D - APPROVED INSTALIIATION PROCEDURE

Raychem ~
(OIL WATER & GAS DIVISION)
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D • APPROVED INSTALLATION PROCEDURE

RaYchem~a
(OIL WATER GAS DIVl5ION)
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 17.0 TESTING & C(>MMI.SIONING
17.1 INTENT
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. The· intent. of this DOCUMENT Is to provide a framework for performing pre-c0ll'!m1sslonlng
checks.on-·-tJ1e, equipment and materials, and flm:illy a scheme of energizing and
commlsslo.nJn9=.lhe Ins~ned cathodic protection system.
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17.2 INS1]~UMENTS
We shall provIde all necessary Instruments, ~qulpment' and labor to perform all the required
checks and test. For thfs purpose, the followln'g Instruments, amongst others, shall be
deployed at site :
'COpper/Copper SUlphate reference half cells (Portable)
4 Pin SoU Resistivity Meter
High Impedance LC.D digital Multimeter
Electricians Tools .Kit
cable Testing' Megger
Clamp on meter
17.3 ELECTRICAL FACILITIES
Before the eJe&trlcal· fadlltles are placed In operation, suitable tests -to establish· that all
equipment, deVi~, Wiring and O?nnectlons tiave been properly Install~ and 'connect~d arid
are 'In good working condition for intended operation. .
1.7.4 INSPECTION & INSTALLATION OF EQUIPMENT·
17.4~1EQUIPMENT . ,
A .visual Inspection of equipment/facility ,~hall' be carried out to deted: any' .mechanical
',damag~ and for co,mparlson and verification of dimensions and finish with d~wlngs and
specifications. .

Detailed phY$lcallnspectlon shall also Involve components and accessories.' If necessary the
same may be- removed and- inspected. " .
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17.4.2TEST CERTIFICATES
We shall submit the test certlflcates for all the materials to. the Sngloeer-In-charge.
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17.4.3ANODEFLEX a ~BLES

Verify the cable Insulation wIth a 500 V megger-.

Check the. correctness of tennlnatlon and· Jug ft~fng . .

Check the proper mark of cables and verify their compliance With desIgn data.

Check the conductor size and, char.a~e.rlstlcs of cables to.

verify their complJance with design

data·, Check the continuity of each cable'. .

17.4.4COMMISSIONING:
. The Installed CP system shall be commIssioned as per the following procedure:
Before energisatlon of the CP system,. the natural structure to soil potential value shall. be
recordecJ at the Jurictlon box.

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06.,fQ-1"20-3V;;f>O REV
DETAIL, ENGINEERING DOCUMENT 02
(:athodlc'Prot~on System for Under Ground·Storag.e ~:~~~
~aychem' RPG Ltd. Vessel~ a.t GGSR-Bathlnda·Refine.ry.. PAGE 54·0F 69

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 After completing the Install~tlon and cable connection.s, the· unit may now be energized. To
energize the· unit, follow the steps ·given below very carefully.

17.4.5GE~~RAi..CHECKING
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Check the insulation between the AC Input and the earth terminal by means of a DC Megger.
The Megger..readlng sho.uld be more than 2 to 3 Mn Initially. 0

(To check Megger Insulation, the external AC cables connected to the uni~ should be
removed).

After ensuring that the Megger read Ion gO Is OK the unit can now be energized.

Initially the :unlt shall be In Manual mode (AVeC mode). The output current.& Voltage shall
be adjusted to achieve the maximum potential value of - 1.5 V with respe~ to
Copper/Copper Sulphate Electrode for at least 48 hours.

The COmplete CP system parameters shall be reCorded &. utmost care must be exercised to
allow the structure to polarize•
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..- The detailed commIssioning procedure~ot theoTR Unit Is been explained separately In the
INSTRUCTION. OPERATION MANUAL Of: THE TR U~IT..

The unit shall be put on the AUTO mode &. all ·theosettings shall be done as Indlcat~ In the
Manual.
"A typical Commissioning Report format Is Indicated below::

Structure °to Soli potential measurement with both ON/OFF ~tent,al me~d shall be
repea~ed after 1$ d~ys 9f polarization•.

17.4.6 AS-BUILT DOCUMENTATION

.After completion of the testing and Commissioning, the" following documents shall be
; " submitted In six sets.
Test certificates of Individual Items of the CP syStem.
All parameters recoorded during commissioning
All structure-to-soll potential readings obtalned:durlng the course afthe sUNey.
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" AS BUILT documentation Includlng all.drawlngs

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Raychem -RPG Ltd.
DETAIL ENGINEERING DOCUMENT
Cathodlo Protection ·System for Under Ground ~torage
Vessels at C?GSR-BathInda Refinery.
06·10·120-3V-DD REV
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PAGE 5S·0F69

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 TESTING Be. COMMISIONING PROCEDURE:
The: Testing-, and' commissioning of CP System is 'carried out as per 'the testing and
cpmmlssloning procedure explaJned below~ , ,
,The formats for Testing' and Commissioning are with as Annexure I.

Te,sti.ng '& c~mmissionlng of CP Sy~tem for Vessels: ,..

The' cp, system is ~ested and commissioned for satisfactory operatlQn of a'node,' string

system Installed under the Vessel pottom.

The testing and commissioning procedure involves following' steps.

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stEP 1: Check. all cable connections required to feed in the CP current ·from TR-Unlt.
Measure Insulation resistance and record it. '

STEP 2: 'Before ~ner9lz1ng of'SYStem nieas~re the natural Potential of the Vesser plate
using permanently Installed reference electrodes. Installed near the Vessel surface.
Record the readings.

STEP 3 energize the, Cp' system and Increase the current In steps until polarized
Potential Level reaChes above -O.85V psp value. Measure the' output DC Soutee voltage
'and measurement OJrrent drawn by the each anode, lead cab'EVioop cable and drainage
qble to Vessels Plate. Measur.e ON potential of the Vessels bottom to sand usl'ng
permanently Installed reference electrodes Installed below the Vessels bottom and
records the readIngs. Record the Readlngs'dally,for,lS.DaXS. '

STEP '4: Furnish the result in' approved format to Owner for review, and records~ This test
Is required to ensure t~e effectiveness of operation of V~I'CP s~stem •

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Raychem RPG Ltd.,

- '. DETAIL ENGJNEERINQ:DOCUM~NT
CathodIc Protection System for Under Ground Storage
Vessels at GGSR-Bathlnda ReRnery. '
06-10·4.2.04Y-DD REV
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 16.0 INSTALLATION PROCEDUR.E

16.1 STAGE
When the sand bed reaches up to bottom of Vessel.
The actIvitieS involved are as given below,
• MakIng of slot In soli for AnodefJex cable . - 2 Nos.
• layIng of Anodeflexat the bottom level of Vessel - 2 strings
• JoInting of Anodeflex strings end with connecting cables by using
Inllne splice kits at front side of Vessel - 2sets

16.2 STAGE - II
When the sand bed reaches up to middle of Vessel shell, the activitIes Involved are as given
below,
• Making of slot In soli for Anodefl~x cable - 4 Nos.
• laying of Anodeflex at the middle level of Vessel - 4 strings.
• Jointing of AnodefJex sb1ngs end with connecting cables by usIng
Iilline splice kits at front side: of V~I -4sets
• 'layrng of Reference Electrodes (Cu/Cu 504) at top ofVe,ssel
& J~lnting with ·connecting cables - 4.' Nos.
•. laying of cathode deat cable and Its tennlnatlon ~t CJ~ - 2 Nos.
• ·;l.ay'.ng of Measurement deat cable and Its termination at CRJB - -2: Nos.
• Connecting cathode ~ble with" deat by Thermit welding on the Vessel - i ~os.
• Connecting Earth cable wIth deat by' Thennlt welding on the Vessel - 2 NoS.
• Connecting Measurement cable with deat by Thermit welcUng on the V~el - 2 Nos.

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• ·,l 16.3 STAGE -'.nl
When the sand bed re~ches the top of 'the VeSsel shell, the actiVities Involved are as given
below,
• Making of slot In soli for Anodeflex cable - 2 Nos.
• laying of Anodeflex ,at the top level of Vessel - 2 Strings
• Jointing of Anodeflex end with connecting cables strings by using
Inllne splice kits at front sld~ of Vessel. '

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Raychem RPG Ltd.
DETAIL ENGINEERING DOCUMENT
Cathodic Protectfon System for Under Ground Storage

Vessels at GGSR·Bathlnda Refinery.

. OG-10·12Q.3V-DD REV
02
PAGE 45 OF 69

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16,.4, STAGE -IV

The a~vltles are the work, which are to be performed outside the'storage area
The activities Involved:are as given below.
• Installation of all junction boxes on a mounting frame in front of the retaining wall
• Te~mlnation & conne~lon 'oGall thEf ~bfes' in-the junction boxes

.• Installation of Transformer ~~~~lfier unit

• ~-Unit connection of all Incoming &. outgoing cables &'tel1l)inatlon

16.5 STAGE - V
Stage - V activItIes are as follows
All pre-commissioning checks shall be carried out before energizing. the TR-Unlt
Tnsnsformer:- Rectifier Unit shan ~ energized and set aU parameters
The detan~ Com~JsslonJng procedul:e Is In(U~at~&..h) ,the .
OPERATION &. INSTRUCTION MANUAL e~cloSed sep.arately
16.6 ANODEFLEX
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Anodeftex Is supplied In wooden drums In lengths of 300 - 400 meters. Special precautions
should be taken dUring transportation, storage and Installation' to p'revent mechanical
damage
When the drum Is'lifted, transpOrted or stored It should be done In such way'that Anodeflex
Is protected frOm any damage the drums can' be rolled for short Clistances 'only (max. 25
mtr.) , .
16.7 STORAGE,
The AO()deftex shall always be stored In a c:;overed or shaded' 'storage are~ with a max
temperature of 50°C and a min. temperature of - 20 deg. C. In order to protect the material
from dirt, mud and dampne!!s, suffident planks, ·tlm~rs oro pallets shall be used underneath
. th~ with necessary space for drc:ulatl011 of air and for- working 9f Uftlng equipment .

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06-10-120-3.V-DD·REV
DETAIL e.NGINEEFdt,lG DOCUMENT. 02
!' Cathodic Protection System.for Under Ground Storage
Vessels, at GGSR:-BathtnCfa'Refinery. .
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Raychem: ~G !-fd. ,PAGE 46·0F 69

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 16.8 INSTALLATION PRECAUTIONS
When the. Anodeflex is pulled out of the reels, the care mus.t be taken not to. damage the
product by abrasion on the ground .
Anodeflex .in-Une splices shall be used to b,)nnect strings of Anodeflex to form one
contlnilous single cable '.
Prior to Installation' of Anodeflex In-Line Splice, .Continuity check of each strlJ1g shall .be
carried out . . ' .
1C x 10 Sq.mm Copper conductor cabie Anode lead· cable· shalf be connected to the
Anodeflex: Cable through lnllne splice kits. The Anode lead cables then terminated In the
AnodeJB .

16.9 TR-UNIT
The Transformer Rectifier shall be Instal1ed on a' mounting trame. Ail the Il)comlng and
outgoing cabl~ shall be terminated'at the bottom a~ per the scheme
The CaP. system shall be provided with automatic potential control. A. switch shan be
provided to change the mode In- Automatic or Manual operation '.
. The reference cell located In the center underneath each Vessel will be the control reference
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~II. Automatic reterence selector logic w~th .3 Nos. reference Inputs located I~ the TR unit will
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be capable to control the current output such that the structure to soli potential at the
connected reference cell Is maintained within 10 mV ~f the set value

16.10 COMMISSI'ONIN~ rEST

After' completion of. Installation. the. Raychem RPG' engineer shall charge th~' "Cathodic
Protection System In presence of owner's representative and demonstrate the operation. The
parameters shall be no~·ln a report dUring the Initlal,start

16.11 COMMISSIONING &'ASBUILT DOCUMENTATION

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A full commissioning report will be submitted with the follOWing data proVided
A full description of the complete' Anodeflex system Installed
As' built drawings
The native soli resfstlVlty at every Vessel prior .to construction
. Test certlflcates of all bought out Items

06--10d120-3V..oO REV .
.1\ DETAiL ENGINEERING DOCUMENT
Cathodic Protection System for Under Grbund Storage
' Vessels at GGSR.sathlnda Refinery.
02
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Raychem RPG Ltd. PAGE 47 OF 69

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