016B - PCP - Rev-4 04.07.2020 R-4

Rev.
: 4
Edition : 1
SPECIFIC
CATIO
ON
FOR
PERMAN
NENT
T CATH
HODIIC
ROTE
PR ECTIO
ON SYS
STEM
M
SPEC
CIFICA
ATION NO.: MEC/TS
M S/05/E9/016B
(OIL
L & GAAS SBU)
MECCON LIMITE
L ED
DELHI 110 0992
MECON LIMITED STANDARD TECHNICAL SPECIFICATION
REGD. OFF: RANCHI
834002 OIL & GAS SBU, DELHI
DOCUMENT NO. Page 1 of 1

PERMANENT CATHODIC
TITLE MEC/TS/05/E9/016B REVISION : 4
PROTECTION SYSTEM
EDITION : 1
CONTENTS
Sl. No. Description
1.0 SCOPE
2.0 CODES AND STANDARDS
3.0 SYSTEM IMPLEMENTATION
4.0 CORROSION SURVEY
5.0 CATHODIC PROTECTION DESIGN PARAMETERS
6.0 CATHODIC PROTECTION DESIGN CRITERIA
7.0 SYSTEM DETAILS
8.0 INSTALLATION
9.0 SHOP INSPECTION AND TESTING
10.0 PACKING AND TRANSPORT
11.0 FIELD TESTING AND COMMISSIONING
12.0 INTERFERENCE MITIGATION
13.0 CLOSE INTERVAL POTENTIAL SURVEY
14.0 DRAWINGS AND DOCUMENTS
15.0 INSTRUMENTS, TOOLS AND SPARES
16.0 INFORMATION REQUIRED WITH BID
PREPARED BY: CHECKED BY: APPROVED BY: ISSUE DATE :
(Aashish Moyal) (Saurabh Singh) (D.K. Pandey) March, 2009

REGD. OFF: RANCHI

PERMANENT CATHODIC
PROTECTION SYSTEM
EDITION : 1
AMENDMENT STATUS
Sl. Clause / Paragraph / Page Revision Date By Verified

No. Annexure / Exhibit / Drawing No. (Name) (Name)
Amended
Revised & re-issued as

1 - 1 Mar-2009 AM DKP
standard specification
Cathodic Protection Design

2 - 1 June-11 AM SS
Parameters Cl No.-6.1 (ii)
3 Cl No. 6.15 - 1 June-11 AM SS
4 6.7 & 8.3 (ii) (Anode Tail - - Sept-12 AM DGM

Cable)
5 8.12 (CP Cables) - - Sept-12 AM DGM
6 Revised & Issued as Standard - 2 Oct-15 AM MKJ

Specification
7 Revised & Issued as Standard - 3 Aug-2019 AM MKJ

Specification
8 Revised & Issued as Standard - 4 July-2020 AM MKJ

Specification
REGD. OFF: RANCHI

PERMANENT CATHODIC
PROTECTION SYSTEM
EDITION : 1
1.0 SCOPE
1.1 This specification defines the requirements of survey, design, engineering, supply of
equipment/ materials, Quality assurance & Quality control (QA & QC), inspection at
manufacturer works, installation, testing and commissioning of a permanent impressed
current Cathodic Protection System for protection of external surface of underground cross-
country pipelines for 35 year design life including supplementing of corrosion survey, close
interval potential logging survey, investigations for interaction / interference problems (AC &
DC) and mitigation of the same.
This specification provides the basic parameters to develop a suitable permanent impressed
current cathodic protection (ICCP) system for the pipeline/ structures requiring protection. All
data required in this context shall be taken into consideration to develop an acceptable
design and for proper engineering of the system.
Compliance with these specifications and/or approval of any documents submitted by

contractor shall in no case relieve the contractor of his contractual obligations of providing
interference free PCP system for the pipeline for 35 year of design life or as mentioned in
PJS.
1.2 Unless otherwise specified in job specifications for contracts involving survey, complete
system design, supply of material / equipment, system installation and commissioning,
integration of the permanent impressed current CP system with the temporary CP system
(whether provided by a different contractor or included along with permanent CP system)
shall be the responsibility of the permanent CP contractor whose scope shall include
disconnection of sacrificial anodes wherever required.
This specification includes certain activities which are common with the temporary cathodic
protection facilities. In cases where temporary and permanent cathodic protection works are
being executed by the same agency, the common activities would be completed as part of
temporary cathodic protection system. In cases where temporary and permanent cathodic
protection works are being executed by different agencies, the contractual scope of work/
Particular Job specification shall be referred for further details.
1.3 All work to be performed and supplies to be effected as a part of contract shall require
specific approval of owner or his authorised representative. Major activities requiring
approval shall include but not be limited to the following :-
 Corrosion survey data interpretation report and design basis for CP system.
 CP system design package
 Purchase requisitions for major equipment and vendor approval
 Detailed engineering package
 ITP & Quality Assurance for Factory test and site work
 Installation, Pre-Commissioning Procedure with record formats
 Field testing and commissioning procedure
 Procedures for interference testing and mitigation
 CIPL survey and system monitoring procedures
 Post Commissioning Reports,
 As Built Documentations
REGD. OFF: RANCHI

PERMANENT CATHODIC
PROTECTION SYSTEM
EDITION : 1
2.0 CODES AND STANDARDS
2.1 The system design, performance and materials to be supplied shall, unless otherwise
specified, conform to the requirements of the following latest relevant applicable
specifications:
i) NACE Standard SP-0169 : Standard Recommended Practice Control of

External Corrosion on Underground or
Submerged Metallic Piping Systems.
ii) NACE Publication 10A190 : Measurement technique related to criteria for
CP of Underground or Submerged Steel Piping
System (as defined in NACE Standard
RPO169-83).
ii) NACE Standard SP-0177 : Standard Recommended Practice Mitigation of
Alternating Current and Lightning Effects on
Metallic Structures and Corrosion Control
System.
iv) NACE Standard SP-0286 : Standard Recommended Practice the electrical
isolation of Cathodically Protected Pipelines.
v) NACE Publication No. 54276 : Cathodic Protection Monitoring for Buried
Pipelines.
vi) NACE Standard SP-0572 : Standard Recommended Practice Design,
Installation & Operation of Impressed Current
Deep Ground beds.
vii) IS: 8062 : Recommended Practice ICCP for Underground
Piping.
viii) BS 7361 Part I : Code of Practice for Cathodic Protection for
land and marine application.
ix) VDE 0150 : Protection against Corrosion due to Stray
Current from DC Installations.
x) Canadian Standard C22.3 : Principles and practices of Electrical
Coordination between pipe lines and Electric
Power Lines.
xi) BS EN 15280 – 2013 : Evaluation of a.c. corrosion likelihood of
buried pipelines applicable to cathodically
protected pipelines.
xii) ISO 18086 – Corrosion : Determination of AC Corrosion –
Protection Criteria of Metals and Alloys
xiii) IEEE 80 standard (latest revision), “Guide for Safety in AC Substation Grounding”.
xiv) ISO 15589 Part I : Cathodic Protection of pipeline/structure

transportation systems Part I-On-land
pipeline/structure, issued by the International
Organization for Standardization (ISO)
xv) IEEE Standards : Institute for Electrical and Electronic Engineers
xvi) OISD Standards : Oil Industry Safety Directorate

REGD. OFF: RANCHI

PERMANENT CATHODIC
PROTECTION SYSTEM
EDITION : 1
xvii) IS: 7098 Part I : XLPE Insulated Cables.
xviii) IS: 1554 Part I : PVC Insulated (heavy duty) cables.
CEOCOR Guidelines for Risk assessment and Mitigation Measures – AC Corrosion

on Cathodically Protected Pipe Lines. (2001)
IEC Standards : International electro technical commission
PNGRB Guidelines : Petroleum & Natural Gas Regulatory Board
ASTM Standards : American Society for Testing and Materials
PESO Norms : Petroleum and Explosive Safety Organisation
API Safety Norms : American Petroleum Institute
2.2 In case of imported equipments standards of the country of origin shall be applicable if these
standards are equivalent or stringent than the applicable Indian standards.
2.3 The equipment shall also confirm to the provisions of Indian Electricity rules and other
statutory regulations currently in force in the country.
2.4 In case of any contradiction between various referred standards/ specifications/ data sheet
and statutory regulations the following order of priority shall govern.
- Statutory regulations.
- SOR/Schedule of rates
- Data sheets.
- Scope of Work/ Job specification.
- Design Basis.
- This specification.
- Codes and standards.
3.0 SYSTEM IMPLIMENTATION
All work to be performed and supplies to be effected as a part of contract shall require
specific approval of owner or his authorised representative. Major activities requiring
approval as per design basis but not limited to the following:
a) Various installation procedures & Erection Methodology.

b) Corrosion survey data interpretation report, formats and plot plans for land
acquisition.
c) Conceptual system design.
d) Basic engineering package.
e) Purchase requisition for major equipment, and vendor approval, if any.
f) Specification/catalogue/data sheet of bought out items.
g) Detailed engineering package.
REGD. OFF: RANCHI

PERMANENT CATHODIC
PROTECTION SYSTEM
EDITION : 1
h) Detailed design of Anode ground bed, typical lay out drawings for Anode bed
connection & installation.
i) QA/QC Plan.
j) Procedure for field testing, pre-commissioning & commissioning.
k) Procedure for AC & DC interference detection & mitigation.
l) Procedure for post commissioning surveys.
m) Monitoring formats for PCP.
n) CPL survey procedure.
o) O&M Manuals.
p) As built documentation.
4.0 CORROSION SURVEY
4.1 General
4.1.1 The details of corrosion survey including soil resistivity, collection of additional data along the
right of way and other data required for CP design, if available with owner, shall be included
as part of project specification. However, verification of its veracity and adequacy shall be
the entire responsibility of the contractor. In addition contractor shall have to generate /
collect additional data as specified elsewhere required for completeness of the job.
4.1.2 Soil resistivity measurement shall be carried out by CP contractor at anode ground bed
locations using Wenner’s 4-pin method by calibrated instruments. Survey instruments shall
have maximum AC and DC ground current rejection feature.
Care shall be taken to ensure that the resistivity observations are not influenced by the
presence of foreign pipelines/ structures, and earth currents in the vicinity of EHV/HV lines
and installations using earth return in their power system etc.
4.2 Soil resistivity survey at impressed current anode ground bed plot
4.2.1 Each selected anode bed plot shall be sub-divided into sub-plots. Sizes of sub-plots shall
depend upon the expected depth for soil resistivity investigations. Each of these sub-plots
shall be investigated for resistivity data individually. Sufficient observations shall be taken at
each of these sub-plots as required and desired by Owner/ Owner’s representative to obtain
sufficient information about sub- soil stratification and, wherever possible, to establish the
depth of water table/ basement. The number of subplots at each ground bed plot may very
from six to ten. The exact number of sub-plots etc shall be decided at site in consultation
with OWNER/ OWNER’s representative.
4.2.2 Number, location, demarcation and size of sub-plots and number of sets of resistivity
observations required for each sub-plot shall be individually decided for each ground bed
plot location.
4.2.3 Two or more ground bed plots may be required to be selected for soil resistivity survey at
proposed anodebed location.
Depth of soil resistivity shall be as per type of anode ground bed.

REGD. OFF: RANCHI

PERMANENT CATHODIC
PROTECTION SYSTEM
EDITION : 1
For shallow type-1.5, 2.5 & 3.5 meter depth
For Deepwell anode bed-10, 15, 20, 25, 30, 35, 40, 45, 50, 100…Meter as per depth of
anode ground bed.
4.3 Topographic Surveys
Cathodic protection stations consisting of anode ground bed, CP power supply equipment
etc. alongwith all associated cabling upto pipeline and any other related equipment and
accessories for CP stations shall be demarcated on the ground. Ground plots so demarcated
shall be surveyed for all other topographical and cadastral features and topo-sheets shall be
developed by the CONTRACTOR which should be suitable for use in land acquisition etc.
4.4 Additional data to be collected
The following data shall be collected to generate design data for evaluation of interaction /
interference possibilities due to presence of other services in ROW/ vicinity. Client shall
provide assistance for liaison work to the extent possible.
i) Route and types of foreign services / pipeline in and around or crossing the right of way
(including those existing and those which are likely to come up during contract execution).
ii) Diameter, wall thickness, pressure, soil cover, and coating scheme used in case of pipelines.
iii) Details of the existing cathodic protection system protecting the services i.e. location, type of
protection, anode beds, test station locations and their connection scheme. Present output of
current and voltage readings of CP power supply units.
iv) Remedial measures existing on foreign pipeline/ services to prevent interaction.
v) Voltage rating, phases and sheathing details of cables running parallel or crossing the ROU.
vi) Graphical representation of existing structure/ pipe-to-soil potential records, T/R unit current /
voltage readings.
vii) Possibility of integration / isolation of CP systems which may involve negotiations with
owners of other services.
viii) Information on existing and proposed DC/AC power sources and system using earth return
path in the vicinity of the entire pipeline route such as HVDC/ earthing stations/ substations,
fabrication yards with electric welding etc.
ix) Crossing and parallel running of electrified and non-electrified traction (alongwith information
regarding operating voltage, AC/DC type etc.) as well as abandoned tracks near ROW
having electrical continuity with the tracks in use and the track to soil potential measurement
using Cu to CuSo4 half cell after tracks in use.
x) Crossing or parallel running of any existing or proposed EHV/HV AC/DC overhead power lines
along with details of voltage, AC/DC type etc.
xi) Voltage rating, phases, sheathing details of underground power cables along ROW or in its
vicinity.
xii) Any other relevant information that may be needed in designing and implementation proper
protection scheme for the proposed pipeline.
Unless otherwise mentioned, contractor shall conduct necessary potential gradient surveys
for any existing anode ground beds that may interfere with the CP system of the pipelines
covered under this project.
REGD. OFF: RANCHI

PERMANENT CATHODIC
PROTECTION SYSTEM
EDITION : 1
4.5 Report
After completion of all field work, a report incorporating all the results generated from site
surveys and details of additional data collected shall be submitted to the MECON/CLIENT
for necessary approval. The report shall also contain detailed interpretation of survey results
and resistivity data, probable interference prone areas etc to form a design basis for the PCP
system. This report shall also include various drawings prepared in connection with the
above work. The soil resistivity values shall be plotted on semi log graph sheets.
5.0 CATHODIC PROTECTION DESIGN PARAMETERS
5.1 Protection current density range :
i) Pipeline with FBE Coating
Pipeline surrounding Minimum Protection current density*@30 deg C

Resistivity Permanent CP
(µA/m²)
Normal Soil (10-100 Ohm- 400
Mtr)
Marshy Area/ HDD (<10
Ohm-Mtr)
High Resistivity Area (more
than 100 ohm-mtr.
Resistivity)
ii) Pipeline with Polyethylene Coating
Pipeline surrounding Minimum Protection current density*@30 deg C

Resistivity Permanent CP
(µA/m²)
Normal Soil (10-100 Ohm- 250
Mtr)
Marshy Area/ HDD (<10
Ohm-Mtr)
High Resistivity Area (more
than 100 ohm-mtr.
Resistivity)
(*) Actual current density to be adopted shall be decided based upon soil and other
environmental conditions, proximity of foreign pipelines and structures affecting interference.
Where considered necessary for satisfactory protection of pipeline the current density shall
be suitably increased by contractor. Where operating temperatures of U/G pipeline is above
30 deg. C, such as CP Stations located near Compressor stations, protection Current
Density shall be increased in minimum by 25% for every 10 °C rise in temperature over 30
°C up to a temperature of 60 deg.C.
REGD. OFF: RANCHI

PERMANENT CATHODIC
PROTECTION SYSTEM
EDITION : 1
For all pipeline sections which are having intermediate HDD Horizontal Directional Drilling
crossings, the nearby CP TRU units should have adequate provision of D.C. output current to
cater to the extra protection current demand at the HDD crossings.
5.2 Safety Factor (SF) : 1.3
5.3 Protection Current Density to be (I2) : 10 mA/m2

considered for Pipeline without Coating
in Soil
5.4 Service Life (SL) : 35 years
5.5 Type of Anode : MMO Coated Titanium Anode/ HiSiCr

Fe Anode
5.6 Anode Consumption Rate 0.2 kg/Amp (Max) Year for HiSiCrFe
anode
1.0 mg/ Amp (Max) Year for MMO

Titanium anode
5.7 Type of Tail Cable : PVDF Insulated/ HMWPE Sheathed

(Kynar)
5.8 Size of Tail Cable : 10mm2
5.9 Type of Anode bed : Shallow- Horizontal / Vertical or

Deepwell
5.10 Shape of Anode for Shallow Bed : Sheet Steel Canistered Anode pre-
System packaged with petroleum coke breeze
5.11 Shape of Anode for deep well anode : String Anode or Individual anode as
bed per Scope of work/PJS
5.12 Current Density for Anode 10 Amp/m2 for HiSiCrfe Anode

100 Amp/m2 for MMO Titanium anode
5.13 Anode Utilisation Factor (UF) : 0.8 for centrally connected HiSiCrFe
anode / MMO Titanium Anode
0.6 for end connected HiSiCrFe anode
0.5 for ribbon anode
5.14 Total Circuit Resistance (RC) : 0.5 - 1.0 ohm (Max.)

(Anode to ground resistance, anode &
cathode cable resistance for CP
System)
5.15 Specific Coating Resistance(Coating : 15,000 ohm-m2 for normal soil
resistivity) 7,500 ohm-m2 for marshy area
REGD. OFF: RANCHI

PERMANENT CATHODIC
PROTECTION SYSTEM
EDITION : 1
20,000 ohm-m2 for high resistivity area
5.16 Steel resistivity : 2.2 x 10-7 ohm-m
5.17 Cathode Polarisation at Drainage Point : (-) 1.2 V (max.)

(Off Potential- w.r.t. Cu/CuSo4)
5.18 Cathode Polarisation at farthest Point : (-) 0.85V (min)

(Off Potential w.r.t. Cu/CuSo4)
5.19 Pipeline Natural Potential : (-) 0.45 V

(w.r.t. Cu/CuSo4)
6.0 CATHODIC PROTECTION DESIGN CRITERIA
Cathodic protection system shall be designed to meet the following criteria:
a) The pipe to soil potential measurements shall be between (-) 850 mV (Off) polarized potentials
with respect to a copper/ copper sulphate reference electrode.
b) In rare circumstances a minimum polarisation shift of (-) 100 millivolts of cathodic polarization
between the structure surface & a stable reference electrode shall indicate adequate levels of
cathodic protection for the pipeline. The formation or decay of this polarisation can be
measured to satisfy this criterion.
Discretion to use any of the criteria listed above shall solely rest with the owner/ owner’s
representative.
c) A positive potential swing of 50 mill volts and above shall be considered as sufficient to
indicate the presence of an interaction situation (i.e. Interference on the pipeline) requiring
investigation and incorporation of mitigation measures by the CONTRACTOR.
d) As such there is no limit for maximum "ON" negative potential; however, in general, it should
not be more negative than -2500 mV (Cu/CuSO4). If any special circumstances exist where
an “ON” potential of more than -2500 mV (Cu/CuSO4) is required to be applied, then it shall
be brought forward for Owner/Consultant approval with proper justification supported by the
pipeline coating Manufacturer's recommendations.
7.0 SYSTEM DETAILS
The system shall include the following major equipment / sub-system unless otherwise
specified in project specifications but not limited to following:
- CP stations
- TR units/ cathodic protection power supply modules (CPPSM).
- Anode ground beds and anodes.
- Anode lead junction box.
- Test stations.
- Permanent reference cells. (Pure Zn/Cu-CuSO4)
- Electrical resistance probes.
REGD. OFF: RANCHI

PERMANENT CATHODIC
PROTECTION SYSTEM
EDITION : 1
- Solid state polarisation cell/ surge diverter/ grounding cell.

- CP system at cased crossing.
- Polarisation coupons for external corrosion monitoring.
- Bonding Stations.
- CTSU (Computerised Test Station Unit)
- Cables & Cable markers.
- Cathode Junction Box.
- Post commissioning surveys
- AC-DC interference study and mitigation
The detailed specification of each system and equipment shall be furnished by the
CONTRACTOR. However, certain minimum requirements for the major equipment are
highlighted in this document.
All equipment shall be new and procured from approved reputed manufacturers. Equipment
offered shall be filed proven. Equipment requiring specialised maintenance or operation shall
be avoided as far as possible. Prototype equipment shall not be accepted. Make and
construction of all materials shall be subject to owner’s approval.
As far as possible, equipment including test stations, anode lead junction boxes etc. shall be
located in safe non-hazardous areas. However, equipments to be installed in hazardous
areas shall be of flameproof type confirming to IS:2148, IS:5572, IEC:79 & API 500C and
suitable for gas groups IIA & IIB and temperature class – T3 (200˚C).
All flame proof equipments/materials manufactured in India should be certified by CMRI or

any other recognised testing body & BIS marked.
All imported equipments/materials for hazardous area shall be tested and certified by an
independent agency of country of equipment/material origin and shall be approved by the
concerned statutory authority in India.
7.1 Cathodic Protection Stations
The number and exact locations of CP stations shall be worked out based on the corrosion
survey data collected. In addition, the following guidelines shall be followed for selecting the
locations.
i) Number of CP stations and their selected location shall ensure that these remain
valid and are adequate for the full design life of the system after considering all
foreseeable factors.
ii) As far as possible, the availability of near by low resistivity areas for location of
associated ground beds must be ensured while selecting the locations of CP
stations.
iii) As far as possible, locations of intermediate CP stations shall coincide with the
locations of SV stations.
The proposed locations of CP stations are detailed in project specifications (PJS). The same
shall be verified for adequacy by the contractor and any additional requirements shall be
clearly brought out at the bidding stage itself.
7.2 Transformer Rectifier Unit/ CPPSM

REGD. OFF: RANCHI

PERMANENT CATHODIC
PROTECTION SYSTEM
EDITION : 1
7.2.1 Cathodic protection transformer rectifier unit (T/R Unit) working on controlled rectification
principle shall supply power for cathodic protection system. The T/R unit shall be provided at
CP stations where reliable AC power supply is available and specified in project
Specification.
The T/R unit shall be field proven. The design, internal component quality, ratings and layout
of components shall ensure high MTBF and low MTTR.
The T/R unit shall conform to MECON’s specification no MEC/TS/05/E9/082A and T/R unit
data sheet.
7.2.2 Cathodic Protection Power supply Module (CPPSM) for supply of power to Cathodic
Protection System shall work on DC input power supply & control the output DC supply
using power switch mode principle. The CPPSM unit shall be provided at CP stations where
reliable DC power supply is available and specified in project Specification.
The CPPSM shall be field proven. The design, internal components, quality, rating & layout
of components shall ensure high MTBF & low MTTR.
The CPPSM shall conform to MECON Standard Specification No. MEC/TS/05/E9/082 and
CPPSM Data Sheet.
7.3 Anode Ground Beds and Anodes
i) Each CP station shall have an independent anode ground bed which may be of shallow or
deep well construction depending upon the corrosion data collected by the contractor. Deep
well ground beds may also be used in the congested locations where availability of suitable
land for spread out ground beds is restricted.
ii) Ground bed shall be located electrically remote from the pipeline. Nearest part of the anode
bed shall at least be 100 metres away from the pipeline and foreign pipelines/ structures.
The anodes installed in the ground shall be located in perennially moist strata, wherever
possible. Horizontal ground beds shall be at right angles to the pipeline, as far as possible.
The location of ground bed shall be checked and ensured for remoteness from the pipeline
and other buried foreign pipelines/ structures, building foundations, switchyards, electrical
earthing systems etc.
All MMO Anodes to be placed in Petroleum cock breeze in Shallow-Horizontal/Vertical or

Deepwell configuration as per design for 35 year of protective life.
iii) Anodes shall be of MMO coated titanium anode or HiSiCrFe anode alongwith tail cable
(Factory jointed) of sufficient length for termination upto the junction box without any joint.
MMO coated titanium anodes
MMO coated titanium anodes shall conform to ASTM A518M-86, Gr-III & composition shall
be as below:-
MMO coated titanium anodes shall be of pure Ti substrate. The MMO anodes shall be centre
REGD. OFF: RANCHI

PERMANENT CATHODIC
PROTECTION SYSTEM
EDITION : 1
connected sealed tubular type & dimensionally stable.
MMO Anode Dimension - As per manufacturer’s detailed drawings
Weight of Anode - Recommended by manufacturer

w.r.t. dimension
Max. Recommended - 100 A/m2

Current density
Service Life - 35 years
Anode Cable - Single MMO Anode–PVDF Insulated/

HMWPE Sheathed (Kynar Cable)
String MMO Anode – EPR/CSPE
Cable Length - As required
Type of Joint - Epoxy Splicing

Anode Consumption Rate - 1 mg/Amp. Yr.
Electrical Resistivity of MMO coating- 6 x 10-5 ohm cms
MMO Coating thickness - > 6gms/m2
Carbonaceous Backfill - Life 35 years
Utilisation Factor - 0.8 for centre connected

0.9 for end connected
The GTP (Guaranteed Technical Particulars) of MMO anodes i.e. Current density,
consumption rate (max. specified), rated current output, shape, dimension, physical &
mechanical property, thickness of coating of noble meta shall be as per manufacturer’s
specification/data sheet & CONTRACTOR shall submit routine & type test report for the
anodes.
High Silicon Chromium Cast Iron Anode
Anode shall conform to ASTM A518M-86, Gr-III & composition shall be as below:-
Silicon : 14.2 – 14.75%

Manganese : 1.5% max.
Carbon : 0.7 – 1.1%
Chromium : 3.25 – 5.0%
Copper : 0.5% max.
Molybdenum : 0.2% max.
Iron : Reminder
Utilisation Factor - 0.8 for centre connected
0.6 for end connected
REGD. OFF: RANCHI

PERMANENT CATHODIC
PROTECTION SYSTEM
EDITION : 1
iv) The anode shall be hollow type centrally connected or solid type end connected, cable to
anode joint shall be reliable and adequate for design life of anode.
v) Sheet steel anode canisters of adequate size shall be provided for each anode of shallow
bed type. Anode canisters shall be filled with petroleum coke breeze with a chemical
composition as given below:-
- Fixed carbon content by mass : 99% min.

- Ash by mass : 0.5% max.
- Moisture by mass : 0.05% max.
- Bulk density – 800 g/m3 Min
- Particle Size: Ranging 0.1 - 1mm
- Volatile matters by mass : 0.5% max.
- Hydrogen/hydrocarbons ‐Nil ( calcination temperature in excess of 1200 deg C)
Contractor shall furnished Test Certificate including the following for review/Approval:
a) Make of coke breeze

b) Batch no.
c) Chemical composition
d) Bulk density and Real density
e) Particle size analysis
f) Resistivity (ohm-cm)
vi) String anode/ Individual anode shall be used for deepwell ground bed. In case of deep well
ground beds calcined fluid petroleum coke breeze with chemical composition as given below
shall be provided in the well surrounding the anodes.
- Fixed carbon content by mass : 99% min.

- Ash by mass : 0.5% max.
- Moisture by mass : 0.1% max.
- Volatile matters by mass : 0.5% max.
vii) Each shallow anode bed shall contain anodes with canisters positioned horizontal or vertical
in the soil with suitable backfill at minimum depth of 2 meter with respect to horizontal or
vertical configuration.
viii) Layout of anode installation in anode bed shall be detailed out in drawings showing anode
installation details, anode grouping, anode wiring, anode cable routing etc.
ix) The deepwell anode ground bed details shall include the details of anodes, deepwell casing,
anode positioning, anode cable supporting, deepwell gas venting, active, passive portions of
ground bed etc.
x) Anodes shall be supplied complete with tail cables which shall be long enough for
termination on their associated junction boxes without intermediate joints. Exact lengths and
termination details shall be indicated in construction drawings by Contractor.
REGD. OFF: RANCHI

PERMANENT CATHODIC
PROTECTION SYSTEM
EDITION : 1
xi) Anode bed separation from pipeline shall be tested for interference.
xii) Potential gradient around the anode bed shall be within safety requirements and its effective
boundary shall be defined and secured.
xiii) In case two parallel pipelines running in the same ROW. The anode ground beds of
respective pipelines shall be located on the respective sides of the pipelines.
xiv) The depth of deepwell anode ground bed shall be sufficient enough to reduce anode
influence on incidental structures within proposed location.
7.4 Anode Junction Box
i) Depending on the size and configuration of anode ground beds, one or more anode junction
boxes shall be provided at each ground bed.
All cable tails from individual anodes shall be terminated to these anode junction boxes
which shall be further connected to anode cable coming from CP station power source.
ii) Junction boxes shall have sheet steel enclosure of minimum 3 mm thickness and hinged
lockable shutters. They shall be weatherproof with degree of protection IP-55. Junction
boxes shall have Tined plated Cu anode bus and terminal plate with adequate number of
anti-loosening type of identified terminals. Provision shall be made for measurement and
control of individual anode current by providing suitable shunt and resistors. Anode
disconnecting link shall be provided for each anode circuit. 30% spare terminals shall be
provided in each junction box. Anode junction boxes shall be epoxy coated (Both inside &
outside surface).
Anodised Al (Aluminium) name plate shall be provided inside the AJB with black background
with white letters with following information-
a) AJB number & location

b) Current rating of ground bed
c) Ground-bed resistance during commissioning
d) Ground-bed resistance_ _ _ Ω with Date_ _ _ _ _ _ (Editable)
e) Connection scheme
f) Distance from pipeline
g) Distance from CP station
iii) In case of sectionalized ground beds, an additional common anode disconnecting link for
each section of ground bed shall be provided for disconnection of any section of ground bed.
iv) Technical requirements of AJB is specified as below-
a) Output Circuit Config.: Anode Bus output distributed into circuit in line with the
number of anodes for current measuring shunt and resistor.
b) Shunt Type: Manganin Alloy
c) Shunt & Resistor Rating: 5A/75mV & 1ohm, 100W
d) Terminal Board Material: Phenolic Bakelite Sheet
e) Insulation Level in between terminals & body: 1.5 KV for 1 minute at 50Hz
f) Busbar: Tinned Copper Bus Bar 25mm x 5mm minimum
g) Input & Output Terminals: Stainless Steel Stud with double nut and washer
REGD. OFF: RANCHI

PERMANENT CATHODIC
PROTECTION SYSTEM
EDITION : 1
h) Enclosure: Completely enclosed, Outdoor type, pole mounted, Natural Air Cooled,
IP-55, The enclosure is provided with two terminals for earthing.
i) The enclosure is made of sheet steel with min 3 mm sheet thickness provided with
Neoprene sealing gasket. The shutter and external fitted nut / bolts are SS
j) Cable entries: Cable entries are sealed through proper visco-elastic sealent to
prevent entry of moisture.
k) Painting: Two coats of Epoxy Paint / Powder Coating
7.5 Cathode Junction Box
One cathode junction box shall be provided at each CP Station for Permanent Pipe to soil
potential measurement circuit & cathode connection. Junction boxes shall have sheet steel
enclosure of minimum 3 mm thickness and hinged lockable shutters & Allen key locks. They
shall be weatherproof with degree of protection IP-55. Junction boxes shall have cathode
bus and terminal plate with adequate number of anti-loosening type of identified terminals.
Cathode junction boxes shall be epoxy coated (Both inside & outside surface).
The negative of the CP power supply source shall be connected to the incoming circuit of the
cathode junction box. The junction box shall have separate out going circuit one for each
pipeline to collect the negative drainage currents from each of the parallel pipelines.
The incoming circuit shall have a current measurement facility. Each out going circuits shall
have provision for measurement and control of current.
Anodised Al (Aluminium) name plate shall be provided inside the CJB with black background
with white letters with information same as test station (TLP) Cl. No. 7.6.(vi) except test
station no.
i) Technical requirements of AJB is specified as below-
a) Output Circuit Config.: Cathode Bus output distributed into 2 + 1 circuits in line with
current measuring shunt. The reference electrode are terminated & further extended
to CPTRU.
b) Shunt Type: Manganin Alloy
c) Shunt & Resistor Rating: 10A/100mV
d) Terminal Board Material: Phenolic Bakelite Sheet
e) Insulation Level in between terminals & body: 1.5 KV for 1 minute at 50Hz
f) Busbar: Tinned Copper Bus Bar 25mm x 5mm
g) Input & Output Terminals: Stainless Steel Stud with double nut and washer
h) Enclosure: Completely enclosed, Outdoor type, pole mounted, Natural Air Cooled,
IP-55, The enclosure is provided with two terminals for earthing. The enclosure is
made of sheet steel with min 3 mm sheet thickness provided with Neoprene sealing
gasket. The shutter and external fitted nut / bolts are SS
i) Cable entries: Cable entries are sealed through proper visco-elastic sealent to
prevent entry of moisture.
j) Painting: Two coats of Epoxy Paint / Powder Coating
AJB & CJB shall be full welded, joint welded AJB & CJB shall not be acceptable.
7.6 Test Stations

REGD. OFF: RANCHI

PERMANENT CATHODIC
PROTECTION SYSTEM
EDITION : 1
Test stations shall be provided In addition to locations mentioned in the TCP specification at
following locations:-
a) At Interference prone area (AC & DC) detected during the interference study.
b) At EHT/HT AC/DC overhead line crossings selected locations where EHT/HT
overhead is in the vicinity of the pipeline.
c) At high voltage cable crossing or along routes where HV cables are running in
parallel.
d) In the vicinity of DC network or grounding systems where interference problems are
suspected.
e) At any other locations considered necessary by OWNER/ OWNER’S
representative/MECON.
i) Installation of TCP system may be in the scope of pipeline laying contractor (not in the scope
of PCP contractor), TLP installed during TCP shall be utilized if there is no inadequacy. New
TLP is required to be installed during PCP, if TLP installed during TCP damaged or
inadequate or existing TLP is not located at the designed location during PCP.
ii) All test stations shall be provided with shunt & resistors.
iii) Bond stations shall be provided at required locations with shunt and resistor as a means to
monitor and control current flow between the pipeline and foreign pipelines / structures /
electrified railway tracks etc that crosses and runs parallel to the pipeline in common ROW
or within 25 metre from the pipeline.
iv) All test stations shall have weatherproof enclosure, with hinged lockable shutter with two
Allen key locks and degree of protection IP-55 with epoxy coating (Inside & out side
surface). Enclosure shall be made of sheet steel of atleast 3 mm thickness and shall be
suitable for MS post mounting. The test station shall be suitable for design life of CP system.
v) Test station shall be installed with the face of the test station facing the pipeline. The
nameplate of test stations shall carry the following minimum information:
- Test station number

- Chainage in Km.
- Test station connection scheme
- Distance from pipeline in mtrs.
- Direction of product flow.
vi) Number of terminals and different schemes of wiring shall be as per the test station
connection scheme sketch. Minimum twenty percent (20%) spare terminals shall be
provided in each test station.
vii) Test station for EHT/HT line crossing shall be installed approx. 100-500 m away from the
EHT/HT line.
viii) The location of all the test station shall be marked with their connection scheme and other
relevant information on alignment sheets. A detailed test- station schedules shall be
prepared.
REGD. OFF: RANCHI

PERMANENT CATHODIC
PROTECTION SYSTEM
EDITION : 1
7.7 Permanent Reference Cells
i) High purity copper / copper sulphate reference cells with proven high reliability shall be
provided for stable pipe to soil potential measurement reference at CP stations and at
computerized test station locations along ROW.
ii) Three numbers reference electrodes shall be installed at each cathodic protection station
location.
iii) The reference cell for high resistivity areas shall be suitable for the prevailing dry soil
conditions to give maximum service life.
iv) Permanent reference cells shall be installed with backfill material.
v) Silver/ Silver Chloride reference cells in place of copper / copper sulphate cells shall be
provided at marshy area locations where water table is high and sub-soil water or soil shows
chlorine concentration more than 300 PPM.
vi) The cable from reference cells shall be provided upto CP power source at CP stations. The
cable shall be routed through cathode junction box near pipeline.
vii) The life of reference cell shall be minimum 10 years under installed condition.
7.8 Electrical Resistance Probe/Coupons
ER Probes-
Where specified in project specifications (PJS)/Data sheet, electrical resistance probes

utilising the electrical resistance technique shall be provided along the pipeline at marshy
areas and at vulnerable locations to monitor the external corrosion activity on the pipeline.
The lead wires of the probe shall be connected to pipeline and terminated inside test station
enabling periodic resistance measurement with the probe using a portable measuring
instrument.
The material of the E/R probe element shall be of the same alloy as of the pipeline material.
The E/R probes shall be provided preferably at the bottom portion of pipeline. The locations
of E/R probes shall be got approved.
Portable E/R probe reading instrument shall be supplied by contractor.
For Internal corrosion monitoring ER probes & Coupons shall be provided if specified in
PJS/Data sheet as per specification of CMS (Corrosion monitoring system).
Polarisation Coupons-
Where specified in project specifications (PJS)/ Datasheet polarisation coupons of pipeline

material shall be provided along the pipeline to monitor the CP system performance.
Coupons shall be installed at CP station, at marshy areas, at vulnerable locations, at foreign
pipeline crossings, Interference prone areas & location deemed necessary by
REGD. OFF: RANCHI

PERMANENT CATHODIC
PROTECTION SYSTEM
EDITION : 1
Owner/Owner’s representative.
The location & the number of coupons to be provided along the pipeline get approved from
owner.
Coupons shall be installed at the bottom of the pipeline. The coupons shall be same as the
pipeline material & having 100mmx100mm uncoated exposed area to the soil. Two cables
one connection for pipeline & other for potential measurement shall be provided with each
coupon. Reed-Switch shall be connected to the protection cable to measure the coupon
“OFF” potential.
A permanent reference shall be provided at the location of Coupon to enable the

measurement of PSP.
AC Corrosion Coupons-
AC corrosion coupons shall be installed at the locations of HT line crossings where high
induced potential is recorded on the pipeline. The location of AC corrosion coupons shall be
decided after AC interference study.
Wherever the pipeline is either crossing or running parallel with overhead EHV/HV
transmission lines of voltage grade 33kV and above, AC interference mitigation study to be
performed and accordingly AC corrosion coupons and other equipments shall be decided.
AC Corrosion Coupons are accurately sized to provide the ability to measure maximum AC
current discharge from a pipeline in areas subject to interaction from overhead AC power
transmission systems. The value so recorded provides a vital indication as to whether AC
corrosion could be occurring on the pipeline.
The coupon consists of a steel disc with an exposed area of 1cm², fitted into thick PVC
housing to give an impression of a holiday. The purpose of the AC corrosion coupon is to
identify the corrosion current density, which will help in classifying the intensity of corrosion.
The connection between the coupon and the cable is properly encapsulated to stop the
ingress of moisture.
7.9 Polarisation Cell and Surge Diverter / Grounding Cell
i) Where high voltage/ Extra High Voltage (66 KV and above) transmission line runs in parallel
or crosses the pipeline, the pipeline shall be grounded through polarisation cells & zinc
anodes of minimum 20 kg net each. Alternatively, grounding could be done directly with zinc
galvanic anodes of minimum 20 kg net each at the discretion of owner. Grounding shall be
done at regular intervals of maximum 1.0 km where EHV/HV transmission lines run parallel
within 25 meter of the pipeline to ground any surges on the pipeline that would appear in
case of transmission line faults. Type of polarisation cell (Electrolyte/Solid state) shall be as
per job specification/Data sheet/Scope of work.
ii) In case of continuous induction of voltage on the pipeline beyond safe limits is expected or
observed during commissioning due to HV Line of any rating/Underground Cables or others
equipment, the pipeline shall be grounded to the earth system of nearest HV transmission
tower of the transmission line causing the voltage induction through polarisation cell or the
pipeline shall be grounded to a separate earthing system of zinc galvanic anodes through
REGD. OFF: RANCHI

PERMANENT CATHODIC
PROTECTION SYSTEM
EDITION : 1
polarisation cell. Alternatively, the pipeline shall be directly grounded with zinc galvanic
anodes/Grounding cells of minimum 20 kg net each at the discretion of the owner. The
polarisation cell shall be installed in test station.
iii) Spark gap arrestor shall be connected across each insulating joint to protect it from high
voltage surges at the location of terminals/end of the pipeline etc.
Alternatively, zinc grounding cell may be provided across insulating joints along ROW where
the pipeline on both the sides of the insulating joint are cathodically protected and difference
of protection voltage is not more then 0.4 volts.
iv) The total system including cables, cable termination, anodes/ surge divertors shall be
suitable for the anticipated fault current at the location of installation.
v) Unless otherwise specified on data sheet, the minimum rating of grounding cells, polarisation
cells and surge diverters shall be as below:
a) Grounding Cell
- Type : Zinc, 2 or 4 plate type.

- Current rating : Suitable to pass more than 10KA surge
(b) Polarisation cell
-Type : Solid state (Min. 5 kA @ 30 Cycle) or

as per scope of work/PJS
-Steady state discharge : 50A @ 50Hz

Current Rating
-Blocking Voltage : +/- 2V DC
-Lightning Current : 100kA (8/20 uS, as per IEC 62305)
(c) Surge Diverter (Spark Gap Arrester)
- Type : Spark gap, Explosion Proof Type

- Current, 10/350 wave : 100 KA (10/350 uS, Lightning)
- Current, 8/20 wave : 100 KA (Surge)
- Spark over AC voltage :
- 50 Hz : 1 kV
- Impulse (1.2/50) : 2.2 kV
micro sec)
vi) The grounding cell, spark gap arrester and polarisation cell system shall be adequately sized
and suitable for the design life of permanent CP system. The directly buried zinc or
magnesium anodes shall also be adequately sized for the life of the permanent CP system,
taking into consideration discharge from the anodes. The grounding system shall have
minimum resistance to earth to restrict the pipeline voltage as per NACE Criteria but shall
not exceed 2 ohms.
REGD. OFF: RANCHI

PERMANENT CATHODIC
PROTECTION SYSTEM
EDITION : 1
vii) The anodes shall be pre packed with special backfill adequately so that the performance of
the anode is not affected by the carbonates, bicarbonates, nitrates, etc. present in the soil. In
any case, the thickness of back fill shall not be less than 50mm on all the sides of the anode.
viii) Motor operated valves where located on the cathodically protected portion of the pipeline
shall be grounded by a zinc anode of 20 kg net. Magnesium anodes grounding, if any,
provided during temporary CP system shall be disconnected. The MOV power supply cable
armour shall be insulated (by cutting and taping with insulation tape) at MOV end to avoid
armour carrying CP current.
ix) The above ground cathodically unprotected pipeline at terminals, intermediate SV stations,
pigging station, etc. shall be earthed with GI earth electrodes. The resistance to earth of
grounding shall be limited to 2 ohms max.
x) HT transmission overhead lines of voltage below 66KV shall also require mitigation
measures in case of continuous voltage induction of 15.0 V AC due to presence of
transmission line in close proximity.
7.10 Computerized Test Stations
Where specified in the project specification/ data sheet computerized test station shall be
provided along the ROW of the pipeline for automatically monitoring and recording the pipe
to soil potential, pipe current, etc of the pipeline, casing pipeline and foreign pipelines, etc,
as required. The computer with in the test station shall measure and record these
parameters regularly at programmed intervals. The computers shall have required number of
input ports for measurement of potentials and current as applicable at the location of its
installation. Computers shall have real time clock and record the time of data measurement.
Each computer shall have an identification number incorporated in its software, which shall
be clearly indicated along with the data display/ print out.
The computers shall be programmed to collect and store all the field parameters at intervals
as specified in the project specification/ data sheet.
Data-retrieval computer of portable type suitable for use in field shall be provided as
specified in the project specification/ data sheet for programming the field computers and
retrieving the data stored by the field computers.
CONTRACTOR shall submit datasheet/specification of CTSU for prior approval.
Computerized test station unit (CTSU) shall have the following feature:
a) Simultaneous recording of 3 No. analogue channels.
CH-1 : -4V to +4V DC (for DC PSP)

CH-2 : 0V to 50 V AC (for PSP AC Interference Monitoring)
CH-3 : 0A to 100 A DC (for Pipeline Current Monitoring)
CH-4 : Battery Level (for Internal Battery Status Monitoring)
The typical accuracy of each channel is + 1.0% of F.S. + 1 digit
b) Shall be able to generate +ve & -ve sign for recorded PSP values.
REGD. OFF: RANCHI

PERMANENT CATHODIC
PROTECTION SYSTEM
EDITION : 1
c) Portable Laptop readers shall be supplied with CTSU for Field downloading of Data (Qty
as per scope of work).
d) The CTSU shall provide Battery Low alarm.
7.11 Painting
The sheet steel used for fabrication shall be thoroughly cleaned and degreased to remove
mill scale, rust, grease and dirt. Fabricated structures shall be pickled and then rinsed to
remove any trace of acid. The under surface shall be prepared by applying a coat of
phosphate paint and a coat of yellow zinc chromate primer. The under surface shall be free
from all imperfections before undertaking the finishing coat.
After preparation of the under surface, spray painting with two coats of final paint shall be
done. The finished panels shall be dried in ovens in dust free atmosphere. Panel finish shall
be free from imperfections like pinholes, orange peels, runoff paint etc. Bidder shall furnish
detailed painting procedure alongwith bids.
All unpainted steel parts shall be cadmium plated to prevent rust formation.
7.12 Cables
i) MMO Anode tail/lead cable (Size 1Cx10 Sqmm)-
Anode tail/lead cable shall be 1Cx10 Sqmm size, annealed high conductivity tinned stranded
copper conductor (7 Strands), PVDF insulated (Thickness 0.040 Inch), HMWPE
sheathed/Jacket (Thickness 0.065 Inch), un-armoured.
ii) Anode & Cathode Header Cable- (Size 1Cx35 Sqmm)-
Anode & Cathode Header Cable shall be 1Cx35 Sqmm size, annealed high conductivity
tinned stranded copper conductor, XLPE insulated, PVC sheathed, FRLS, 1.1kV Grade
armoured cable as per IS: 7098.
iii) TR/CPPSM Input Power Supply Cable - (Size 3Cx10 Sqmm)-

TR/CPPSM Input Power Supply Cable shall be 3Cx10 Sqmm size, annealed high
conductivity tinned stranded copper conductor, XLPE insulated, PVC sheathed, FRLS, 1.1kV
Grade armoured cable as per IS: 7098 for Single Phase TR Units and 4 core type for 3
phase TR units.
iv) Measurement cable & Permanent Reference cell tail cable- (Size 1Cx6 Sqmm)-
k) Measurement cable & Permanent Ref cell tail cable from Pipe/Tank/Buller/Vessel to
CJB & CJB to TR/CPPSM Unit shall be 1Cx6 Sqmm size, annealed high conductivity
tinned stranded copper conductor, XLPE insulated, PVC sheathed, FRLS, 1.1kV Grade
armoured, screened cable as per IS: 7098.
v) The colour of outer sheath of the cables shall be as per the PJS/Scope of work/Design Basis
and outer sheath should have marking of “CP system Cable” in each one meter interval by
black colour for identification purpose.
REGD. OFF: RANCHI

PERMANENT CATHODIC
PROTECTION SYSTEM
EDITION : 1
vi) The cables for connecting various transducers from TR unit/ CPPSM to telemetry interface
junction box shall be twisted pair with individual pair shielded and overall shielded with
aluminium backed by mylar/polyster tape, PVC sheathed, armoured, PVC over all sheathed
type.
7.13 Panel Cabling and cable glands
Adequate space shall be provided inside the panel for termination of cables. Termination
shall be performed using crimped lugs. Tags with cable numbers engraved on it shall be
attached to each cable at both ends. Cable glands shall be double compression type of
Nickel/ Chromium plated brass. The lugs shall be of tinned copper. Phases of AC power
cables shall be identified with red, yellow, blue PVC adhesive material.
The armour of the cables from pipeline to CP station (potential measurement, reference cell
& drainage cables etc.), CP station to ground bed (anode cable) and test station to pipeline
shall be earthed only at one end of the cable to avoid armour carrying CP current.
8.0 INSTALLATION
8.1 Cable Laying
i) Cables shall be laid in accordance with approved layout drawings to be prepared by the
contractor. No straight through joint shall be permitted in a single run of cable. Cable route
shall be carefully measured and cables cut to required length. Enough slackness in cable
shall be provided near anodes, AJB, test stations, pipelines etc to account for any settling.
ii) All cables inside station/plant area shall be laid at a depth of 0.75 M. Cables outside
station/plant area shall be laid at a depth of 1.5m. Cables shall be laid in sand under brick
cover and back filled with normal soil. Outside station/plant area, the routes shall be marked
with polyethylene cable warning mats placed at a depth of 0.9 mtr. from the finished grade.
iii) In case of above ground cable installations, all un-armoured CP cables shall be laid in GI
conduits of sufficiently large size (up to accessible height for protecting against the
mechanical damage.).
iv) All underground unarmoured cables shall run through PE sleeves. Distant measurement
cables and permanent reference cell cables routed along the pipeline shall be carried at the
top of the carrier pipe by securely strapping it with adhesive tape or equivalent as required.
v) RCC or GI pipes of proper size shall be provided for all underground cables for road
crossings.
vi) Cables shall be neatly arranged in trenches in such a manner that criss-crossing is avoided
and final take-off to equipment is facilitated.
vii) Cable marker & tags (at both end) shall be provided to mark the cable route. Inside plant
area cable routes shall be marked by means of cable markers located at maximum intervals
of 30M and at locations of changes in direction of cable route.
viii) Cable crossing with Underground pipeline, All cables shall be placed above underground
REGD. OFF: RANCHI

PERMANENT CATHODIC
PROTECTION SYSTEM
EDITION : 1
pipeline (Below underground pipeline is not permitted).
8.2 Cable to pipe connections
All cable connections to the pipeline including charged foreign pipelines shall be made by an
approved (by owner) exothermic process. A suitable water proof sealing system of the cable
connections shall be made which will be compatible with parent coating system of the
pipeline after exothermic process. The resistance of cable to pipe at pin brazing/ thermit
weld connection point shall not exceed 0.1 ohm.
For charged pipeline, pin-brazing shall be used. Eutectic solder shall not be accepted for
charged or non-charged pipeline. Pipe coating shall be repaired after connection of cable to
pipeline. The coating repair material shall be compatible with original coating and shall
prevent ingress of water along cable surface and at the interface of coating repair with
original pipe coating.
Pin Brazing shall be as per ISO 15589-1 & ISO 13847.
8.3 Ground bed fencing
Chain link fencing shall be provided around each ground bed & AJB location as per job
requirements/PJS.
8.4 Civil Works
All civil works as per enclosed specifications associated with the complete cathodic
protection system are included in scope of contractor. This shall include providing cable
trenches and foundations for all equipment, outdoor T/R units, anode lead junction boxes, all
test stations, polarisation cells, etc.
9.0 SHOP INSPECTION AND TESTING
i) Owner/ Owner’s representative shall visit the works during manufacture of various
equipment to assess the progress of work as well as to ascertain that only quality raw
materials & fabrication technology are used. All necessary assistance shall be provided by
contractor and vendors during such inspections.
ii) The minimum testing, inspection requirements for all components/equipment shall conform
to requirement as defined in the relevant codes and standards. Detailed inspection and
testing procedures alongwith the acceptance criteria shall be prepared by contractor for
Owner’s approval.
iii) Test certificates including test records, performance curves etc. shall be furnished with
sufficient information to identify the equipment to which the certificate referes and must carry
project title, owner’s name and purchase order details etc.
iv) Owner reserves the right to ask for inspection of all or any item under the contract and
witness all tests and carryout inspection or authorise his representative to witness tests and
carryout inspection. Contractor shall notify the Owner/ Owner’s representative atleast 20
days in advance giving exact details of tests, dates and addresses of locations where the
tests would be carried out.
REGD. OFF: RANCHI

PERMANENT CATHODIC
PROTECTION SYSTEM
EDITION : 1
10.0 PACKING AND TRANSPORT
All equipment/material shall be protected for inland/marine, transport, carriage at site and
outdoor storage during transit and at site. All packages shall be clearly, legibly and durably
marked with uniform block letters giving the relevant equipment / material details. Each
package shall contain a packing list in a water proof envelope with one set of final drawings.
Copies of the packing list, in triplicate, shall be forwarded to owner prior to despatch. All
items of material shall be clearly marked for easy identification against the packing list.
The equipment may be stored outdoors for long periods before installation. The packing
shall be completely suitable for outdoor storage in areas with heavy rains and high ambient
temperature unless otherwise agreed.
All equipment/material shall be wrapped in polythene sheets before being placed in crates/
cases to prevent damage to finish the crates/ cases shall have skid bottoms for handling.
Special notations such as 'Fragile', 'This side up', 'Centre of gravity', 'Weight', 'Client's
particulars', 'PO no., Name, Project, contractor, supplier name' etc shall be clearly and
indelibly marked on the packages together with other details as per purchase order.
11.0 FIELD TESTING AND COMMISSIONING
11.1 System Testing at Site
The contractor shall furnish the detailed field testing and commissioning procedures for
approval. Field tests as per these approved procedures shall be carried out on the
equipment/systems before these are put into service. Acceptance of the complete
installation shall be contingent upon inspection and test results. Field testing shall include
but not be limited to the following.
i) Contractor shall carryout pre-commissioning operation after completion of installation of the

system including all pre-commissioning checks, setting of all equipment, control and
protective devices. All site tests, reliability and performances tests shall be carried out by
contractor in direction of equipment supplier.
ii) Before the electrical & CP facilities are put into operation, necessary tests shall be carried
out to establish that all equipment, devices, wiring and connection have been correctly
installed, connected and are in good working condition as required for the intended
operation.
iii) Owner/ Owner’s representative may witness all tests. At least one week’s notice shall be
given before commencing the tests.
iv) All tools, equipment and instruments required for testing shall be provided by contractor.
v) Generally, the following minimum tests must be carried out and recorded in proformas given
in subsequent clauses :
Checking : Visual inspection, comparison with drawings and specifications

REGD. OFF: RANCHI

PERMANENT CATHODIC
PROTECTION SYSTEM
EDITION : 1
Inspection : Detailed physical inspection, if necessary, by taking apart the

component parts
Testing : Simulation tests of equipment to determine its operational
fitness
a) Cables
- Cable no.
- Voltage grade.
- Conductor cross section
- Continuity check
- Voltage test
- Insulation resistance values between each core & earth, between cores.
- All cables shall be tested by 500V megger.
b) E/R Probe
- Location / Identification number

- Checking of wiring as per schematics
- Resistance reading of probe
- Location of installed probe
c) Polarisation coupons
- Location
- Exposed area/size of coupon
- Coupon to soil “ON” & “OFF” potential
- Type of reference cell
- Magnetic reed switch rating & its operation with magnet
- Wiring, Depth and distance from pipeline of coupon and reference cell shall be as per
drawing
d) Reference Cell
- Location
- Potential reading
- Type of cell
- Installed Location
e) Insulating Joint
- Insulation resistance across the joint shall be checked before and after charging the
pipeline by means of insulating joint tester. Pipe to soil potential of both protected
and non-protected sides of the insulating joint shall be checked before and after
energisation of CP system.
Healthiness of the insulating joints
Healthiness of the insulating joints provided on the pipeline shall be checked by

REGD. OFF: RANCHI

PERMANENT CATHODIC
PROTECTION SYSTEM
EDITION : 1
measuring the pipe to soil potentials on both protected and non protected sides of the
IJs prior PCP commissioning & maintenance and monitoring of PCP system. (By
Taking ON-OFF PSP values on both side of IJ)
f) Surge Diverter
- Location / identification number

- Rating
- Check for healthiness
g) Polarisation Cell

- Rating
- Check for electrolyte
- Check for wiring
- Check standby current drain after CP system energisation. (Current drain with
respect to voltage across the cell shall be recorded).
- Details of grounding provided for the polarisation cell.
h) Anode Ground Bed
- Location / Station
- Check for actual layout and compliance with drawings
- Resistance of each individual anode
- Current dissipation by each individual anode with respect to anode voltage
- Total resistance of complete anode bed
- Mutual interference
-
i) Grounding Cell
- Location
- Type / no. of anodes
- Ratings
j) CTSU (Computerised test station unit)

- Check for wiring
- Checking programmed interval for collection of the field data by the computer
- Type of reference cell
11.2 CP Commissioning Procedure
A model commissioning procedure for a 3 station CP system of a pipeline is given below for
general guidance. Contractor shall develop detailed commissioning procedure as per this
guideline and get it approved before commencing CP system commissioning activities.
REGD. OFF: RANCHI

PERMANENT CATHODIC
PROTECTION SYSTEM
EDITION : 1
i) On completion of installation of anode beds and other systems as envisaged in this

specification, they shall be individually checked, tested and compared against the agreed
specifications and procedure.
ii) The CP commissioning shall be carried out with current interrupter provided in the output of
the TR/ CPPSM Unit to measure CP “ON” & “OFF” potentials.
iii) Current dissipated by each anode shall be corrected through anode lead junction box.
iv) Electrical continuity of the entire pipeline shall be verified in conformity with design.
v) Input resistance of the pipeline at all the drainage points shall be checked and recorded.
vi) All current measuring test stations shall be calibrated and recorded using portable battery,
variable resistance, voltmeters, ammeters, etc. as required.
vii) Temporary protection facilities provided (if any) which do not form part of permanent CP
shall be disconnected from the system & removed unless agreed otherwise.
viii) Anodes provided for grounding at the MOVs on cathodically protected portion of the pipeline
shall be disconnected. Sacrificial anode where provided for the protection of the casing pipe
at cased crossing shall be disconnected.
ix) The pipeline shall be allowed to depolarize for at least 72 hours after switching ‘off’ the
protection (if any) of all other pipelines in the common ROW.
x) Before the pipeline are put on charge by switching ‘ON’ any of the CP stations, natural
structure-to-electrolyte potential (PSP), Casing pipe to soil & coupon to soil values at all the
test stations of the system shall be measured with respect to Copper/ Copper Sulphate half
cell.
xi) CP station no. 1 shall be energised so as to achieve a maximum pipe soil potential (PSP) as
specified at the test station nearest to the drainage point, and observations on either spread
of protected portion of pipeline under this CP station and coupons (coupon to soil potential at
the locations of the coupon installations) shall be taken for PSP values (Both “ON” & “OFF”
values) at each installed test station. Pipeline current values across the cross section of the
pipeline shall also be determined at all the intended test stations influenced by this station.
xii) The typical switching cycle of current interrupter shall be 4 seconds 'ON' and 1 second
'OFF'.
xiii) CP station no. 1 shall now be switched “OFF’’ and CP station no. 3 shall be switched “ON”
and measurement procedure as adopted in above step (at cl. xi) shall be repeated.
xiv) In case of more than three CP stations in a continuous pipeline section (IJ-IJ),
alternate CP stations shall be switched ON and above step (at cl. xi) shall be repeated.
xv) Reach of protection (Km) shall be taken during the commission with individual CP
station charging current to the Pipeline, and a graphical presentation shall be made to
show the overlapping region of protection.
xvi) All the CP stations of the system shall be switched “OFF” and the pipelines shall be allowed
to depolarize. All the three CP stations (CP stations on the continuous section IJ-to-IJ) in the
system shall then be simultaneously switched “ON” and PSP values at the drainage points of
pipeline shall be brought to a value of maximum PSP (ON PSP, as derived from the
individual CP stations commissioning) as specified, and a complete set of PSP observations
shall be taken.
Another complete set of PSP observations (ON-OFF) shall be taken after lines have stayed
on charge for 48 hours. If there are appreciable differences in these observations as
compared to those of earlier set, a third set of observations (ON-OFF) shall be taken after 72
hrs. Maximum drainage point protective potentials shall not be allowed to go beyond the
maximum PSP values as specified, in any case.
The output of all CP stations shall then be so adjusted that the sites of occurrence of least
REGD. OFF: RANCHI

PERMANENT CATHODIC
PROTECTION SYSTEM
EDITION : 1
negative protective potentials are not less negative than (-) 0.85V “OFF” or not more
negative than (-) 1.20V “OFF”. A full set of observations shall again be taken 72 hrs after the
adjustment of potentials and the protection system shall be left in this state of operation.
xvii) Care shall be exercised to ensure that power supply remains uninterrupted during the period
of commissioning. In case of an interruption, the test in progress shall be repeated after
allowing time for polarization. More sets of observations may be advised to be taken by the
Owner/ Owner's representative in any of the above-mentioned steps.
xviii) PSP values at each of the test stations of the existing pipelines shall be measured and
plotted where existing pipelines run in parallel to the new pipeline and mutual interference
situations between the pipelines shall be identified and necessary mitigation shall be carried
out. Interference situations shall also be identified and mitigated by comparing different sets
of readings taken at same test stations at different intervals of time under identical conditions
where positive potential swing exceed 50 mV.
xix) The zinc anodes for grounding of MOVs at the locations of MOVs on cathodically protected
portion of the pipeline shall be reconnected to the MOVs.
xx) At cased crossings where casing is protected, sacrificial anodes provided for the casing shall
be connected to the casing pipe. The casing to soil potential and anode out put current shall
be measured and recorded. Where casing pipe protection is inadequate or the out put
current of the anode is more than the designed current, then additional anodes shall be
provided as required.
xxi) Current readings at all the current measuring test stations shall be measured and recorded.
xxii) Where computerized test stations are provided the computer shall be initialized/ started to
collect and store the field data of potentials, current readings, etc as programmed.
xxiii) After one month of starting the computer to collect the field data, the data stored by the
computers at all the computerized test stations shall be retrieved/ down loaded using the
field data-retrieving computer. The data shall be analysed with the help of a station main
computer.
xxiv) At the locations of the Electrical resistance probe installations the resistance readings of the
probes shall be measured using probe reader.
xxv) Final records of testing and commissioning including graphical representation of final
structure to electrolyte potential readings shall be compiled with interpretation in consultation
with owner/ owner's representative and submitted.
xxvi) As a result of these tests, if any deficiencies are found in the system, the same shall be
rectified by the contractor at no extra cost or time effect, to the complete satisfaction of
Owner/ Owner's representative. Such deficiencies shall include mitigation of interference
problems that may be found existing in the course of testing and commissioning. A set of
PSP observations shall also be taken during the peak of the first dry season after
commissioning the system into regular operation. Any deficiency found in the protection of
the pipeline shall have to be rectified by the contractor at his own cost.
xxvii) If it is found during commissioning that the sites of occurrence of least negative protective
potentials are less negative than (-) 0.95 V off & more negative than (-) 1.20 V off even after
72 hrs of operation, then the drainage point potentials shall be adjusted depending upon
anode ground bed currents in consolation with Owner/ Owner's representative In any case,
the drainage point protective 'ON' & 'OFF' potential shall not exceed the PSP values
specified in Cl.No. 6.0 & 7.0 of this document, at any location of pipeline.
xxviii) The reference cell shall be calibrated minimum once in 24 hours during the commissioning.
xxix) The current dissipated by individual anodes shall be measured from the anode lead junction
box and corrected for equal dissipation to the extent possible keeping the total ground bed
current same.
REGD. OFF: RANCHI

PERMANENT CATHODIC
PROTECTION SYSTEM
EDITION : 1
xxx) After connecting all anode gorundbeds to pipeline PSP shall be taken at each test station
locations to ensure the protection criteria.
12.0 INTERFERENCE MITIGATION
i) Investigation shall be made for stray current electrolysis of the pipeline, mutual interference
between the pipeline and foreign pipelines / structures, interference on foreign pipelines /
structures due to the CP of the pipeline and ground bed, interference on metallic structures
which lie in between pipeline and ground bed or near to ground bed, AC induction on
pipeline due to overhead EHV/HV power lines, interference due to high voltage DC lines,
electric traction, HV earthing system/Substation earthing system etc.
ii) Measurements including pipe to soil potentials and pipe currents etc. on the pipeline /
structure being CP protected and on foreign pipelines / structures, and ground potential
gradient etc. shall be made to investigate the current discharge and pickup locations. In case
of fluctuating stray currents, investigations shall be made continuously over a period of time
and if required simultaneously at different locations to find out the stray current source (s).
Recorders shall be preferably be used for long time measurements.
iii) Where foreign pipelines (Cathodically protected or unprotected) by an independent CP

system run in parallel to the protected pipeline, either in the same trench or very near to the
protected pipeline and are not bonded to it, investigations shall be performed for current
discharge points on both the pipelines.
iv) Mitigative measures shall be provided depending upon the type of interference. These shall
include installation of bond with variable resistor and diodes, installation of galvanic anodes
for auxiliary drainage of current, adjustment/ relocation (if possible) of offending interference
source, provision of electrical shield etc. depending on the type of interference.
v) Bonding with foreign pipelines / structures as a mitigation measure shall be provided where
the owners of the foreign pipelines / structures have no objection. Otherwise alternative
mitigation measures shall be provided. Wherever bonding is provided for mitigation, the
bonding resistor shall be adjusted for optimum value for minimum / no interference. Galvanic
anodes installed as a mitigation measure shall be adequately sized for the design life
specified for permanent CP system.
vi) Where high voltage (66 KV and above) transmission lines run in parallel or cross the
pipeline, the pipeline shall be grounded through polarisation cells at regular intervals (1km)
through zinc anode/Zn ribbon anodes to ground any surge on the pipeline that would appear
in case of transmission line faults. Grounding shall be done at regular intervals of maximum
1 km where transmission lines run parallel within 1km of the pipeline (both side) and have
separation distance of 100 mtr on both side of the pipeline.
vii) A.C. voltage measurements shall also be made on the pipeline to find out continuous
induction of voltage beyond safe limits. In such a case, the pipeline shall be grounded to the
earth of nearest transmission tower causing voltage induction through polarization cell or to
a separate earthing system of zinc anodes through polarization cell.
viii) CRITERIA FOR AC INTERFERENCE

REGD. OFF: RANCHI

PERMANENT CATHODIC
PROTECTION SYSTEM
EDITION : 1
Max. pipe to soil induced voltage must be less than 15V AC RMS for steady state condition
of power line. Under fault condition, the permissible touch & step voltages must be limited to
the levels efined in IEEE-80 latest revision for human safety.
Total coating stress voltage (inductiv e & conductive) within 3kV AC for 3LPE coating, to
prevent coating damages.
AC current density measured over a period of 24hrs should be less than 30A/m2. If the
current density is more than 30A/m2 but less than 75A/m2, then ratio between AC current
density (I ac) and DC current density (I dc) shall be less than 5 over period of 24 hrs. In no
case, AC current density above 75A/m2 shall be permissible in the pipeline.
Necessary mitigation measures shall be provided to reduce the AC discharge densities.
Detailed Procedure shall be submitted for review and approval to Owner/MECON.
ix) DATA COLLECTION
Contractor shall carry out field survey for collecting data from various sources
likeClient/Consultant/Power Authorities/ Foreign facility Owners/Pipeline alignment sheets
for thefollowing information:
 Existing or proposed (33 kV & above) EHV/HV AC/ DC overhead power lines along with
detailsof voltage, AC/DC type etc, crossing or parallel to the pipeline, phase configuration,
numberof circuits and other line parameters.
 Voltage rating, phases, sheathing details of underground power cables along ROW or in
itsvicinity.
 Tower footing, earthing distance from tentative ROU to be recorded for ascertaining
safedistance.
 Fault current rating of each HT line,Designed load current ,operating load currentLocation of
grounding of tower and substation location etc. to be obtained from powercompanies.
 Multi-layer soil resistivity near the area of AC tower parallel or crossing.
x) CALCULATIONS
Study shall include the following calculations:
 Induced voltages on pipeline under steady state operating condition of the transmission line
 Induced voltages on pipeline under fault conditions
 Ground Potential (GPR) during fault conditions
 AC current density/soil resistivity measurement
 Coating stress voltage under fault conditions
 Detailed Bill of Material
 Post mitigation verifying the induced voltage/ current density
xi) REPORT
Recommendation shall be for both operating load and design load of the pipeline. AC/DC
REGD. OFF: RANCHI

PERMANENT CATHODIC
PROTECTION SYSTEM
EDITION : 1
interference mitigation report shall have the following:
 Mitigation measure location details with detailed BOM

 Type of grounding: distributed vertical zinc ground anodes, horizontal zinc ribbon anode,
multiple zinc ribbon anodes, independent deep ground beds. The grounding system shall be
de-coupled with the ICCP system using suitably located and rated solid state de-couplers.
 Location of TLP’s where AC corrosion coupons/ Polarization coupons shall be installed for
monitoring the induced potentials and AC current densities for safe operation of the pipeline.
 Locations of additional TLP’s
Post commissioning, the values of current density and AC induced voltages shall be
measured at site and the same cross checked with the modelled values, the overall profile of
the site data and the modelled data as seen over a segment shall be in similar.
Specialist agency shall also verify the induced voltage/ current density after the mitigation
are taken care & installed at the site.
13.0 POST COMMISSIONING SURVEY
CLOSE INTERVAL POTENTIAL SURVEY
Where specified, contractor shall carry out a close internal potential survey over the entire
length of pipeline by computerised potential logging method and identify suspected holiday
spots on the pipeline coating, under protected/overprotected areas after the back filling has
been consolidated sufficiently and CP system has stabilized. Contractor shall identify the
necessary pipe coating required to be repaired. Detailed procedures for running this survey
shall be submitted for approval. During survey the reference cell shall be calibrated minimum
once in 24 hours.
Post commissioning of the CP System, after 30 days of line polarization, a Computerized

Potential Logging [CPL] survey will be conducted, as per approved procedure. “ON/OFF”
Potential survey @1m interval along entire ROW shall be recorded. For the survey, Data
Logger of reputed make (Calibrated) & Current interrupter [in-built in the CPTRU] will be
used by experienced and trained manpower. All CPTRU to be synchronized ON or OFF for
this survey using GPS synchronizing equipment. All the survey data and findings of under-
protected, over-protected zones, short etc. shall be handed over to CLIENT/ MECON as part
of final technical documentation. Suitable remediation measures to be recommended for
achieving adequacy of Cathodic protection throughout the pipeline length.
DCVG SURVEY
Post commissioning of the CP System, after 30 days of line polarization, CPL Survey will be
conducted for evaluation of coating condition to serve as future benchmark for comparative
evaluation. Based on the report of CPL survey, DCVG survey is required to be carried out at
the locations identified in the CPL report or on full length of the pipeline (as defined in scope
of work).
Only Good & Proven survey equipment and trained, experienced manpower to be used. The
scope includes identification of defects and rectification of coating defects and testing of
coating permanents (TS, Boding of coating with pipe, coating physical verification) at defect
REGD. OFF: RANCHI

PERMANENT CATHODIC
PROTECTION SYSTEM
EDITION : 1
locations examinations and coating repair.
All survey Data to be submitted to Client as part of Technical Documentation.
CAT SURVEY
Post commissioning of CP system, current attenuation test to be performed on the entire

length of the pipeline to check the condition of the coating of the pipeline and serve as
reference for future comparison. Bidder shall submit the CAT survey procedure for approval
and survey shall be conducted accordingly.
The basic objective of CAT survey is to make comparative analysis of electrical insulation
properties of one segment of the pipeline coating with another. If pipeline coating is
electrically consistent along its length, then the rate of current attenuation shall be uniform.
An increase in rate of current attenuation indicated leakage of impressed current signal
/current through coating indicating a coating fault.
The concept of current attenuation test is to measure the impressed signal leakage from the
buried pipeline. The signal leakage will depend directly on the health of the Coating.
CAT WITH A FRAME

After CAT survey, A-frame is used with receiver to precisely pinpoint coating defects and
isolationfaults.CAT with A frame is performed at the coating defect location. A frame spikes
need to make good electrical contact with the ground, preferably with damp, conductive
earth.
To determine the severity of fault and compare different faults on the pipeline to decide
repair priorities, take the dB microvolt reading with the A Frame at 90 degrees to the pipeline
also.
14.0 DRAWINGS AND DOCUMENTS
14.1 General
i) Within three weeks from the date of issue of Purchase Order, Contractor shall submit four
copies of the list of all drawings / data/ manuals / procedures for approval, identifying each
document by a number and descriptive title and schedule date. This list shall be revised and
extended, as necessary, during the progress of work.
ii) All drawings and documents shall be in English and shall follow metric system. Number of
copies for each submission shall be as follows unless specified otherwise :
Submission No. of copies
a) For Review/ Approval 5 copies
b) Drawings issued for 5 copies+2 soft copy

Execution / construction
REGD. OFF: RANCHI

PERMANENT CATHODIC
PROTECTION SYSTEM
EDITION : 1
c) Final / As-built drgs. 5 copes+2 soft copy
d) Operation / Maintenance 5 copies+2 soft copy

Manual, Vendor data
14.2 Contract Drawings and Documents
As a part of the contract, drawings and documents to be furnished by the contractor shall
include but are not limited to the following :
i) Report on corrosion survey.
ii) Basis of system design and design calculations, equipment selection criteria and sizing
calculations.
iii) Bills of material, material requisitions and Purchase requisitions.
iv) QA/QC Procedures/Formats
v) Detailed construction drawings (including as-built status).
a) Separate layout drawings for each CP station showing anode- ground bed location, anode-
ground bed installation details, CP station location, cable laying, ROW location. Drainage
connection location, permanent reference cell locations and topographic details of the entire
area.
b) Equipment layout, cable layout and schedules.
c) GTP of MMO or Hi-Cr cast iron anodes.
d) Marker drawings for cable route, anode-ground bed, drainage connection point, permanent
reference cell, E/R probe, polarisation cell, pipeline grounding anodes, grounding cells, etc.
e) Fabrication details of High Silicon Cast Iron/MMO canistered anode with tail cable.
f) Fabrication, connection and installation drawing for anode-junction box.
g) Anode- ground bed construction and installation details for horizontal anode-ground bed and
deep well ground bed.
h) Fabrication, installation and connection scheme drawing for different types of test-stations.
i) Fabrication and installation details of Copper/ Copper Sulphate type, Silver/ Silver Chloride
type and Zinc type permanent reference cells, E/R probes, grounding cells, surge divertor,
etc.
j) Fabrication and installation details of polarisation cell and its enclosure/ housing.
k) Cable to pipe joint details for charged and non-charged pipelines.
l) Incorporation of corrosion survey data, CP stations, test stations, anode beds, polarisation
cells, grounding cells, grounding anodes, surge diverters etc. and other relevant features of
CP system in pipeline alignment sheets and other related drawings.
m) Identification of sections of pipeline affected by interference, sources of interference, details
of interference mitigation arrangements provided. Various measurement data at all relevant
test stations with and without mitigation measures provided.
n) Detailed commissioning report including various measurement data at all test stations.
o) Vendor drawings and catalogues, test certificates.
p) Contractor shall hand over the complete CP system to CLIENT/MECON, with all
documents pertaining to land [for PCP anode bed location] and right to lay cable &
subsequent use for O&M purposes, from anode bed to power source.
REGD. OFF: RANCHI

PERMANENT CATHODIC
PROTECTION SYSTEM
EDITION : 1
q) Operation and maintenance manual.

r) Miscellaneous
- Equipment inspection and testing procedures.
- Construction, installation procedures.
- Field testing and commissioning procedures.
- Procedures and report on close interval potential survey.
- Procedure for monitoring of cathodic protection after commissioning.
- Quality control procedure.
15.0 INSTRUMENTS, TOOLS AND SPARES
i) Contractor shall provide a list of all instruments, tools and tackles necessary for proper
operation and maintenance of complete cathodic protection system and associated
equipment alongwith prices.
ii) Contractor shall provide a list of spares and consumables required alongwith prices for
proper operation and maintenance of complete cathodic protection system and associated
equipment for two years’ operation of the system.
iii) All commissioning & start-up equipment/spares shall be part of contract.
16.0 INFORMATION REQUIRED WITH THE BID
Bidders are advised in their own interest to provide the following information alongwith the
bid offer without which the bids are liable for summary rejection:
a) Basis and calculations for preliminary system design of permanent cathodic protection
system.
b) List of formula to the used for detailed system design calculations, with brief explanations.
c) Basis of system design, design calculations, equipment selection criteria, sizing calculations
alongwith characteristic curves for various equipments.
d) Preliminary bill of material for major equipment.
e) Details of the equipment/ material offered along with technical leaflets / related literature /
catalogues, make, rating, type test certificates etc.
f) Dimensions, weight and general arrangement drawings for each offered equipment.
g) List of instruments, tools, tackles offered for maintenance and operation.
h) List of recommended maintenance / operation spares.
i) Clause wise deviations, if any, to the specifications alongwith justifications.
j) Project schedule & manpower chart to be deployed at site.
-x-x-x-

016B - PCP - Rev-4 04.07.2020 R-4

Uploaded by

Document Informationclick to expand document information

Copyright:

Available Formats

016B - PCP - Rev-4 04.07.2020 R-4

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

016B - PCP - Rev-4 04.07.2020 R-4

Uploaded by

Copyright:

Available Formats

Rev.

DOCUMENT NO. Page 1 of 1

Sl. No. Description

2.0 CODES AND STANDARDS

3.0 SYSTEM IMPLEMENTATION

4.0 CORROSION SURVEY

5.0 CATHODIC PROTECTION DESIGN PARAMETERS

6.0 CATHODIC PROTECTION DESIGN CRITERIA

7.0 SYSTEM DETAILS

9.0 SHOP INSPECTION AND TESTING

10.0 PACKING AND TRANSPORT

11.0 FIELD TESTING AND COMMISSIONING

12.0 INTERFERENCE MITIGATION

13.0 CLOSE INTERVAL POTENTIAL SURVEY

14.0 DRAWINGS AND DOCUMENTS

15.0 INSTRUMENTS, TOOLS AND SPARES

16.0 INFORMATION REQUIRED WITH BID

PREPARED BY: CHECKED BY: APPROVED BY: ISSUE DATE :

(Aashish Moyal) (Saurabh Singh) (D.K. Pandey) March, 2009

DOCUMENT NO. Page 1 of 1

Sl. Clause / Paragraph / Page Revision Date By Verified

Revised & re-issued as

Cathodic Protection Design

3 Cl No. 6.15 - 1 June-11 AM SS

4 6.7 & 8.3 (ii) (Anode Tail - - Sept-12 AM DGM

5 8.12 (CP Cables) - - Sept-12 AM DGM

6 Revised & Issued as Standard - 2 Oct-15 AM MKJ

7 Revised & Issued as Standard - 3 Aug-2019 AM MKJ

8 Revised & Issued as Standard - 4 July-2020 AM MKJ

DOCUMENT NO. Page 1 of 33

Compliance with these specifications and/or approval of any documents submitted by

DOCUMENT NO. Page 2 of 33

2.0 CODES AND STANDARDS

i) NACE Standard SP-0169 : Standard Recommended Practice Control of

xiv) ISO 15589 Part I : Cathodic Protection of pipeline/structure

xv) IEEE Standards : Institute for Electrical and Electronic Engineers

xvi) OISD Standards : Oil Industry Safety Directorate

DOCUMENT NO. Page 3 of 33

xvii) IS: 7098 Part I : XLPE Insulated Cables.

xviii) IS: 1554 Part I : PVC Insulated (heavy duty) cables.

CEOCOR Guidelines for Risk assessment and Mitigation Measures – AC Corrosion

IEC Standards : International electro technical commission

PNGRB Guidelines : Petroleum & Natural Gas Regulatory Board

ASTM Standards : American Society for Testing and Materials

PESO Norms : Petroleum and Explosive Safety Organisation

API Safety Norms : American Petroleum Institute

3.0 SYSTEM IMPLIMENTATION

a) Various installation procedures & Erection Methodology.

DOCUMENT NO. Page 4 of 33

4.0 CORROSION SURVEY

Depth of soil resistivity shall be as per type of anode ground bed.

DOCUMENT NO. Page 5 of 33

For shallow type-1.5, 2.5 & 3.5 meter depth

4.3 Topographic Surveys

4.4 Additional data to be collected

DOCUMENT NO. Page 6 of 33

5.0 CATHODIC PROTECTION DESIGN PARAMETERS

5.1 Protection current density range :