange. Insulating washers shall then be fitted over
the bolts next to the opposite flange. A steel washer and the nuts shall then be
installed. The bolts shall be tightened up so that even stress is maintained on the
flange faces.
6. Isolating flanges inside bunded or other hazardous areas, with the exception of flanges
used in hydrogen sulfide service, shall be profiled with moulding putty and wrapped
with an approved self-adhesive reinforced bitumen/PVC laminate tape. The tape shall
be suitable for the expected service temperature and shall be resistant to degradation
by ultraviolet radiation.
7. Isolating flanges shall be painted with non-conductive paint or shall be tape wrapped
using a standard contrasting colour for easy identification.
13.3.1.2 Installation procedures
1. Flanges shall be free of pits, gouges, rust, debris, oil and grease. Surface finish shall
be no greater than 250 RMS. Refinish flange face(s) if surface finish does not meet the
foregoing. Check flanges and bolt holes spot facing for burrs, etc., and clear from
facing.
2. Check bolts and nuts and clean. Apply non-conductive lubricant to all threads and
flange side of nuts.
3. Open isolating kit to inspect and determine that components are as specified. The
gasket ID shall not be greater than the flange bore or raised face ID.
4. Align flanges so they are concentric and parallel and install gasket carefully. DO NOT
USE LUBRICANT, GREASE OR ADHESIVE ON EITHER THE GASKET OR FLANGE
FACES. Guard against damaging sealing element.
5. Line up bolt holes with non-tapered drift pins using three at 120˚ degrees separation
(particularly on large flanges), or at least two at 180˚ degrees separation.
6. Insert bolt sleeves as shown in DEP Standard Drawing 41.027. Do not force. If force is
needed, recheck alignment and sleeve for damage. Follow up with studs, nuts and
washers, placing lubricated face of nut next to steel washer.
NOTE: This will help to reduce galling of the insulating washer on flange, should the whole bolt assembly
rotate.

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7. Initially cross-tighten bolts, as shown in DEP Standard Drawing 41.066, until flange to
gasket contact has been made.
8. Check flange set alignment for gaps or separation between gasket and flange faces,
using flashlight, calipers, or feeler gauge. If one exists, the flanges are not parallel.
9. Re-tighten loosened nuts and proceed with torque bolts according to DEP Standard
Drawing 41.066, to 10-15% of specified torque. Remove drift pins and replace with
bolts, nuts and washers, tightened to the same value as others in place.
10. Repeat torque sequence, increasing to 50% of balance.
11. Repeat tightening to final torque.
12. All of the above shall be done using torque wrenches or stud tension-measuring
devices approved by the Principal.
13.3.1.3 Flange sealing and test leads
1. Insulating putty and vinyl tape shall be applied on above ground or in vault assemblies
as shown in DEP Standard Drawing 41.026 to prevent shorting of the flange set from
debris.
2. When insulated flanges are buried, the entire flange set shall be sealed to prevent
shorting. DEP Standard Drawing 41.028 is a typical method used to protect buried
insulated flanges with wax tape coating.
3. Unless specified otherwise, test leads shall be placed on both sides of the insulated
flange set and brought to a test station for future testing. A typical insulating flange test
station is shown on DEP Standard Drawing 41.073. An insulated valve test station is
shown on DEP Standard Drawing 41.074.
4. Test leads shall be placed on both sides of buried insulated flanges and brought above
grade for future testing. See DEP Standard Drawing 41.028 and (11) of this DEP for
type of test station/bonding box required and Thermite weld connections.
13.3.1.4 Testing after installation
1. After installation, isolating flanges shall be tested similarly to an isolating joint.
2. If an isolating flange is found to be defective, the bolt-to-flange resistance shall be
measured in dry condition using a 500 V insulation tester. If the resistance between any
bolt and the flange is less than 100 kΩ the bolt shall be marked and the insulation
repaired. If all bolt-to-flange resistances are in excess of 100 kΩ and the flange has not
been accepted due to the test results, the gasket shall be replaced.
13.3.1.5 Repairs
1. Bolts showing low resistance to flange shall be removed and the insulation sleeves and
washers replaced. If the gasket requires replacement, the flange shall be dismantled
and reassembled using new insulating materials.
2. If existing isolating flanges are repaired, bolts shall be removed and replaced on a line
in service (hot bolting), only if the following conditions are met:
a. the line cannot be shut down;
b. the flange has eight bolts or more;
c. prior approval is obtained from the responsible operations department using the
required procedure;
d. bolts are removed and replaced one at a time;
e. bolts are correctly tightened after replacement;
f. the line is not subject to pulsating pressure;
g. the line is not blocked off and subject to a static pressure exceeding the maximum
operating pressure.

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13.3.2 Isolating joint

13.3.2.1 Welding
1. Insulating joints shall be designed so that they can be welded into the pipeline utilizing
standard pipeline welding procedures.
2. The isolating joint shall be welded into the pipeline at the specified location so that the
joint is not subject to bending moments and stress.
3. Welding shall be carried out so that the heat generated does not damage the insulating
material. Manufacturer's instructions with respect to welding shall be strictly followed.
13.3.2.2 Testing prior to installation
Following delivery of the isolating joint, the Contractor shall measure the electrical
resistance with a 1000 V insulation tester. Resistance of the isolating joint shall be greater
than 1 MΩ in air.
13.3.2.3 Installation
1. Test leads shall be placed on both sides of insulating joints and brought to a test station
for future testing. Test leads can be installed the same way as for an insulating flange.
See DEP Standard Drawing 41.073 for typical installation details.
2. Typically insulating joints are internally coated. In order to avoid damage to the coating
by the heat generated during the Thermite welding process, test leads shall be
attached a distance away from the insulating joint.
13.3.2.4 Testing after installation
1. After installation and with both sides of the joint earthed, the isolating joint shall be
tested by applying a DC current in the pipeline on one side of the joint.
a. Test may be achieved by the use of a permanent cathodic protection system or by
a temporary groundbed and DC supply.
b. A Swain meter shall be used to confirm zero current flow across the isolating joint.
c. As an alternative to the above test, a potential measurement may be performed.
Upon applying the current to one side of the joint, the ON/OFF potentials on both
sides shall be recorded.
d. Test results shall be reported to the Principal for review and acceptance.
2. Isolating joint may fail the test if more than one isolating device is installed in parallel, or
if grounding or instrument cables are installed in parallel with the isolating joint. If the
joint fails the test, an additional test using the “Swain” type meter may be required to
locate the fault.
3. To protect isolation joints and CP equipment in areas of lightning activity, lightning
protection shall be installed. Isolation joints and cathodic protection equipment shall be
protected from lightning by the use of surge arrestors. The arrestors shall be mounted
across isolation joints and output terminals of DC voltage sources.
13.3.2.5 Repairs
Isolating joints are factory assembled and repairs shall not be performed by the Contractor.
If a joint is found to be faulty, it shall be replaced.
13.3.3 Insulation unions
13.3.3.1 Above ground
1. Insulation unions shall be installed above ground as shown in DEP Standard
Drawing 41.030.
2. The union shall be placed in a vertical position, where possible.
3. The piping shall be properly aligned to avoid undo wear of the isolation materials.

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4. The insulating union shall be assembled as shown in DEP Standard Drawing 41.029.
13.3.3.2 Below ground
When isolated unions are buried, the entire union shall be sealed to prevent shorting. An
approved underground corrosion coating shall be used to separate the union from the
environment.
Test leads shall be placed on both sides of each buried isolated union and brought above
grade for future testing. See (11) of this DEP for type of test station required.
13.3.4 Tubing insulators
1. Tubing insulators shall be installed above grade.
2. Tubing insulators shall be of the type that provides direct connection to tubing or piping
systems.
3. Tubing insulators shall not be disassembled and shall not be used as a disconnection
point.
13.4 SPECIAL INSULATING REQUIREMENTS

13.4.1 General
Typical locations that require special insulating methods and materials are listed in this
section.
13.4.2 Piping system protected by galvanic anodes
Galvanic anodes are occasionally used to protect small structures and short pipe sections.
To maintain a proper protection level, the structures shall be electrically isolated from other
adjoining steel structures.
13.4.3 Valves in steel or other conductive material box
Valves in steel or other conductive material boxes should be insulated at the point of
support with a non-conductive material such as Micarta. Also, valves may be supported on
two sheets of steel plate separated by an insulating material.
13.4.4 Cross lines and parallel lines
1. A minimum space of 300 mm (12 in.) shall be provided between crossing lines for
insulating purposes. If such spacing cannot be obtained, insulation assurance shall be
obtained by using sheet insulation material between the lines such as Micarta.
2. The distance between lines governs the thickness of the insulating sheet, but it shall
not be less than 6 mm (1/4 in.).
3. If practical, space between paralleling pipelines 150 mm (6 in.) and larger, should be a
minimum of 2½ times the diameter of the largest line. As a minimum, a distance of
300 mm (12 in.) should separate paralleling lines.
13.4.5 Utility systems
Non-steel sewer, water, gas and buried electrical service lines shall be insulated from the
protected structures if impressed current will have a deleterious effect on these lines.
13.5 INSPECTION
2. Determination of deficiencies in the installation shall be made by the Principal.
3. Installation Contractor shall correct any deficiencies found in the electrical isolation
installation.

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14 INSTALLATION OF SYSTEMS FOR MITIGATING ALTERNATING CURRENT EFFECTS

AND FAULT CURRENTS
14.1 GENERAL
1. Installation of systems to mitigate the effects of alternating current shall be installed
when levels are determined to be above safety or corrosion thresholds.
2. The mitigation system shall be engineered to be compatible with the cathodic
protection system and utilize properly rated and located components and compatible
materials in order to fully mitigate AC effects to desired levels.
3. Mitigation systems shall be installed in accordance with NACE SP 0177.
4. Mitigation systems shall be installed in accordance with applicable government
regulations, local requirements, and this DEP.
5. Electrical portion of the mitigation systems shall be installed in accordance with the
National Electrical Code.
6. Installation of grounding and /or isolating devices shall be considered at the appropriate
insulating joints and to isolate the pipeline from the AC mitigation system, if necessary.
Where the installation of grounding and isolating devices are specified, they shall be
installed as per this DEP.
7. To verify the AC current density levels, coupon test stations shall be installed in areas
where the pipeline has a mitigation system connected directly to the pipeline and in
areas where the installation of potential gradient control mats are required. Installation
of coupon test stations shall be as per this DEP.
1. Personnel engaged in system installation shall be qualified by education, training, and
experience to fulfill requirements of this DEP.
1. Equipment, tools, and materials used in system installation shall be proper and
14.1.5 Existing facility considerations
1. Location of mitigation systems shall take into consideration existing facility easements,
field conditions, and other utilities or structures.
2. Installation Contractor shall make every effort to prevent damage to existing facilities.
14.1.6 Drawings
1. Drawings included in this DEP are diagrammatic and shall not be scaled for
determination of exact locations.

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2. As-built drawings shall be prepared and maintained by the Contractor during

construction and installation.
3. As-built drawings shall show exact location of the installation including dimensions.
4. As-built drawings shall be submitted to the Principal immediately after completion of
system installation.
5. As-built drawings shall be submitted in AutoCAD® format. AutoCAD files shall be fully
purged and free of all external references.
6. Drawings shall show the AutoCAD file name. If there is a difference between the
drawing number and the file name, a cross-reference table shall be provided with the
files. A transmittal letter shall accompany file transmittals.
14.1.7 Permits
14.1.8 Safety
14.2 SYSTEMS
14.2.1 Copper cable parallel to the pipeline in AC corridors
1. When mitigating the potential for AC corrosion on pipelines, copper cable shall be used
as the grounding medium. The system shall be installed along the pipeline at the
locations provided by Principal.
2. For new pipelines, cable shall be placed at the base of the trench between the pipe and
the overhead power line. Cable shall be installed in accordance with DEP Standard
Drawing 41.089.
3. For existing pipelines, cable shall be placed in a trench dug 1.2 m (4 ft.) from the
pipeline toward the power line. Trench shall be no less than 1.2 m (4 ft.) deep.
4. Cable lead wires shall be connected to the pipeline at intervals of approximately 150 m
(500 ft.); specific spacing will be provided by the Principal and based on environmental
parameters.
5. Lead wires shall be the same size as the designated copper cable with HMWPE
insulation and terminate into the specified SSD or PCR.
a. Lead wire insulation shall be black in color.
b. Lead wires shall be continuous without splices and without damage to the
insulation.
6. Electrical connectors for connecting lead wires to copper grounding cable shall be
appropriately-sized Burndy® compression crimpits, or an approved equal.
7. When required by Principal, materials for insulation of connections of lead wires to
copper cable shall be electrical insulation putty, tape and coating or 90-B1 splice kits.
8. Heat shrinkable marker tubing shall be 3M FP-301™ or an approved equal. Colors and
sizes of tubing to be used for marking wires, shall be as indicated in DEP Standard
Drawing 41.059.
14.2.2 Zinc anode systems
1. When mitigating the potential for AC corrosion in localized areas of unacceptable AC
current density, zinc anode grounding beds may be designated over copper cable

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installation. The grounding beds shall be installed along the pipeline at the locations
provided by Principal.
2. Anodes shall be installed in accordance with DEP Standard Drawing 41.088.
insulation.
4. Electrical connectors for connecting lead wires to copper grounding cable shall be
appropriately sized Burndy® compression crimpits, or an approved equal.
5. Materials for insulation of connections of lead wires to copper cable shall be electrical
insulation putty, tape and coating or 90-B1 splice kits.
sizes of tubing to be used for marking wires shall be as indicated in DEP Standard
Drawing 41.059.
14.2.3 Zinc grounding cell systems
1. When mitigating potential damage caused by high voltages across electrically isolated
above ground appurtenances, zinc grounding cells may be designated by Principal.
When designated, zinc grounding cells shall be prepackaged, complete with zinc
anodes, anode lead wires and backfill material as manufactured by Harco
Technologies, or an approved equal.
2. Each grounding cell shall have one zinc anode.
3. Zinc alloy used for anodes shall conform to ASTM B-418, Type II, for use in soil
applications. Zinc alloy composition shall be as follows:
a. Aluminum - 0.005% maximum
b. Cadmium – 0.003% maximum
c. Iron – 0.0014% maximum
d. Lead – 0.003% maximum
e. Copper – 0.002% maximum
f. Remainder shall be zinc.
4. Zinc anodes shall be 1.5 m (5 ft.) long and shall have 35 mm (1.4 in.) x 35 mm (1.4 in.)
cross sectional dimensions.
5. Bare weight of the anodes shall be approximately 13.6 kg (30 lbs.).
6. Core wire of zinc anodes shall be 6 mm (¼ in.) diameter mild steel. Core wire shall
extend the entire length of the anode and shall protrude from one end to facilitate lead
wire connection.
7. Lead wires shall be No. 6 AWG stranded copper cable with high molecular weight
polyethylene (HMWPE) insulation.
b. Lead wire provided with anodes shall be a minimum of 3 m (10 ft.) long. Longer
lead wires shall be provided as required.
8. Connection of lead wires to anode core wires shall be made with copper crimp
connectors. Connections shall be silver-soldered after installation of the crimp
connectors.
9. Electrical insulating material shall be used to insulate and waterproof lead wire
connections and all exposed core wire and lead wire.

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10. Zinc anodes and backfill material shall be packaged in cloth bags.
c. Backfill shall be a mixture of 50% gypsum and 50% bentonite clay.
d. Cloth bags shall be approximately 125 mm (5 in.) in diameter and 1.7 m (66 in.)
long.
e. Anode shall be centered in the backfill and bag.
f. Quantity and compaction of backfill material shall be adequate to completely fill and
produce a bag that is firm and rigid, and capable of being transported and installed
without experiencing significant distortion.
11. Assembled grounding cells shall be packaged in paper bags or cardboard boxes for
shipment. Approximate packaged weight of the grounding cells shall be 43 kg (95 lbs.)
12. A typical grounding cell installation is shown on DEP Standard Drawing 41.074.
14.2.4 Potential gradient control mats - aboveground appurtenances, valves, and
blowdowns
When mitigating potentially hazardous step-voltages at above ground appurtenances,
potential gradient control mats shall be installed. The Principal shall specify mat
construction either copper or zinc, depending on environment and cathodic protection
requirements.
When copper is required, materials shall be as follows:
1. Copper cable, the size of which shall be designated by the Principal and based on
design requirements.
insulation.
3. Electrical connectors for connecting lead wires to copper cable shall be appropriately-
sized Burndy® compression crimpits, or an approved equal.
4. When required by the Principal, materials for insulation of connections of lead wires to
copper cable, shall be electrical insulation putty, tape and coating or 90-B1 splice kits.
sizes of tubing to be used for marking wires, shall be as indicated in DEP Standard
Drawing no. 41.059.
When zinc is to be used, materials for potential gradient control mats at aboveground
appurtenances shall be as follows:
1. Zinc ribbon shall be extruded by an approved Manufacturer. Folded zinc ribbon is not
acceptable.
2. Zinc ribbon shall have a rhombus (diamond) cross sectional shape, diagonal
dimensions of 13 mm (1/2 in.) x 14 mm (9/16 in.), and a nominal weight of no less that
0.9 kg / m (0.6 lbs./ft.).
3. Zinc alloy shall conform to ASTM B-Type II, for use in soil applications. Zinc alloy
composition shall be as follows:
a. Aluminum - 0.005% maximum
b. Cadmium – 0.003% maximum
c. Iron – 0.0014% maximum
d. Lead – 0.003% maximum
e. Copper – 0.002% maximum

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f. Remainder shall be zinc.

4. Zinc ribbon shall have a 3 mm (1/8 in.) diameter steel wire core to which the zinc shall
be permanently bonded.
5. Unless otherwise specified, zinc ribbon shall be coiled in 300 m (1000 ft.) long rolls.
6. Lead wires shall be No. 6 AWG stranded copper cable with HMWPE insulation.
insulation.
7. Electrical connectors for connecting lead wires to zinc ribbon core wires shall be
Burndy YC4C8 compression crimpits, or an approved equal.
8. Materials for insulation of connections of lead wires to zinc ribbon shall be electrical
insulation putty, tape and coating or 90-B1 splice kits.
sizes of tubing to be used for marking wires shall be as indicated in DEP Standard
Drawing no. 41.059.
10. Electrical connectors for connecting potential gradient control grid lead cables to zinc
ribbon core wires shall be Burndy® YC26C2 compression crimpits or equivalent where
approved by the Principal.
11. Materials for insulating connections of potential gradient control grid lead cables to zinc
ribbon core wires shall be electrical insulation putty, tape and coating, or 90-B1 splice
kits.
12. Pipe lead cables shall be No. 6 AWG and No. 2/0 AWG single conductor stranded
copper wire and cable with HMWPE insulation.
a. Insulation shall be black in color.
b. Wires and cables shall be continuous without splices and without damage to the
insulation.
13. Pipe lead cables shall be connected as shown in DEP Standard Drawings 41.054 and
41.055.
14. Fence post grounding clamps shall be Burndy® Type “GAR” or Type “GD” as required
or approved equal.
14.3 UNPACKING AND MAKING READY

1. Promptly upon receipt at the installation site, all mitigation system materials shall be
unpacked and thoroughly inspected.
2. If damage is evident, the Manufacturer and/or the freight company shall be promptly
notified, and corrective action shall be taken.
3. If required by the Principal, function testing shall be carried out in accordance with
Manufacturer's recommendations.
4. If material will not be installed immediately after receipt, it shall be stored in a protected
manner until installed. Principal shall not be liable for materials that have not been
installed.
14.4 POTENTIAL GRADIENT CONTROL MATS AT ABOVE GROUND APPURTENANCES

14.4.1 General
1. Potential gradient control mats shall be installed at all aboveground appurtenances,
such as cathodic protection test stations, valve actuators, risers, piping, or other
metallic structures, in the area of influence.
NOTE: Mats are intended to provide protection for personnel who may come in contact with the pipeline.

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2. Mats shall be installed in accordance with the following DEP Standard Drawings:
a. 41.038
b. 41.045
c. 41.051
d. 41.056
e. 41.057
14.4.2 Lead wires

1. Prior to backfilling the pipeline at aboveground appurtenances, two lead wires shall be
installed on the pipeline.
2. Lead wires shall be connected to the pipeline as specified in (11) of this DEP.
3. Lead wires shall be sufficiently long to reach from the pipeline to the connection points
on the zinc ribbon mat with approximately 300 mm (12 in.) of slack for backfill
settlement.
4. After lead wires are installed, the pipeline shall be backfilled to approximately 150 mm
to 200 mm (6 in. to 8 in.) below final grade.
a. Lead wires shall be protected from damage during the backfill operation and shall
be maintained in a vertical position so that the ends of the wires are accessible
after this initial backfilling is complete.
b. Backfill material shall be sifted native soil or other approved material.
c. Backfill surface shall be relatively smooth and level to provide a supporting bed for
the zinc ribbon mat.
14.4.3 Zinc ribbon mat
1. After initial backfilling of the pipeline is complete, zinc ribbon shall be placed in spirals
or loops around the aboveground appurtenance.
2. Zinc ribbon shall start approximately 150 mm to 200 mm (6 in. to 8 in.) from the
aboveground appurtenance and continue in a spiral or looping pattern until the outside
run of the ribbon is a minimum of 1.2 m (4 ft.) horizontally from all accessible points on
the aboveground appurtenance.
3. Separation between two adjacent runs of ribbon shall be approximately 150 mm (6 in.).
4. Ribbon shall be placed in a manner that does not damage the zinc or the steel wire
core.
5. Ribbon shall lie flat on the surface of the backfill.
6. Following placement of the ribbon, the two lead wires that were installed on the pipeline
shall be connected to the ends of the ribbon.
a. Connections shall be made with the specified compression crimpits.
b. After the connections are completed, they shall be insulated using electrical
insulation putty, tape and coating as specified in (11.3) of this DEP.
7. Backfilling above the zinc ribbon mat shall consist of a layer of sifted native soil on top
of the mat and a layer of fine-to-medium gravel on top of the sifted native soil.
8. Native soil layer shall be firmly compacted to a thickness of approximately 50 mm
(2 in.).
9. Gravel layer shall be approximately 100 mm (4 in.) thick and shall fully cover the soil
layer immediately above the zinc ribbon mat.

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14.5 POTENTIAL GRADIENT CONTROL MATS AT VALVES AND REMOTE BLOWDOWNS

14.5.1 General
1. Potential gradient control mats shall be installed at mainline valves and remote
blowdowns as shown on the DEP Standard Drawings.
2. Installation procedures shall be essentially the same as those described for
aboveground appurtenances in (14.4).
3. Lead wires shall be installed using the shortest, most direct route practicable.
4. Mats shall be installed in accordance with the following DEP Standard Drawings:
41.033 41.050
41.036 41.051
41.039 41.052
41.040 41.053
41.041 41.054
41.042 41.055
41.043 41.056
41.045 41.057
41.048 41.059
41.049
14.5.2 Mats and grids at mainline valves

1. Prior to backfilling piping at mainline valves, lead wires shall be provided on the piping
as shown on the DEP Standard Drawings.
2. Lead wires shall be of the specified cable and wire, and shall be connected to the
piping as shown in the DEP Standard Drawings.
3. Lead wires shall be sufficiently long to reach from the piping to the connection points on
the zinc grids and zinc mats.
4. After the lead wires are connected to the piping, the piping shall be backfilled to
approximately 450 mm (18 in.) below final grade.
a. Backfill material shall be sifted native soil or other approved backfill material.
b. Surface of this initial backfill shall be relatively smooth and level.
5. Lead wires shall not be damaged during initial backfill operation and shall be
maintained in a vertical position so that the wire ends are accessible for connection to
the grids and mats.
6. After initial backfill operation is complete, trenches shall be excavated in a grid pattern
as shown in the design drawings to accommodate the zinc grid.
7. Trenches shall be routed around piping and other facilities so that runs of zinc ribbon
are not closer than 150 mm (6 in.) to the piping and other facilities.
8. Runs of zinc ribbon for the grids shall then be rolled out, cut to required lengths, and
placed in the trenches.
a. Rolling out of the ribbon shall be done in a manner that does not damage the zinc
or the steel wire core.
b. Ribbon shall lie flat in the bottom of the trenches.
9. After ribbon is placed in the trenches, intersections of the ribbon runs shall be
connected together, as shown on the drawings.

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10. Lead wires for connecting to fence posts shall be connected to the zinc ribbon core
wires as shown on the drawings. These lead wires shall be connected to the fence
posts after the fence posts are installed.
11. Lead wires connected to the piping shall be connected to the grid as shown on the
drawings.
12. After all potential gradient control grid components are installed and lead wires are
connected, the trenches shall be backfilled to final grade, except around aboveground
valve components that require potential gradient control mats as shown in the
drawings.
13. Zinc ribbon grids around above grade valve components shall be backfilled using sifted
native soil to approximately 150 mm (6 in.) below final grade in preparation for
installation of the potential gradient control mats.
14. Zinc ribbon shall be installed parallel to the fencing inside and outside of the fencing
and connected to the fencing at all fence corners as shown on the drawings.
15. Lead wires that extend above grade shall be marked with colored heat shrinkable
tubing as specified in DEP Standard Drawing 41.059.
14.5.3 Mats at remote blowdowns
1. Potential gradient control mats at remote blowdowns shall be installed in a similar
manner as mats for aboveground appurtenances.
2. Zinc ribbon shall be installed parallel to the fencing inside and outside of the fencing
and connected to the fencing at all fence corners as shown on the drawings.
3. Zinc ribbon shall be installed parallel to the blowdown line from the valve assembly
fence to the blowdown fence as shown in the drawings. Zinc ribbon shall be installed in
the same manner as zinc ribbon parallel to the pipeline. Refer to (14.2.1).
4. Lead wires that extend above grade shall be marked with colored, heat shrinkable
tubing, as specified in DEP Standard Drawing 41.059.
14.6 ZINC GROUNDING CELL SYSTEMS

1. Zinc grounding cell system shall be installed in accordance with the following DEP
Standard Drawings:
41.044 41.053
41.045 41.054
41.046 41.055
41.047 41.056
41.051 41.059
41.052
2. Zinc grounding cells shall be installed in trenches parallel to, and 3 m (10 ft.) to 4.6 m
(15 ft.) from, the pipeline on the side of the pipeline toward the HVAC system.
3. Trenches shall be approximately 2.4 m (8 ft.) to 3 m (10 ft.) deep and 300 mm (12 in.)
wide.
4. Bottom of trenches shall have 150 mm (6 in.) to 200 mm (8 in.) of bedding made of
select backfill. Top of bedding shall be reasonably flat and smooth.
5. After the bedding is in place, the specified number of zinc grounding cells shall be
placed on top of the bedding on 3 m (10 ft.) centers.
6. Cells shall be placed so that the lead wires point toward the center of the trench or
toward the zinc-to-pipe connections.

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7. Cell lead wires shall be secured to the top of the trench while placing the cells in
position. Cells shall not be lifted by the lead wires during installation.
8. After the cells have been placed in the trenches, sifted select backfill shall be placed to
a total thickness of 450 mm (18 in.).
a. Trenches shall then be backfilled with native soil to a depth of approximately 0.6 m
(2 ft.) below grade.
b. Cell lead wires shall not be damaged during backfill operation.
c. Large rocks that may damage the lead wires shall not be allowed in the backfill.
9. After the initial backfilling operation, the buss cables shall be laid out and the cell lead
wires shall be connected to the buss cables.
a. Buss cables shall not have any splices or damaged insulation.
b. Connections shall be made using the specified compression crimpits.
c. Completed connections shall be insulated using electrical insulation putty, tape and
coating.
10. Pipe lead wires shall be connected to the pipe as shown on the drawings.
11. Buss lead cables shall be connected to the zinc grounding cell buss cables, routed in
the trenches and connected to the pipe.
12. After connections are completed, trenches shall be backfilled with native backfill and
finished to original grade.
a. Pipeline, pipeline coating, and zinc grounding cell system shall not be damaged
during backfill operation.
b. Large rocks that may damage the system shall not be allowed in the backfill.
14.7 GROUNDING AND ISOLATING DEVICES

1. The type of grounding and/or isolating device to be installed depends on the purpose of
the installation. For a typical installation detail see DEP Standard Drawing 41.078.
2. Grounding and isolating devices shall be installed at the locations shown on the project
drawings.
14.8 COUPON TEST STATIONS

1. Coupon test stations shall be installed along the pipeline in areas where potential
gradient control mats are required at test stations.
2. Coupon test stations shall be installed at all locations where mitigation has been
installed parallel to the pipeline and has been connected directly to the pipeline.
Coupon test stations shall also be installed at all specified locations to monitor AC
levels on the pipeline.
3. Coupon test stations shall be installed as per (11.9) of this DEP.
4. For a typical coupon test stations with potential gradient control mat installation, see
DEP Standard Drawing 41.079.
14.9 INSPECTION
1. The Principal retains the right to inspect equipment, tools and materials prior to, and
during installation of the mitigation system.
3. Determination of deficiencies in the installation shall be made by the Principal.
Installation Contractor shall correct all deficiencies in the installation.

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15. PERFORMING CLOSE-INTERVAL PIPE-TO-SOIL POTENTIAL SURVEYS
15.1 GENERAL
15.1.1 General surveys compliance
Close-interval, pipe-to-soil potential surveys shall be conducted in accordance with NACE
SP0169 and TM0497.
15.1.2 Types of surveys
This section covers requirements for the following types of surveys:
1. On/off surveys in which current interrupters are placed on all sources of current that
could affect the structure-to-soil potential of the pipe.
2. Native potential surveys in which all rectifiers and other sources of current are turned
off and disconnected.
3. On potential surveys in which current sources are not interrupted.
4. Global positioning system (GPS) surveys. See (15.9.1).
5. Depth-of-cover (DOC) surveys. See (15.9.2).
15.1.3 Contractor supply
Unless otherwise specified, Survey Contractor shall supply all equipment, materials, and
personnel required to perform the survey.
15.2 EQUIPMENT AND MATERIALS

15.2.1 Current interrupters
1. Unless otherwise specified, current interrupters shall have the timing mechanism
operated by a GPS.
2. Interrupter on and off time intervals shall be synchronized by a GPS.
3. Non-GPS interrupters may be used only on “short” surveys, if approved by the
Principal.
4. Interrupter internal resistance shall be low enough so that no adjustment to the rectifier
tap settings is required to maintain normal rectifier current output.
5. Interrupters shall conform to NEMA 4X requirements and shall be rated to operate at
ambient 100% humidity.
6. Interrupter enclosure shall be sealed to protect against moisture and dust.
15.2.2 Line locators and depth of cover
Line locators and depth-of-cover instruments shall be Radiodetection PLX-2 or Principal-
15.2.3 Datalogger/voltmeter
1. Datalogger/voltmeter:
a. Shall have an input impedance of 100 Megohms with an accuracy of 0.1% of full
scale over the operating temperature range.
b. Enclosure shall be sealed to protect against moisture and dust.
c. Shall conform to NEMA 4X requirements and shall be rated to operate at ambient
100% humidity.
2. Data stream produced by datalogger/voltmeter shall be synchronized with the current
interrupters and each data point shall be tagged to indicate whether it is an “on” or an
“off” reading.
3. Datalogger/voltmeter shall record all data in a continuous, single stream.

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4. Survey crews shall have a handheld voltmeter with adjustable input impedance up to
200 Megohms, such as a Miller LC-4™, for determining possible measurement errors
in high resistivity soils.
15.2.4 Distance counter
1. Unless otherwise specified, distance counter shall be a wire footage counter.
2. Counter shall be mounted on a backpack or on a holster-type wire dispensing
apparatus.
3. Counter shall have an electronic wire measuring device with magnetic sensing and an
LCD display.
4. Maximum variation between the distance displayed by the counter and the wire
dispensed shall be 3 m per 1.6 km (10 ft. per mile).
5. If approved by the Principal, distance measurement may be performed using a
continuous GPS system in lieu of a distance counter.
15.2.5 Survey wire
1. Survey wire shall be No. 34 AWG copper conductor with two coats of insulation.
2. Wire dispensing spools shall be plastic and shall contain approximately three miles of
wire.
3. Heavy gauge wire with thick insulation shall be used at road crossings where traffic
may be expected.
4. Wire splices shall be carefully coated to prevent moisture entry.
15.2.6 Portable computers
Portable computers shall be IBM compatible and equipped with Windows Operating
Systems.
15.2.7 Printers
1. Printers shall be ink-jet with draft and graphics quality.
2. Print speed shall be a minimum of 190 characters per second.
15.2.8 Reference electrodes
1. Unless otherwise specified, reference electrodes shall be industry standard
copper/copper sulfate with ceramic plugs.
2. Reference electrodes to be used in brackish water shall be silver/silver chloride
(Ag/AgCl).
3. Clear windows on cells shall be covered to avoid photoelectric effects.
4. Connection between the electrode and cable shall be insulated to protect against
moisture.
5. Reference electrodes to be used in water immersion conditions shall have totally
encapsulated, factory made connection between the electrode and cable.
15.2.9 Oscilloscope or waveform meter
Oscilloscope or waveform meter shall be Polycorder 700, Fluke ScopeMeter® 120 Series
or Principal-approved equivalent.
15.2.10 Datalogger package
1. Datalogger package shall consist of a computer, a high input impedance digital
voltmeter, a solid-state memory, a keyboard, and a liquid crystal display (LCD).
2. Datalogger package shall allow identification of physical features such as fences,
roads, and creeks, by typing on the keyboard or by using hot-keys with pre-
programmed features.

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3. Pre-programmed features shall be displayed on the LCD for visual verification.

4. Keyboard shall allow input of other pertinent data, such as long lead potentials, local
point potential and IR drop measurements at reconnects, Depth of Cover
measurements, GPS coordinates, test station re-chain numbers, direction of survey,
weather conditions, road names, and anomalies.
15.3 GENERAL REQUIREMENTS FOR SURVEYS

15.3.1 General Principal and Contractor communication
1. There shall be a meeting at the start of each day, between the Principal and the
Contractor, to discuss the plans for the day, number and location of interrupters used,
possible foreign influences, review of previous day’s work, and safety considerations,
etc.
2. Contractor shall maintain adequate communication between its personnel and the
Principal’s representative.
3. Unless otherwise specified, the Contractor shall provide portable two-way radios to
each survey crew and the Principal's representative to maintain adequate contact.
4. Unless otherwise specified, each survey crew shall consist of a minimum of three
persons and two vehicles. The Principal and Contractor shall agree to number of
survey crews.
5. Survey shall be conducted at normal walking pace with individual half cell placements
approximately every 63 mm (2.5 ft.).
6. If there are other pipelines or structures in the vicinity of the pipeline that may cause
inaccurate survey data, the Principal shall be consulted to determine course of action.
7. Soil condition shall be recorded at the beginning of each survey run (i.e., reconnect of
survey wire) and shall be indicated on the survey plots. Soil condition shall be
recorded as “dry”, “moist”, or “wet.”
8. DC voltage and current output of Principal and foreign rectifiers shall be measured with
a digital voltmeter and recorded.
9. Prior to the survey, the Principal shall supply the Contractor with DEP Standard
Form 30.10.73.81-Gen. containing test point information for the facilities to be
surveyed.
10. Number and description of all Principal rectifiers and test leads as written on Principal’s
Standard Form DEP 30.10.73.81-Gen., shall be recorded on the survey plots.
11. If a test lead is not on Standard Form DEP 30.10.73.81-Gen., the comment on the
survey plot shall read, "TL not on Standard Form DEP 30.10.73.81-Gen.”
12. All prominent features such as test leads, rectifiers, valves, roads, railroads, fences,
pipeline markers, power lines, foreign line crossings, water crossings (exposed pipe
and/or washouts), buildings or other permanent structures within 6 m (20 ft.) of the
pipeline and significant changes in terrain, shall be noted in the survey data.
13. “On” and “off” pipe-to-soil potentials of all foreign lines and Principal’s line, and the
current in all bonds (during on and off cycles) shall be measured during the survey.
Polarity of bond currents shall be shown as positive (+ or no sign) if the current is going
toward the foreign structure, and negative (-) if the current is going toward the
Principal’s pipeline.
14. The current drains at bonds shall be recorded during the “on” cycle.
15. When survey sections terminate at a river or other obstacle where there is no test lead,
a probe bar shall be used where requested by the Principal to make contact with the
pipe, so pipe IR drops can be obtained. This shall be done at the discretion of the
Principal and will normally not be necessary where such sections are fairly short.
16. Copper sulfate solution for reference electrodes shall be maintained clean.

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17. Reference electrode tips shall be regularly cleaned and maintained in good condition.
18. Reference electrodes shall be calibrated every day against a master reference
electrode of the same type that is reserved for that purpose. Electrodes shall be within
5 mV of the master.
19. Survey operator shall handle the reference electrodes in a manner that ensures good
contact between the electrode tip and the earth to avoid spikes in the data. Bad
readings due to poor contact or not having the electrodes on the ground shall be
avoided.
20. Precautions shall be taken at all crossing of metallic fences and other metallic objects
to prevent short-circuiting the survey wire to ground.
21. Each survey crew shall maintain a log book that includes data such as names of crew
members, sections surveyed, number and location of interrupters, test lead readings,
bond currents, pipe IR drops in the “on” and “off” conditions, and weather conditions.
22. Stakes, flags, and survey wire shall be completely and promptly removed from
completed pipeline sections, especially in fields containing livestock or where these
items may interfere with normal use of the land. In all cases, items shall be removed
prior to the end of the day.
23. Daily survey data shall be plotted each evening, for review by the Principal.
a. If the data proves to be incomplete or not in accordance with this DEP, the affected
pipeline sections shall be surveyed again at Contractor’s cost.
b. Data plots shall be clearly legible.
c. The Principal reserves the right to restrict further survey activity until legible data
from the previous day can be reviewed and analyzed.
15.3.2 Locating and measuring the pipeline
1. Pipeline shall be located using electromagnetic line locators.
2. Survey shall be maintained on the proper pipeline at all times.
3. In congested pipe alleys and other areas where locating the pipeline may be difficult,
the Principal reserves the right to require the use of locators, directly coupled to the
pipeline in the conductive mode or other methods, to locate the pipeline.
4. If conductive mode line location is used, it shall be done in advance of the survey so no
interference with the survey measurements is created.
5. If conductive mode line location is used, pipeline location shall be indicated with flags.
Flags shall be placed at maximum intervals of 90 m (300 ft.). Closer flag spacing shall
be used as necessary around bends, in the vicinity of pipeline crossings, or if directed
by the Principal.
6. GPS coordinates of all survey data shall be automatically entered into the computer.
7. If required by the Principal, the pipeline right-of-way shall be surveyed and staked at
30 m (100-ft.) intervals.
8. If staking and flagging is used, it shall be performed not more than one day ahead of
the CIS.
9. Unless otherwise specified, documented distances shall be based on the distance
measurement system used for the survey (e.g., wire counter, GPS, or staked survey)
Distances to data points in the GPS survey shall be based on GPS equipment.
15.3.3 Individual potential readings
Either of the following methods for capturing individual potential readings may be used:
1. Automatic method that takes a reading every 63 mm (2.5 ft.) based on the measured
distance of the trailing wire, provided that there is an audible tone every 63 mm (2.5 ft.)
and only one electrode is in contact with the earth for each reading.

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2. Manual method using electrode extensions equipped with a switch that the survey
operator engages to cause the computer to capture each reading.
15.3.4 Water crossing considerations
1. Unless otherwise specified, water crossings shallower than waist deep shall be
surveyed by wading or by using a boat.
2. Unless otherwise specified, water crossings deeper than waist deep and swamp or
marsh areas may be skipped and the opposite bank approached from a test lead on
that side.
15.3.5 Pavement considerations
1. Sections of the pipeline under pavement shall not be surveyed, unless otherwise
specified, or unless the pipeline is parallel to, and within 6 m (20 ft.) of, the edge of the
pavement and there are no other pipelines or structures in the vicinity that would result
in inaccurate data.
2. Beginning and end of paved areas shall be noted in the survey data. At these points
the potentials shall be measured over the line and at the lateral distance.
3. If required by the Principal, spot survey readings shall be taken over paved areas by
drilling holes through the pavement to good soil beneath. Unless otherwise specified,
holes shall be drilled at 75 m (250 ft.) intervals. Holes shall be repaired as required by
the pavement owner.
15.3.6 High voltage power line considerations
1. If the pipeline is adjacent to high voltage power lines, or if otherwise requested by the
Principal, AC voltage shall be measured and recorded at test leads.
2. For AC voltage measurements exceeding 10 volts, filters shall be used as required to
reduce the effect of the AC on the survey data.
3. For AC voltages measurements between three and ten volts, the Principal shall be
notified of the effect of AC on the survey data to determine if AC filtering is to be used.
15.3.7 Extraneous currents
1. If telluric or other extraneous currents affect the pipeline during the survey, the Principal
shall be notified immediately.
2. No further surveys shall be done in the affected area until appropriate measures are
taken to mitigate the effect of the extraneous current or the Principal approves special
survey procedures.
15.3.8 Significant feature correlation
1. Principal survey stationing ,as shown on alignment maps, shall be correlated to the CIS
stationing at significant features such as roads, pipeline crossings, valves, and station
features every 1500 m (5000 ft.) as a minimum.
2. If the spacing between significant features is greater than 1500 m (5000 ft.), correlation
of CIS stationing shall be to the next landmark observed.
15.4 ON/OFF SURVEYS

15.4.1 General
1. Unless otherwise specified, on/off cycle shall be eight seconds on and two seconds off.
2. The following locations shall be equipped with current interrupters:
a. Principal rectifiers and accessible galvanic anodes that affect the survey.
b. Rectifiers and accessible galvanic anodes on any intersecting or parallel pipelines
that affect the survey.

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c. Bonds between Principal's pipeline and any foreign intersecting or parallel

pipelines.
d. Any other structure directed by the Principal.
3. An on/off waveform print shall be recorded at approximately two-hour intervals at a test
lead to ensure that all interrupters are still operating and are synchronized.
4. IR drop in the pipeline shall be measured between adjacent test lead locations during
the on/off cycles each time a new connection to a test lead is made. Unless otherwise
specified, IR drop during the "off" cycle shall be as close to zero as possible, and shall
be less than both of the following:
a. 10% of the IR drop in the "on" condition.
b. IR drop specified on table below.
NOTE: Complying with the above requirement may include investigating the source of unexpected current or
checking the operation of interrupters and resurveying.
Table 3a - Pipe IR Drop vs. Pipe Span Length for 1/2 Amp Current (SI)
Pipe Resistance
(Ohm/ MV IR Drop .5 AMP
Diameter.
(Per Pipe Span in Meters)
(Millimeters) 1000 Meters)
150 305 1525 3050
meters meters meters meters
150 .04987 3.8 7.6 38.0 76.0
200 .03314 2.5 5.0 25.0 50.0
250 .02339 1.8 3.6 17.8 35.5
350 .01736 1.3 2.7 13.3 26.5
600 .01004 0.8 1.6 7.8 15.5
1000 .00597 0.5 1.0 4.8 9.5
Table 3b - Pipe IR Drop vs. Pipe Span Length for 1/2 Amp Current (USC)
Pipe Resistance
(Ohm/ MV IR Drop .5 AMP
Diameter.
(Per Pipe Span in Feet)
(Inches) 1000 Ft)
500 1000 5000 10,000
feet feet feet feet
6 0.0152 3.8 7.6 38.0 76.0
8 0.0100 2.5 5.0 25.0 50.0
10 0.0071 1.8 3.6 17.8 35.5
14 0.0053 1.3 2.7 13.3 26.5
24 0.0031 0.8 1.6 7.8 15.5
40 0.0019 0.5 1.0 4.8 9.5
5. At the option of the Principal, above requirements for IR drop may be waived if unable
to meet after diligent effort has been made. Waiving of requirements shall be
applicable to specific pipeline sections. All such sections shall be specifically identified
in the survey report.
6. If a survey negative cable breaks before reaching the next test lead, or if it becomes
short-circuited to a metallic structure, that section of the survey shall be completed by
(1) starting again from the previous test lead or by (2) coming back from the next test
lead to the point where the last valid reading was taken.

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a. If the second method is used, the IR drop in the pipeline shall be computed for both
the “on” and “off” conditions by calculating the difference between the pipe-to-soil
potentials at the point the surveys meet.
b. IR drops shall be reported during the daily meeting.
c. Difference between the “off” potentials shall be less than 10% of the difference
between the “on” potentials.
7. Unless otherwise specified, test lead reconnects shall be made at every new test lead
unless they are less than 150 m (500 ft.) apart.
8. All test leads shall be read in the “on” and “off” condition by a separate meter
independent of the close interval survey.
9. The following data shall be recorded at each reconnect:
a. Near ground “on” and “off.”
b. Far ground “on” and “off.”
c. Pipe IR drop “on” and “off.”
d. Differences between near ground “on” and “off” and far ground “on” and “off.”
10. Polarity of the voltage gradient in the IR drop shall be positive (+) in the direction of the
survey.
11. “On” and “off” pipe-to-soil potentials of all foreign pipelines and the Principal pipeline,
and the current in all bonds (during on and off cycles) shall be measured.
15.4.2 Current interrupters
1. Current interrupters shall be installed on all current sources, such as Principal rectifiers,
foreign rectifiers, and bonds that affect the pipeline to be surveyed. Current sources
shall be interrupted simultaneously at uniform time intervals.
2. Contractor shall determine the required number and location of interrupters to use
based on information provided by the Principal and observations made in the field.
NOTE: Principal will provide reasonable information about foreign current sources and access to all necessary
Principal and foreign rectifiers. A Principal technician will be available throughout the survey to assist
in this regard. It is the intention that all potential current sources be considered and interrupted.
3. Current interrupters shall be installed across the secondary taps of the AC transformer.
a. Tap settings shall be recorded and marked on a temporary tag that is left in the
rectifier cabinet.
b. Tap settings shall be restored after the interrupter is removed.
4. After current interrupters are installed and checked for proper timing and operation, the
current output of the rectifier shall be measured and adjusted, if necessary, to the tap
setting that results in the closest possible output to normal. Initial tap setting and
current output shall be recorded and restored after the survey is completed and the
interrupter is removed.
5. If non-GPS synchronized interrupters are used, they shall be picked up at the end of
each day and shall be re-synchronized again prior to placement the following day. The
Principal shall be notified about any interrupters that are not properly operating when
picked up at the end of the day.
6. GPS synchronized interrupters may remain in place overnight provided that the
Contractor has a procedure approved by the Principal to determine that the interrupters
are all still operating and are properly synchronized at the beginning of the next day.

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15.5 RIVER CROSSING SURVEYS

15.5.1 General
1. Unless otherwise specified, river crossing surveys shall be performed from a boat using
the trailing wire/weighted electrode survey method.
2. Boat shall travel at a speed of approximately one knot.
3. Potential measurements shall be taken at approximately .75 m (2½ ft.) intervals.
4. Pipeline distances shall be recorded along with data readings and physical features,
which shall be visible on the final plots.
5. Survey wire shall be double coated (lacquer and plastic) wire that has been subjected
to both wet and dry spark tests.
NOTE: Holidays in the wire insulation would create a downward step function in the data stream when the
copper conductor comes in contact with the electrolyte.
15.5.2 Locating pipeline

1. Pipeline shall be located using a magnetometer.
2. Pipeline location shall be recorded every 15 m (50 ft.) using a GPS system.
3. If approved by the Principal, the pipeline may be marked using inflatable buoys or other
devices approved by Principal.
15.6 NATIVE POTENTIAL SURVEYS

1. Before the survey is started, the Contractor shall verify that:
a. All rectifiers and other current sources that affect the pipeline are turned off.
b. Pipeline-to-soil potential is stable.
c. Pipeline is electrically isolated from all other structures.
d. Rectifier negative cables are disconnected from the pipeline.
2. Disconnected cables shall be tagged and reconnected after the survey is completed.
3. If requested by the Principal, rectifiers shall be re-energized and bonds shall be
reconnected after the survey.
15.7 ON POTENTIAL SURVEYS

1. Before survey is started Contractor shall verify that all rectifiers and other current
sources that affect the pipeline are turned on and the polarization level of the pipeline is
stable.
2. No bonds shall be disconnected, unless otherwise directed by the Principal.
15.8 SURVEY DOCUMENTATION

15.8.1 Hard copy report
1. A hard copy report of the survey containing the plots shall be produced.
2. Plots report shall have a cover page with the following information:
a. Month and year that survey was conducted.
b. Name of Principal representative(s).
c. Commonly used name of the pipeline.
d. Commonly used description of the pipeline segment, such as “Alpha Station to
Beta Station” or “Mile Post 10 to Mile Post 25.”
e. Name of person in charge of the Contractor field survey team.

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f. Book Number. If more than one book is required, books shall be numbered as
Book 1 of 3, Book 2 of 3, etc.
3. Plot report shall be 216 m x 280 mm (8-1/2 in. x 11 in.). Plots shall be at a scale of
25 mm = 30 m (1 inch = 100 feet). In addition to the plot report a hard copy report shall
be prepared for on/off surveys, native potential surveys, and on potential surveys. This
report shall include the following:
a. Tabular listing of the operating features (i.e., volts, amps, tap settings) of all
rectifiers, including date measured.
- For Principal rectifiers, the number and description as shown on Standard
Form DEP 30.10.73.81-Gen.
- For foreign rectifiers, the foreign company name and rectifier location.
b. Tabular listing of bond data during on and off cycles, including the pipe-to-soil
potentials on both lines, bond current and bond current polarity.
c. Tabular listing of locations of exposed pipe and/or washouts including the length of
the washout and the footage location at the start. For surveys using GPS, the GPS
coordinates at the beginning and end of the location, shall also be included.
d. Tabular listing of buildings or other structures within 6 m (20 ft.) of the pipeline.
e. Tabular listing of test leads found that were not on Standard Form
DEP 30.10.73.81-Gen. or other information provided by the Principal.
f. On/off waveforms recorded at test leads to check rectifier operation and
synchronization.
g. Tabular listing of readings in which the difference between the near ground and far
ground instant off potentials is more than 20 mV from the measured IR drop in the
pipe during the cycle.
h. Tabular listing of readings (and associated locations) with pipe IR drop greater than
that permitted by this DEP.
4. Report for on/off surveys shall also include a tabular listing of potential readings (and
associated locations) with an “instant off” value less negative than -850 mV Cu/CuSO4.
5. Report for native potential surveys when plotted on on/off surveys shall include also a
tabular listing of potential readings (and associated locations) where the difference
between the instant off and native potentials is less than 200 mV.
6. Report for on potential surveys shall also include a tabular listing of potential readings
(and associated locations) with an “on” value less negative than -850 mV Cu/CuSO4.
7. Report for GPS and DOC surveys shall include data as specified in (Appendix 1) and
(Appendix 2).
8. Three copies of the survey plot data and the additional reports shall be provided.
9. Report binders shall not be more than 38 mm (1-1/2 in.) thick.
10. All measurements of potentials on foreign structures, bond currents, rectifier outputs,
pipe IR drops, GPS coordinates and DOC shall be shown and identified in the margins
or another clean area of the survey plots.
11. Black and white hard copy plots of the “on” and “instant-off” potentials shall be put on
the same page in a single continuous line.
a. A dashed line shall be drawn at -850 mV for ease of interpretation.
b. No averaging or manipulation of the data is permissible.
c. All actual measured data in the CIS shall be plotted.
d. If additional survey data is to be plotted (e.g., a previous on/off or native survey), it
shall be plotted in a different line type.

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15.8.2 Electronic data

Three copies of the following electronic data shall be provided on CD:
1. CIS data in Bass-Trigon Close Interval Survey Manager® (CISM), Version 5.025
format.
2. On and instant off potentials at test leads in Bass-Trigon Cathodic Protection Data
Manager® (CPDM), Version 5.025 format.
3. All other CIS data, specified in this DEP, in a Microsoft Excel® spreadsheet.
15.9 SURVEY OPTIONS

15.9.1 Global positioning system survey
1. If requested by the Principal, a GPS survey shall be conducted along the pipeline route
in conjunction with the close interval survey (CIS).
2. GPS survey shall be used to obtain latitude and longitude coordinates.
3. GPS equipment shall be of the constant measuring type so that continuous data is
collected along the pipeline route, as the close interval survey is performed.
4. In areas where continuous GPS coordinates are difficult to obtain, the survey crew shall
collect coordinate information at no greater than 30 m (100 ft.) intervals.
a. Datum shall be WGS 84, and coordinates shall be reported to a minimum of five
decimal places.
b. Coordinate points shall be numbered sequentially along the length of the pipeline.
5. GPS unit shall be electronically connected to the CIS datalogger so that GPS
coordinates are directly loaded in the datalogger.
6. GPS equipment shall be accurate to within ±3 meters (± 10 ft.) using the differentially
corrected Wide Area Augmentation System (WASS). Sub-meter differential GPS
(DGPS) may be used if it does not slow down the survey, or if requested by the
Principal.
7. Coordinates shall also be given for all prominent features such as potentials below
criteria, test leads, roads, railroads, fences, pipeline markers, valves, foreign line
crossings, DOC measurements if a DOC survey is requested, exposed pipe and/or
washouts, beginning and end of PIs, and significant changes in terrain.
8. Unless otherwise specified, GPS data shall not be plotted on the close interval plots.
GPS data shall be given to the Principal in a Microsoft Excel® file, separate from the
close interval data, in the format given in the table below.
Table 4a – GPS Data Format To Be Provided In XLS File (SI)
Point ID Survey Latitude Longitude Comments
Footage
1 0+00 32.00001 96.00005
2 3+38 32.00002 96.00005 Valve
3 5+00 32.00002 96.00004
4 9+85 32.00003 96.00004 Begin PI left
5 10+38 32.00003 96.00003 End PI
6 16+13 32.00004 96.00003 Centerline
Hwy 31
7 20+00 32.00004 96.00002

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15.9.2 Depth-of-cover survey

1. If requested by the Principal, a Depth of Cover (DOC) survey shall be conducted along
the pipeline route in conjunction with the CIS and GPS surveys.
2. Electronic depth measurements to determine depth to the top of the pipeline shall be
taken at a minimum of 150 m (500 ft.) intervals, and at locations such as maintained
dirt road crossings, roadside ditches, dry stream crossings, large changes in ground
elevations, tops and bottoms of hills, foreign line crossings, exposed pipe and/or
washouts and other places as may be directed by the Principal.
3. In addition to measurements at the above spacing, all locations where the pipe is less
than 0.6 m (2 ft.) deep shall also be reported.
4. In order to verify the accuracy of the electronic measuring equipment, the pipe shall be
physically probed once every day at the start of the survey.
a. In addition, the pipe shall be probed if requested by the Principal or if there is
reason to believe that the readings are inaccurate.
b. Probing shall be done after an initial reading with the electronic instrument and
shall be done as gently as possible, given the soil conditions, as to not damage the
pipeline coating.
c. Probing may be eliminated if requested by the Principal.
5. Electronic equipment used to measure the DOC shall be as specified in (15.2) and
shall have an accuracy of ±10%.
6. DOC data shall be shown together with the CIS data in both printed and electronic
format.
7. Electronic data shall submitted in a stand-alone report (depth against distance) in an
Excel® spreadsheet, as shown below.
Table 5a – Electronic CIS Data Format (SI)
Point Survey Depth
Latitude Longitude Comments
ID Footage (M)
1 0+00 32.00001 96.00005 3.5 Block Valve No.
101
2 3+38 32.00002 96.00005 4.2 Bottom Of Hill
3 5+00 32.00002 96.00004 2.1
4 9+85 32.00003 96.00004 0 Ditch At Hwy 101
5 10+00 32.00003 96.00003 3.9
6 16+13 32.00004 96.00003 4.0 Stream Crossing
7 20+00 32.00004 96.00002 2.2

September 2011
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Table 5b – Electronic CIS Data Format (USC)

Point Survey Depth
Latitude Longitude Comments
ID Footage (Ft.)
1 0+00 32.00001 96.00005 3.5 Block Valve No. 101
2 3+38 32.00002 96.00005 4.2 Bottom Of Hill
3 5+00 32.00002 96.00004 2.1
4 9+85 32.00003 96.00004 0 Ditch At Hwy 101
5 10+00 32.00003 96.00003 3.9
6 16+13 32.00004 96.00003 4.0 Stream Crossing
7 20+00 32.00004 96.00002 2.2

September 2011
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16. REFERENCES
In this DEP, reference is made to the following publications:
NOTES: Unless specifically designated by date, the latest edition of each publication shall be used, together
with any amendments/supplements/revisions thereto.
The DEPs and most referenced external standards are available to Shell staff on the SWW [Shell
Wide Web] at http://sww.shell.com/standards/.
SHELL STANDARDS
Cathodic Protection DEP 30.10.73.10-Gen.
Cathodic Protection Systems for Subsea Pipelines and Hardware DEP 30.10.73.32-Gen.
(Amendments/Supplements to ANSI/NACE SP0607-2007/
ISO 15589-2)
Electrical Engineering Design DEP 33.64.10.10-Gen.
Shell Pipeline Inspection and Maintenance Manual, Section 3.10
STANDARD DRAWINGS
Typical Aboveground Test Station 41.001
Thermite Welding Procedure 41.002
Thermite Welding for No. 4 AWG or Larger Conductors 41.003
Mechanical Connection of Wire and Cable 41.004
Typical Flush-to Grade Test Station 41.005
Air-Cooled Pole-Mounted Rectifier Installation – Overhead Electric 41.006
Power
Air-Cooled Pole-Mounted Rectifier Installation – Underground 41.007
Electric Power
Oil-Immersed Pad-Mounted Rectifier Installation – Top View and 41.008
Side View
Negative and positive cable junction box 41.009
Type “A” surface anode bed installation details 41.010
Type “B” surface anode bed installation details 41.011
Optional Surface Anode Bed Installation Details 41.012
Shunt Box for Surface Anode Beds 41.013
Typical Surface Anode Bed Installation for Tank Bottoms 41.014
Distributed Surface Anode Bed System in an Operating Unit 41.015
Fabrication and installation of deep anode bed 41.016
Surface Completion of Deep Anode Bed 41.017
Shunt Box for Graphite/Cast Iron Deep Anode Bed 41.018
Shunt Box for Lida® Deep Anode Bed 41.019
Single Galvanic Anode Installation 41.020
Test station for single anode installation and installation details 41.021
Multiple galvanic anode installation and installation details 41.022
Guy Wire Galvanic Anode Installation 41.023
Insulating Putty and Vinyl Tape Application to Pipe Flange 41.026
Insulating Flange Kit for Steel Pipe Flange 41.027
Buried Insulated Flange Wax Tape Coating Detail 41.028
Insulating Mechanical Steel Pipe Union 41.029
Installation Point of Insulated Mechanical Pipe Union 41.030
Horizontally Bored Impressed Current Anode System for Existing 41.031
Tank Bottoms
Under Tank ICCP Anode Detail 41.032
Zinc Ribbon System Parallel to Pipeline No. 6 AWG Wire 41.033
Zinc ribbon system splice and lead wire connection detail for no. 2/0 AWG cable 41.036
Potential Gradient Control Mat at Casing Vent with Test Station 41.038
Potential Gradient Control Grids at Mainline Valves – Plan View 41.039
Potential Gradient Control Mats at Mainline Valves – Typical Plan 41.040
View
Potential Gradient Control Grids and Mats at Mainline Valves – 41.041
Section View

September 2011
Page 135
Potential Gradient Control Mat at Remote Blowdown – Plan View 41.042

Fence Post Grounding Lead Connection Detail 41.043
Zinc Grounding Cell System 41.044
Zinc Ribbon Lead Wire Connection Detail 41.045
Zinc Grounding Cell Wire to Buss Cable Connection 41.046
Buss Lead Cable to Buss Cable Connection 41.047
Zinc Ribbon Splice and Lead Wire Connection for No. 6 AWG Lead 41.048
Wires
Zinc Ribbon to Zinc Ribbon Splice Detail 41.049
Zinc Ribbon to Zinc Ribbon Splice Detail 4 Way Connection 41.050
Tape Insulation of Buried Electrical Connection 41.051
Tape insulation of buried electrical 3 way connection 41.052
Tape insulation of buried electrical 4 way connection 41.053
No. 2/0 AWG Cable-to-Pipe Connection Detail 41.054
No. 2/0 AWG Cable - to - No. 6 AWG Wires Splice Detail 41.055
Cathodic Protection Cable & Wire Connections to Pipe 41.056
Thermite Weld Connection Procedures 41.057
Lead Wire and Cable Marking Conventions 41.059
Typical Big Fink® Test Station 41.065
Flange Bolt Tightening Sequence 41.066
Tank Foundation Detail Monitoring Tube Assembly 41.067
Rectifier DC Failure Warning System 41.068
Typical Coupon Test Station 41.070
Horizontal Impressed Current Anode System for New or 41.071
Replacement Tank Bottoms
Insulated Flange Test Station 41.073
Insulated Valve Test Station 41.074
Typical Bonding Box 41.075
Polarization Cell Installation Across Insulated Flange 41.077
Typical Polarization Cell Installation 41.078
Coupon Test Station with Potential Gradient Control Mat 41.079
Typical Isolation Locations 41.080
Typical Cathodic Protection Grid System Installation Details 41.081
Conductor Bar, Anode Ribbon, Power Feed and Reference 41.082
Electrode Installation Details
Cathodic Protection Grid System and Fiberglass Junction Box 41.083
Installation Details
Air Cooled Rectifier Installation Details 41.084
Junction Box Wiring Details 41.085
Reference Cell Monitoring Tube Installation Details 41.086
Power Feed Cable Junction Box Installation 41.087
AC Mitigation Wiring Diagram - Typical Anode Installation 41.088
Test Station and SSD Decoupler with Mitigation Cable 41.089
STANDARD FORMS
Pipe and Crossing Report DEP 30.10.73.80-Gen.
Cathodic Protection Status Survey DEP 30.10.73.81-Gen.
AMERICAN STANDARDS
Recommended Practice for Classification of Locations for Electrical API RP 500
Installations at Petroleum Facilities Classified as Class I, Division 1
and Division 2 - Second Edition; Errata 10/17/1998
Cathodic Protection of Aboveground Petroleum Storage Tanks - API RP 651
Third Edition
Boiler and Pressure Vessel Code, Rules for Construction of ASME Section VIII -1
Pressure Vessels
Standard Specification for Titanium and Titanium Alloy Strip, Sheet ASTM B265
and Plate

September 2011
Page 136
Standard Specification for Cast and Wrought Galvanic Zinc Anodes ASTM B418
Standard Specification for Aggregate for Masonry Mortar ASTM C144
Standard Specification for Standard Sand ASTM C778
Standard Test Methods for Chloride Ion In Water ASTM D512
Standard Test Method for Sulfate Ion in Water ASTM D516
Standard Test Method for Measuring pH of Soil for Use in ASTM G51
Corrosion Testing
Standard Test Method for Field Measurement of Soil Resistivity ASTM G57
Using the Wenner Four-Electrode Method
Enclosures for Electrical Equipment (1000 Volts Maximum) NEMA 250
Industrial Laminating Thermosetting Products NEMA LI-1
Electrical Polyvinyl Chloride (PVC) Conduit NEMA TC2
National Electric Code NFPA NEC 70
INTERNATIONAL STANDARDS
Degrees of protection provided by enclosures (IP code) IEC 529
Semiconductor converters – General requirements and line IEC 60146
commutated converters
External Cathodic Protection of On-Grade Carbon Steel Storage NACE RP0193
Tank Bottoms - Item No: 21061
Standard Practice Electrical Isolation of Cathodically Protected NACE RP0286
Pipelines - Item No. 21032
Control of External Corrosion on Underground or Submerged NACE SP0169
Metallic Piping Systems - Item No. 21001
Mitigation of Alternating Current and Lightning Effects on Metallic NACE SP0177
Structures and Corrosion Control Systems - Item No. 21021
Standard Practice Design, Installation, Operation, and Maintenance NACE SP0572
of Impressed Current Deep Anode Beds - Item No. 21007
Measurement Techniques Related to Criteria for Cathodic NACE TM0497
Protection on Underground or Submerged Metallic Piping Systems
- Item No. 21231
UL Standard for Safety Specialty Transformers UL506

September 2011
Page 137
APPENDIX 1 – Partial List of Materials for Graphite / Silicon Iron Anode System
SHEET 1 OF 1
Partial List of Material for a Graphite/Silicon
Iron Anode System REVISION
JAN 2011
Qty. Type Description
1. Anode Hole Size: Installation of the anode bed shall be in accordance with
“ dia. x ‘ deep drawing SA-57921.
2. 3” x 60” Wax Treated center connected graphite anodes complete with
4” x 80” Linseed # 8 AWG stranded copper cables with HMW-PE,
Kynar or Halar insulation, cut at proper length to
x Resin
connect into shunt boxes without splices. Anode spacing
shall be on ft. centers.
3. Tubular Rod High silicon cast iron anodes complete with # 8 AWG
Size “Dx “L stranded copper cables with HMW-PE Kynar or
Halar insulation, cut at proper length to connect into
shunt Boxes without splices. Anode spacing shall be on
ft. centers
4. LF Positive Header Cable. No. 2 AWG stranded copper with HMWPE insulation.
5. LF Negative Cable No. 2 AWG stranded copper with HMWPE insulation.
6. Petroleum Coke Breeze ALCOKE (std.) ALCOKE (fine)
SW SWK SWS DW1 SC2 SC3
7. 3/4 inch washed gravel or crushed stone, as required in Section 3.4
8. Bentonite pellets, as required in Section 3.4
9. Circuit positive lead Box fabrication material per dwg. SA-57924.
shunt box complete with 14 gauge aluminum with urethane topcoat.
angle-iron support and
12 gauge steel with hot-dipped galvanized coating.
conduit as per dwg.
SA-57923. Stahlin Fiberglass enclosure, NEMA 4x, or equal.
10. LF in. I.D. Schedule 40 PVC bellied end glued pipe with PVC cap (no substitution).
11. Bow-type stainless steel casing centralizers for inch OD casing in inch ID hole.
12. LF 1” I.D. AllVent™ (with vertical slits) plastic vent pipe complete with end cap.
13. LF 1” I.D. non-slited PVC vent pipe to be used outside the active anode area.
14. Misc. 1” PVC nipples, ells, etc. for vent pipe.
15. 2” filament wound epoxy pipe, Sch. 80, or 2” Sch. 40 steel pipe coated with polyethylene
16. Cement grout to fill annulus between casing and well wall per section 3.4.
17. Concrete and steel reinforcing for concrete pad per drawing SA-57922.
18. Stainless steel, gear hose clamps, with hex head screws.
19. Burndy # YA6C-L hylug connectors.
20. Burndy # YA25-L4 hylug connectors.
ALSO: All other material required for completing the job.

September 2011
Page 138
APPENDIX 2 – Partial List of Materials for MMO or LIDA® Anode System
SHEET 1 OF 1
Partial List of Material for a Mixed Metal Oxide
or Lida Anode System REVISED
JAN 11
1. Anode Hole Size: Installation of the anode bed shall be in accordance with
“ dia. x ‘ deep drawing SA-57921.
2. Anode Type: Individual Leads Loop System - Anode cable shall be
Lida MMO # 6 Halar cable cut for installation at the required depths and
“ Dia x ” Long marked accordingly. No splices are permitted. Anode
spacing shall be on ’ centers. On loop system
pig tail to first anode shall be feet.
3. Lida Ventralizer One centralizer per anode Lida Ventralizer™ or approved
MMO Centralizer equal
4. LF positive header cable. No. 2 AWG stranded copper with HMWPE insulation.
5. LF negative cable No. 2 AWG stranded copper with HMWPE insulation.
6. Petroleum Coke Breeze ALCOKE (std.) ALCOKE (fine)
7. 3/4 inch washed gravel or crushed stone, as required in Section 3.4.
8. Bentonite pellets, as required in Section 3.4.
9. Circuit positive Lead Box fabrication material per dwgs. SA-57923 or SA-57926.
Shunt Box complete with 14 gauge aluminum with urethane topcoat.
angle-iron support and
12 gauge steel with hot-dipped galvanized coating.
conduit per dwgs. SA-
57923 or SA-57925. Stahlin fiberglass enclosure, NEMA 4x, or equal.
10. LF inch I.D. Sch. 40 PVC bellied end glued pipe with PVC cap (no substitution).
11. Bow-type stainless steel casing centralizers for inch OD casing in inch ID hole.
12. LF 1” I.D. AllVent™ (with vertical slits) plastic vent pipe complete with end cap.
13. LF 1” I.D. non-slited PVC vent pipe to be used outside the active anode area.
14. Misc. 1” PVC nipples, ells, etc. for vent pipe.
15. 2” filament wound epoxy pipe, Sch. 80, or 2” Sch. 40 steel pipe coated with polyethylene
16. Cement grout to fill annulus between casing and well wall per section 3.4.
17. Concrete and steel reinforcing for concrete pad per drawing SA-57922.
18. Stainless steel, gear hose clamps, with hex head screws.
19. Burndy # YA6C-L hylug connectors.
20. Burndy # YA25-L4 hylug connectors.

September 2011
Page 139
APPENDIX 3 – Deep Anode Bed Drilling Log

(Sheet 1 of 2)
SHEET 1 OF 2
Deep Anode Bed Drilling Log Sheet REVISION

JAN 2011
COMPANY DATE
LOCATION JOB NO.
GROUNDBED BACKFILL ANODES CASING

TOTAL DEPTH DIAMETER TYPE LBS / KG TYPE LEAD CABLE NO. SIZE DEPTH
DEPTH TEST ANODE LOG

DRILLING LOG LITHOLOGY REMARKS
FT / M VOLTS AMPS OHMS
5
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
100
105
110
115
120
125
130
135
140
145
150
155
160
165
170
175
180
185

September 2011
Page 140
APPENDIX 3 – Deep Anode Bed Drilling Log

(Sheet 2 of 2)
SHEET 2 OF 2
Deep Anode Bed Drilling Log Sheet REVISION

JAN 2011
COMPANY DATE
LOCATION JOB NO.
DEPTH TEST ANODE LOG

DRILLING LOG LITHOLOGY REMARKS
FT / M VOLTS AMPS OHMS
195
200
210
215
220
225
230
235
240
245
250
255
260
265
270
275
280
285
290
295
300
305
310
315
320
325
330
335
340
345
350
355
360
365
370
375
380
385
390
395

September 2011
Page 141
APPENDIX 4 – Deep Well Anode Installation Log

SHEET 1
Deep Well Anode Installation Log Sheet REVISION

JAN 2011
COMPANY DATE
LOCATION JOB NO.
GROUNDBED BACKFILL ANODES CASING

TOTAL DEPTH HOLE DIA. TYPE LBS / KG TYPE CABLE TYPE NO. SIZE DEPTH
ANODE TAG
ANODE DEPTH ANODE RESISTANCE REMARKS
NUMBER

September 2011
Page 142
APPENDIX 5 – Partial List of Materials for Surface Anode Bed System
SHEET 1 OF 1
Partial List of Material for a Surface
Anode Bed System REVISION
JAN 2011
1. Vertical hole Type of installation:
Horizontal trench Type “A” SA-57912, Type “B” SA-57913,
Size: Optional SA-57914
“ dia./width x ‘ deep Estimated distance (feet or meters) from rectifier
to 1st anode or shunt box.
x ‘ long
Anode spacing - (feet or meters)
2. Anode Type Standard Pre-packaged cannister
3. 3” x 60” Wax Treated center-connected graphite anodes complete
4” x 80” Linseed with # 8 AWG stranded copper cables with
HMW-PE, Kynar or Halar insulation, cut at
x Resin
proper length to connect into shunt boxes without
splices.
4. Tubular Rod High silicon cast iron anodes complete with # 8 AWG
Size “Dx “L stranded copper cables with HMW-PE Kynar or
Halar insulation, cut at proper length to connect into
shunt boxes without splices.
5. LF - Positive header cable No. AWG stranded copper with HMWPE insulation.
6. LF - Negative cable No. AWG stranded copper with HMWPE insulation.
7. Metallurgical coal coke Particle size
breeze
Petroleum coke breeze ALCOKE (std.) ALCOKE (fine)
8. 3/4 inch washed gravel or crushed stone, as required
9. Bentonite pellets, as required
10. Circuit shunt box 14 gauge aluminum with urethane topcoat.
complete with 4” x 4” x 6’ 12 gauge steel with hot-dipped galvanized coating.
treated post per dwg.
Stahlin fiberglass enclosure, NEMA 4x, or equal.
SA-57915.
11. Circuit positive 14 gauge aluminum with urethane topcoat.
junction box per dwg. 12 gauge steel with hot-dipped galvanized coating.
SA-57910.
Stahlin fiberglass enclosure, NEMA 4x, or equal.
12. LF – 3” wide yellow plastic burial tape with “Cathodic Protection Cable Buried Below”
marking
13.
14.
15.

September 2011
Page 143
APPENDIX 6 – Partial List of Materials for Galvanic Anode System
SHEET 1 OF 1
Partial List of Material for a Galvanic
Anode System REVISED
JAN 2011
Qty. Description
1. High potential prepackaged magnesium anodes with feet / meters of no. 12 AWG
cable with TW yellow insulation.
Anode weight (lbs.) 9 17 32 48 60
2. Prepackaged zinc anodes with feet of no. 12 AWG cable with TW yellow
insulation.
Anode weight (lbs.) 12 18 30 45 60
3. Condulet test station, complete with Holloway type RS (0.01 ohm) shunt and support
post.
See drawing SA-57928 for details.
4. Big Fink, or equal, 5-lead terminal test station, 3” by 5 LF PVC with (0.01 ohm)
shunts.
See drawing SA-57931 for details.
5. LF of #12 AWG stranded copper wire with black TW or THW insulation.
6. LF of #8 AWG stranded copper wire with HMWPE insulation.
7. Lot Properly sized thermite weld mold, copper sleeves, and #15 weld cartridges.
8. Thermite weld caps
9. Lot Coating repair material
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
All other material required for completing the job

September 2011
Page 144
APPENDIX 7 – Installation Checklist for Rectifiers

Referenced in (9.4.1.1)
Procedure Activity / Property Result / Unit

Check
Check that the installation AC side
has been de-energised DC side
Make rectifier data sheet
Check and compare Drawings
rectifier unit with Requisitions
Check protection type of IP 20, door open
the enclosure IP 54, door closed
Check exterior for Rust
Painting
Damage
Scratches
Dents
Broken parts
Check and compare Labels
against drawings Tag plates
External cable connections
Check fixing bolts for Tightness
Check for tightness by Wire connections
hand
Check cable terminals Separated from other terminals
Check packing material Remove packing material
Check presence of Terminal partition
Warning plates
Cover plates
Check inside the cubicle Permanent electrode connections
Check rating and Fuses
compare with drawings Circuit breakers
Check information/
instruction plates against
drawings
Check the cubicle interior Clean, dry, free from dust and loose
articles

September 2011
Page 145
APPENDIX 8 – Material Requirement Sheet for Air Cooled Rectifier Installation

Referenced in (9.4.1.1)
1. Rectifier as specified in this document
2. Negative Cable Junction Boxes, in accordance with DEP Standard Drawing 41.009.
3. Positive Cable Junction Boxes, in accordance with DEP Standard Drawing 41.009.
4. LF No. 2 AWG Stranded Copper Cable with 3 mm (1/8-inch) thick HMWPE insulation.
5. 150 mm (6 in.) diameter by 7.6 m (25 ft.) long Creosoted Utility Pole (yellow pine or better).
6. 150 mm (6 in.) diameter by 7.6 m (25 ft.) long Steel Mounting Pole (grit blasted and painted).
7. Lot Angle or Channel Iron for rectifier mounting and/or support.
8. Lot Galvanized bolts, washers, lock washers and nuts.
9. Lot 25 mm (1 in.) and 50 MM (2 in.) diameter Rigid Galvanized Steel conduit.
10. Lot 25 mm (1 in.) diameter Seal-Tite Flexible conduit.
11. Lot 50 mm (2 in.) diameter Seal-Tite Flexible conduit.
12. Lot ST 100 25 mm (1 in.) Seal-Tite connectors complete with gasket assembly, locknut and
bushing.
13. Lot ST 200 50 mm (2 in.) Seal-Tite connectors complete with gasket assembly, locknut and
bushing.
14. Lot Galvanized Conduit clamps for 25 mm (1 in.) diameter conduit (two hole).
15. Lot Galvanized Conduit clamps for 50 mm (2 in.) diameter conduit (two hole).
16. 19 mm (¾ in.) diameter by 3 m (10 ft.) long Copperweld ground rod complete with clamp for
ground wire.
17. LF #2 stranded copper wire with green THW insulation for driven ground rod.
18. LF # AWG Type Insulation, stranded copper wire, black for AC power (THW,
XHHW or TW Insulation).
19. LF # AWG Type Insulation, stranded copper wire, green for AC power ground
(THW, XHHW or TW Insulation).
20. All other materials required to complete the installation.

September 2011
Page 146
APPENDIX 9 – Installation Checklist for Impressed Current Surface Ground Bed

Referenced in (4.3)
Result /
Procedure Activity / Property Unit
Check
Check anode materials and Material: Silicon Iron / Magnetite
dimensions, check for damage. /Graphite /MMO
Dimensions: cm x cm
kg
Weight:
Damage:
Check anode backfill type, Type: Coke breeze /other
quality, Fine/course/pre-packaged
volume and weight. Backfill, volume, weight m3, tons
Check anode cable dimensions Size: mm²
and check for damage of Length m
sheathing and anode Colour coding
connection. Measure cable Insulation / sheathing checked
resistance Cable connection checked
Cable resistance ohm
Check the feeder system and None/single anode
splicing materials Central distribution, distribution box
Ring feeder, size mm²
Check groundbed location Location correct
Excavate trench to required
depth for horizontal installation Measure depth + length m
Auger or drill holes for vertical
anode installation Spacing anode holes m
Check soil resistivity Depth holes m
Resistivity at anode depth ohm.cm
Horizontal:
Install anodes on layer of backfill
and cover anodes.
Backfill acc. to specification.
Vertical:
Poor backfill material in hole
[bottom] and centre anode in
hole in tamped backfill.
Cover anode with backfill
material.
Connections to feeder cable Line taps, C-crimps, other, Splice kits
connections to junction box type
Commissioning
Measure anode groundbed Anode groundbed resistance to ohm
resistance to remote earth. remote earth
Update as-built information Location, Station name
As built drawings
Finish trench with native soil Cable warning tape/tiles, groundbed
markers

September 2011
Page 147
APPENDIX 10 – Installation Checklist for Impressed Current Deep Well Ground Bed
Referenced in (3.1.1)
Result /
Check
Check anode materials and Material: Silicon Iron / Magnetite /
dimensions, check for damage. graphite / Pt-Ti / Pt-Nb /MMO
Use suitable centralisers and Dimensions, Weight: cm, kg
suspension ropes.
Damage:
Spacers, suspension rope
Check anode backfill type, Type: Coke breeze /other / fine/course
quality, volume and weight. backfill slurry / dry
Backfill, volume, weight m3, tons
For each anode check cable Size, length mm², m
dimensions and check for Colour coding
damage of sheathing and anode Insulation / sheathing checked
connection. Measure cable Cable connection checked
resistance Cable resistance ohm
Check the feeder cable and None
splicing materials Single via junction box
Size mm²
Check borehole details. Drilling equipment suitable
Check borehole location Location correct
Drill 5 m depth and set surface
casing. Surface casing, dia, length mm, m
Drill hole to total depth and log Hole diameter mm
hole using borehole checklist.
Check total depth and water Total depth m
level in hole Water table m
Set casing according to design, Casing diameter / uncased mm
record casing details, Active section: steel / perforated plastic,
cut casing above grade isolating top section, steel [coated]/ m
plastic, length m
Install headworks with cable
conduit, anode suspension
system, distribution box, vent
pipe, shunts calibrated A/mV
Remove anode protection, lower Number of anodes per hole
anodes in centre of hole and fix Use centralizers and suspension rope
suspension rope,
Install vent pipe with lower anode Vent pipe material, diameter, length mm, m
Record installation details on Perforated over length m
"Anode log sheet"
Poor coke backfill [slurry] in hole.
Record backfill used, record level Coke Used tons
of backfill. Final level m
Backfill with gravel above active
length. Backfill gravel, particle size, max min mm
volume, weight m3, tons
Measure each anode to remote Anode resistance to remote earth ohm
earth resistance
Measure total groundbed to Groundbed resistance ohm
remote earth resistance
Update as-built information Location, Station name

September 2011
Page 148
APPENDIX 11 – Installation Checklist for Underground Sacrificial Anode Bed

Referenced in (8.2.1)
Result /
Check
Check anode materials and Material: Magnesium / Zinc /
dimensions, check for Aluminum cm
damage. Dimensions: kg
Weight: mV [ref]
Potential:
Damage:
Check anode backfill Type: Gypsum-Bentonite / other
Pre-packaged / separate:
Check anode cable Size: mm²
dimensions and check for Length m
damage Colour coding
Insulation / sheathing checked
Cable connection checked
Cable resistance ohm
Check the feeder cable and None [one anode]
splicing materials Single via junction box ring
Splice kits
Check installation details. Horizontal/vertical
Take soil sample if required. Soil sample, Resistivity: ohm.cm
Remove protection, install Depth bottom m
anode in centre of hole and Hole diameter mm
compact backfill. Spacing m
Backfill with native soil. Waterproof container removed.
Water groundbed from Depth top of anode m
surface [if specified] Loose backfill compacted
Install cable. Water added [if specified]
Cable depth m
Install distribution box No of anodes
No of feeders
shunts calibrated A/mV
Marker post
Commissioning
Measure structure native Pipe-to-soil native potential mV [ref]
potential Anode-to-soil open circuit potential mV [ref]
Measure anode open circuit Anode resistance to remote earth ohm
potential and resistance Connection to structure made
Make connection to the Resistors installed ohm
structure, measure anode anode current mA
current, adjust resistor, Structure-to-soil “On” and “Off” mV [ref]
Measure structure “On” and potential
“Instant-off” potentials after 0,
hr., 24 hr. and 72 hr.
Update as-built information Location
Station name/number

September 2011
Page 149
APPENDIX 12 – Material Requirement Data Sheet for Isolation Fittings

Referenced in (13.1)
SHEET 1 OF 1
MATERIAL REQUIREMENT DATA SHEET
FOR ELECTRICAL ISOLATION FITTINGS REVISED
JAN 2011
1. FLANGE KITS
NOMINAL GASKET SEALING
QUANTITY PIPE SIZE ANSI CLASS TYPE GASKET STYLE RETAINER ELEMENT
150# 300# F LB = Linebacker G-10 Nitrile
???? ???? 400# 600# (PSI) G-11 Viton
900# 1500# PGE = (Pikotek) Teflon
2500# VCS = (Pikotek)
WASHER SLEEVE GASKET ID

WASHERS MATERIAL MATERIAL Specify: inches FLANGE TYPE
DW = Double Washer G-10 G-10 W = Weld Neck BX = API BX
G-11 G-11 S = Slip-On RX = API RX
R = RTJ Other = ??????
2. INSULATED UNIONS
NOMINAL
QUANTITY PIPE SIZE ANSI CLASS TYPE NUT STYLE
150# Octagon "O" Ring
???? ???? 600# Ground Joint
3000#
3. TUBING INSULATORS
NOMINAL
QUANTITY TUBE SIZE MANUFACTURER MODEL or TYPE
???? ???? ???? ????
4. INSULATING JOINTS
NOMINAL WALL
QUANTITY PIPE SIZE ANSI CLASS JOINT LENGTH PIPE GRADE THICKNESS
???? ???? ???? ???? ???? ????
External Coating:
Internal Coating:
5. ADDITIONAL INFORMATION
Pipe Diameter:
Pressure Rating:
Fluid Service:
Other Special Requirements:
6. REMARKS


Installation and Commissioning of Onshore Cathodic Protection Systems

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Installation and Commissioning of Onshore Cathodic Protection Systems

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DEP SPECIFICATION

INSTALLATION AND COMMISSIONING OF ONSHORE

DESIGN AND ENGINEERING PRACTICE

© 2011 Shell Group of companies

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14 INSTALLATION OF SYSTEMS FOR MITIGATING ALTERNATING

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1.2 DISTRIBUTION, INTENDED USE, AND REGULATORY CONSIDERATIONS

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1.5 PROPRIETARY NAMES

1.6 SUMMARY OF MAIN CHANGES

1.7 COMMENTS ON THIS DEP

1.8 DUAL UNITS

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2.1 GENERAL GUIDELINES FOR CATHODIC PROTECTION

2.2 INSTALLATION AND COMMISSIONING OF GROUNDBEDS

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3. INSTALLATION OF DEEP ANODE BED SYSTEMS FOR CATHODIC PROTECTION

3.1 GENERAL REQUIREMENTS

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3.3 HYDROGEOLOGIC SURVEY

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3.3.3 Hydrogeologic profile

3.4 INSTALLATION OF CASING

3.4.2 Mud/slurry pits

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2. If the anode bed is installed in a zone with multiple aquifers:

3.5 ANODE HOLE

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3.6 INSTALLATION OF ANODES

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3.6.3 Installation of graphite/cast iron anodes

3.6.4 Installation of mixed metal oxide or LIDA® anodes

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3.7 INSTALLATION OF CABLES

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3.8 SYSTEM REQUIREMENTS AT GRADE

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3.9 INSPECTION AND TESTING

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3.10 ENERGIZING THE SYSTEM

5. If grounding facilities/polarization cells have been installed to mitigate induced AC

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3.11 SYSTEM DATA

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4. INSTALLATION OF IMPRESSED CURRENT SURFACE ANODE BED SYSTEMS

4.1 GENERAL REQUIREMENTS

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4.3 INSTALLATION OF ANODE BED

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4.3.2 Installation of cable

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4.4 INSTALLATION OF ANODE SHUNT BOXES

4.5 INSTALLATION OF RECTIFIERS

4.6 INSPECTION AND TESTING