Cathodic Protection Installation Method
Statement
This method statement will serve as a minimum guideline to carry out
the Cathodic Protection Installation. Main keywords for this article are
Cathodic Protection Installation Method Statement, Sacrificial Anode
installation, Reference Electrode Calibration, Cathodic Protection
System Commissioning.
Cathodic Protection Installation Method Statement
Work Execution Procedure
Installation of Anodes (Impressed Current or Sacrificial) for
Underground Pipe
1. Cathodic Protection materials shall be withdrawn and handled
carefully when loading and unloading on the transport vehicle.
2. Study latest issued approved for construction drawings and details.
Consider priority areas for construction with respect to milestone
schedule.
3. Anodes shall be installed in place based on the latest issued
approved for construction drawing and with approved vendor
recommendation together with their approved manual installation
procedures and/or brochure.
4. Anode ground bed area should have been prepared and ready for
anode assembly installation. Soil sample for each anode bed shall
require Earth Resistance Testing. Thermal sand bedding must be
provided, and inspected by QC Inspector, shall be recorded.
5. The method of applying cathodic protection to buried pipe
work/structure using sacrificial anode, impressed current and/or
combination of both shall be in detailed with latest issued approved
for construction drawing and Cathodic Protection vendor’s manual.
The extent of the protection system shall be shown in the drawing,
and shall be normally limited to the onsite installation by means of
insulating joints/flanges, physical segregation of electrical earthing
system, polarization cells and the like. Precautionary measures
shall be taken during installation to pipe works/structures to
exclude as much as possible the unwanted extension of the
protection system by inadvertent contact with metal sleeve, piling
reinforcement and other extraneous buried steel work, which may
result shielding or increase current drain.
6. Survey the pipe route to determine accurately the anode and test
box installation as shown on the construction drawings. Anodes will
be installed in placed manually taking into consideration all
necessary precaution to prevent material damages due to poor
handling.
7. Install anodes horizontally below pipe bottom elevation as specified
in the AFC drawing. Otherwise, install it with a depth of 900mm
minimum and offset from pipelines by minimum of 600mm, as per
standard drawing . Should there be conflict with AFC drawing
and/or this method statement, a request for inspection (RFI) shall
be raised to resolve such issue.
8. Route anode lead wire(s) to assigned positive junction box. Anode
lead wire shall be routed close to pipe and laid below pipe bottom
elevation in clean sand, free of sharp stones and other foreign
objects that could cause mechanical damage.
For Sacrificial Anode Installation
A sacrificial anode is a device used in cathodic protection systems to
protect metal structures from corrosion. It is a less noble metal that is
intentionally installed and connected to the metal structure that needs
protection. The sacrificial anode is designed to corrode preferentially
instead of the protected metal, thus sacrificing itself to prevent the
corrosion of the more important structure.
The principle behind sacrificial anodes is based on galvanic corrosion,
which occurs when two dissimilar metals are in electrical contact in an
electrolyte (such as soil, water, or concrete). In the presence of an
electrolyte, a galvanic cell is formed, and one metal acts as an anode
(where corrosion occurs) and the other metal acts as a cathode (where
corrosion is prevented).
Sacrificial anode shall be installed as per approved for construction
drawing/ or Saudi Aramco Standard Drawing in accordance with
vendor recommendation.
Electrical connection between anode and pipe work/structure is
normally to be made by bracing or exothermic (cad weld) welding.
The attachment shall ensure a minimum of 1500mm spacing from
the other weld if not specified in the drawing.
Anode shall be provided with either steel inserts for mounting direct
onto pipe work or insulated copper tails for remote installations.
Sacrificial Anode shall be sprayed with water prior to back filling.
Provide sufficient slack cables at each end of cable run to prevent
stress to cable connections during backfilling of pipelines.
QC inspection for anode installation shall be requested for
inspection and result will be filed and recorded.
Backfilling should be monitored to prevent possible vandalism or
damage to CP cables.
INSTALLATION AND REFERENCE
ELECTRODE CALIBRATION
A reference electrode is a crucial component in cathodic protection
systems used to measure and monitor the effectiveness of corrosion
protection measures. It provides a stable and known electrical potential
against which the potential of the structure being protected can be
measured. This allows for accurate evaluation of the corrosion status
and the performance of the cathodic protection system.
Cathodic Protection materials shall be withdrawn and handled
carefully when loading and unloading on the transport vehicle.
Study latest issued approved for construction drawings and details.
Consider priority areas for construction with respect to milestone
Anodes shall be installed in place based on the latest issued
approved for construction drawing and with approved vendor
recommendation together with their approved manual installation
procedures and/or brochure.
Calibrate reference electrodes in accordance with specific standard
prior to installation. Quality Control Engineer shall witness the
activity as required.
Install the reference electrodes as per layout drawing and route the
cables via the cable conduit entry to the temporary manhole
located outside the ring wall.
Install proper markers or identifications to cathodic protection
conductors as per approved by company.
Review carefully the installation detail provided ensuring that the
reference electrodes are properly installed in accordance with
design standards and specifications.
Hazardous installation regarding cathodic materials shall be
addressed to include material specifications and workmanship with
precautionary measures shall be taken while connecting to power
source.
QC inspection and test for installation of monitoring tube and
reference electrode shall be requested and result shall be filed and
recorded on approved QC Forms.
Rectifier and Junciton Boxes
Rectifiers: A cathodic protection rectifier is an electrical device used to
supply a direct current (DC) to the protected structure, such as pipelines,
tanks, or other metallic assets, to counteract corrosion. It converts
alternating current (AC) from the power source into the required DC
output that drives the cathodic protection process. The primary function
of the rectifier is to provide a controlled amount of current to the anode
system, either sacrificial anodes or impressed current anodes, to
generate the protective electrochemical reactions that mitigate corrosion.
Junction Boxes: Junction boxes are used in cathodic protection
systems to provide a safe and organized enclosure for connecting
various components of the system, including anodes, cables, reference
electrodes, and bonding conductors. These boxes serve as distribution
points where different cables are terminated and connected to each
other or to the main power source.
Cathodic Protection materials shall be withdrawn and handled
carefully when loading and unloading on the transport vehicle.
Study latest issued approved for construction drawings and details.
Consider priority areas for construction with respect to milestone
schedule.
The junction box shall be fixed in position. A foundation with
mounting frame shall be prepared as per drawing following.
Rectifier and Junction Boxes shall be installed in place based on
the latest issued approved for construction drawing and with
approved vendor recommendation together with their approved
manual installation procedures and/or brochure.
All rectifiers and junction boxes concrete foundation should have
been completed and steel supports shall be fabricated and
installed as per Standard Drawing and approved for fabrication
drawing and procedures.
Rectifiers and junction boxes shall be installed manually or by
using lifting machine (if necessary based on the approved for
construction drawing).
The transformer and rectifier unit shall be installed in reference
with SAES-X-400 Sec. 6.3.2.
Alignment and stability of installed equipment shall be carefully
checked.
QC inspection for rectifier and junction box shall be done as per
request for inspection and the result shall be filed and recorded on
approved forms.
Cable Installation
Cable materials will be visually inspected for possible manufacturer
or handling damages and correctness of packaging based on
specification before withdrawal and transporting to work site. Any
sign of damages or discrepancies on document specification shall
be reported immediately to Representative for disposition.
Installation of direct buried electric cables in the plant shall be in
accordance with standard drawings following.
Cable laying work will be performed manually using cable reel
stand and rollers, putting extra attention on cable route’s bends
and sharp edges to eliminate the possibility of cable necking or
damages.
Cable tags must be installed at the lead end of the cable before the
start of cable pulling and the other end of the cable after cable
pulling.
All system cables shall be routed in accordance with International /
Saudi Aramco standard drawing BELOW and collected together at
the appropriate junction box location.
QC inspection shall be requested for power cable insulation test
and loop check prior to backfilling of the trench. After inspection,
cable ends will be tapped to protect and avoid moisture entry. All
inspection results of power cable insulation test and loop checking
shall be recorded on approved QC form.
Installation of DC cables shall be as per International Standards or
Saudi Aramco Best Practice SABP-X-003 Cathodic Protection
Installation requirements section 4.2.4.
Cable Termination
Cable gland (if required) should be checked against the actual
cable size and cable schedule to ensure proper fitness and usage
to which it conforms to area classifications.
Cable glanding shall be performed by competent and qualified
industrial electrician under the supervision of his foreman.
Unarmored cables should be dressed properly, neat, and safely
manner inside the equipment termination panel, taking extra
attention not to damage the cable insulation while performing the
termination works.
Correct size of terminal lug and crimping tool dies should be used.
Lead wire connection to the rectifier must be mechanically secure
and electrically conductive. Proper terminal lugs must be used,
saying right materials for the right job.
Visual inspection will be conducted on the completed termination
work to be witness by concerned DEC/JGC representative.
Before the power source is energized it must be verified that the
negative lead is connected to the anodes.
Cable Bonding
Bonding of cathodic protection cables to underground pipes shall
be by exothermic process and should conform based on the
requirements of International Standard Drawing, Cathodic
Specifications, Cathodic Protection Vendor manual and installation
assembly provided.
Pipe and cable for bonding should be clean, dry and free from any
oil or grease.
Strip the cable end insulation just enough to match the cad weld
mold. Check mold tag and cartridge for proper size and type of use
suitable to the pipe material to be welded, using manufacturer’s
recommendation.
Clean area of pipe approximately 50x50mm for each cad weld
connection. Wire brush and file this area to obtain a clean surface.
Thermite bonding shall be performed by a competent industrial
electrician under close supervision of his foreman. Safety
requirements shall be addressed and followed all throughout the
activity.
Test strength of weld connection by lightly tapping top of weld with
a one-pound hammer.
Remove all weld slag and spatter, sharp edges and burrs with a
metal file or wire brush.
All bonding point shall be coated with bitumen paint and let dry
before filling all void areas with seal patty.
All bonding point shall be Holiday tested (refer to SAES-X-400
Sec 6.4 sub Sec. 6.4.3) and inspected by the concerned QC
inspector prior to the backfilling of the pipe.
After above ground piping connection to underground pipeline a
Leakage/ Isolation Test will be performed on all insulating flanges.
All test result shall be recorded on approved incorporate form
provided and file for future reference.
CABLE SPLICING
Underground connecting splices of the cathodic
protection cables to the ground installation shall be avoided
whenever possible.
Extension cable whenever required and shall be of the same type,
size, and color as the cable being extended.
Alternative cables during short term supply limitations shall be of
larger size and the insulation color can be match with heat shrink
extending from junction box terminal to at least 300mm beyond any
conduits and into direct burial.
Locate the cables to its final position and make it straight as
possible. Only the minimum length of extension cable required
shall be added.
Square cut the cable ends and remove sharp points. The
conductor to conductor joints shall be made by appropriate
crimping tool and butt-connector.
All splices shall be carefully checked prior to backfilling ensuring
that sufficient slack are left to avoid strain on the cables.
If in case a short cable requires extension, splicing shall be made
by using splicing kit and to be performed by qualified
splicer/terminator.
QC inspection shall be requested for all completed underground
cable splices. Inspection results shall be properly recorded and file
for reference.
Cathodic Protection System Commissioning
The pipe to soil native potential (i.e. the potential before the
transformer rectifier is switched on) shall be measured at each test
station and recorded on form. A portable reference electrode shall
be placed in contact with the soil as close as possible to the pipe
under test. The soil should be pre-wetted at this location to ensure
good electrical contact. The digital multi-meter should be switched
to “DC volts”. As suitable scale shall be selected (commonly 2V
DC). The negative terminal of the DVM should be connected to the
portable reference electrode cable and the positive terminal should
be connected to a test lead connected to the structure negative
terminal inside the test station. The resulting reading of voltage will
be pipe-to-soil potential.
Any rheostat inside positive distribution boxes, anode junction
boxes or positive and negative junction boxes shall initially be set
to minimum resistance.
The TR (transformer rectifier) shall be switched on using the
breaker. Initial tap setting of the TR shall be course 1, medium 1
and fine 1 (there are four course, four medium and four fine
adjustments. A total of 64 increments are therefore available). The
correct polarity shall be confirmed by measuring a negative shift in
potential at any convenient test station. If the polarity is incorrect
(i.e. if there is a positive shift in potential) the unit shall be switched
off and the system reconnected insuring correct polarity.
The total output current and voltage shall be determined by reading
the TR meters and checked using a portable meter. The current is
calculated by multiplying the voltage across the shunt within the TR
by the appropriate conversion of factor. The current shall be
adjusted (using the tap settings) to approximately 25% of the
design current.
The distribution of current shall be checked on the positive and
negative sides of the circuit by measurement across the
appropriate shunt in the anode junction boxes and negative
junction boxes. All results shall be recorded on form.
The system shall be left to operate as set for 24 hrs.
On potentials shall be measured at all test stations. All results shall
be recorded on the form.
The level of protection shall be assessed form the values of ON
potentials. If any values are less than –1,000 mV (vs. Cu/CuSO4)
then the system shall be adjusted to achieve at least –1,000 mV at
all locations whilst minimizing the number of locations where –
3,000mV is exceeded. If all potentials are between –1,000 mV and
-3,000 mV the system will not require any adjustment and
commissioning shall be recorded as complete.
If adjustments are required the system shall be left to operate for a
minimum of 24 hrs at the new settings before re-testing.
