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REV DATE DESCRIPTION BY APPD REVIEWD

01 07/06/2014 ISSUED FOR APPROVAL

00 15/04/2014 ISSUED FOR APPROVAL

NAME YOGESH JAYRAJ

RAYCHEM RPG KSS

TITLEDESIGN DOCUMENT FOR TEMPORARY

CATHODIC PROTECTION SYSTEM FOR PHASE-ICONTRACT NO- DOCUMENT NO-

R1WORK ORDER NO- MH2145-C000-EL-SPC-SPC-0025, DATED 2/5/13 06-10-1403-DD-PH1

EPMC SERVICES FOR REWARI-KANPUR

PIPELINE PROJECT

OWNER

HINDUSTAN PETROLEUM CORPORATION LIMITED

MAIN CONTRACTOR

KSS Petron Private Limited

Formerly KazStroy Service Infrastructure India Pvt.Ltd)

CONSULTANT

WORLEYPARSONS SEA INDIA PVT. LTD.

CP CONTRACTOR

RAYCHEM RPG P) LIMITED

WORLEYPARSONS APPROVAL

Approved by

NAME SIGN


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DESIGN DOCUMENT FOR TEMPORARYCATHODIC PROTECTION SYSTEM FOR

PHASE-I

EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT

06-10-1403-DD-PH1, Rev-01 Page 2 of 113

Contents1.0 INTRODUCTION .................................................................................................................................. 4

2.0 SCOPE ................................................................................................................................................. 4

3.0 ABBREVATIONS ................................................................................................................................. 5

4.0 SYSTEM OVERVIEW .......................................................................................................................... 7

5.0 CORROSION SURVEY REPORT ....................................................................................................... 8

5.1 OBJECTIVE OF THE SURVEY ........................................................................................................... 8

5.2 SCOPE OF WORK .............................................................................................................................. 8

5.3 SOIL RESISTIVITY SURVEY .............................................................................................................. 8

5.4 SOIL RESISTIVITY VS. DEGREE OF CORROSIVITY ....................................................................... 9

5.5SOIL SAMPLES................................................................................................................................... 9

5.6 ADDITIONAL DATA COLLECTION ................................................................................................... 11

5.7 SURVEY RESULT ............................................................................................................................. 13

6.0 DESIGN DATA & CRITERIA ............................................................................................................. 13

6.1 INTRODUCTION ................................................................................................................................ 13

6.2 PIPELINE DETAILS ........................................................................................................................... 13

6.3 CATHODIC PROTECTION SYSTEM DESIGN LIFE ........................................................................ 13

6.4 CODES AND STANDARDS .............................................................................................................. 13

6.5 PHILOSOPHY OF CATHODIC PROTECTION SYSTEM ................................................................. 14

6.6 PROTECTION CURRENT DENSITY ................................................................................................ 15

6.7 CATHODIC PROTECTION DESIGN CRITERIA ............................................................................... 15

7.0 DESIGN CALCULATION ................................................................................................................... 16

7.1 TOTAL CURRENT REQUIREMENT ................................................................................................. 16

7.2 CURRENT REQUIREMENT .............................................................................................................. 17

7.3 ANODE WEIGHT REQUIREMENT ................................................................................................... 18

7.4 HORIZONTAL GROUNDBED RESISTANCE ................................................................................... 19

8.0 EHV / HV CROSSINGS ..................................................................................................................... 23

9.0 CATHODIC PROTECTION AT CASED CROSSINGS ...................................................................... 27

9.1CATHODIC PROTECTION FOR CARRIER PIPE ............................................................................ 27

10.0 INSULATION JOINTS ...................................................................................................................... 30

11.0 EARTHING ELECTRODE ............................................................................................................... 30

12.0 POLARISATION COUPONS ........................................................................................................... 31

13.0 REFERENCE CELL ACCESS POINTS........................................................................................... 31

14.0 ER PROBE & READER ................................................................................................................... 31


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15.0 TEST STATION ............................................................................................................................... 32

16.0 CABLE LAYING DETAILS ............................................................................................................... 50

17.0 CABLE TO PIPE CONNECTIONS .................................................................................................. 50

18.0 INSTALLATION PROCEDURE ....................................................................................................... 51

18.1 FOR TEST STATION ....................................................................................................................... 51

18.2 FOR SACRIFICIAL ANODES .......................................................................................................... 55

18.3 FOR CABLE LAYING....................................................................................................................... 59

18.4 FOR SURGE DIVERTER ................................................................................................................ 63

18.5 FOR THERMIT WELD ..................................................................................................................... 66

18.6 FOR PIN BRAZING .......................................................................................................................... 71

18.7 FOR POLARISATION CELL ............................................................................................................ 75

18.8 FOR PERMANENT REFERENCE CELL......................................................................................... 78

18.9 FOR POLARISATION COUPON ..................................................................................................... 82

18.10 FOR ZINC RIBBON ANODES ....................................................................................................... 85

18.11 FOR ER PROBE ............................................................................................................................ 88

19.0 INCOMING MATERIAL INSPECTION REPORT ............................................................................ 91

20.0 STANDARD QAP ............................................................................................................................. 92

21.0 RECORD OF CALIBRATION OF MEASURING INSTRUMENTS .................................................. 94

22.0 INTERFERENCE DETECTION AND MITIGATION ........................................................................ 95

22.1 PROCEDURE FOR AC INTERFERENCE SURVEY ...................................................................... 96

22.2 PROCEDURE FOR DC INTERFERENCE SURVEY ...................................................................... 99

23.0 TESTING AND COMMISIONING .................................................................................................. 105

24.0 SYSTEM MONITORING ................................................................................................................ 109

25.0 BILL OF MATERIAL ....................................................................................................................... 111

26.0 REFERENCE DRAWING LIST ..................................................................................................... 113


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3.0 ABBREVATIONS

SN Terms Description

1 AnodeAn electrode placed in the electrolyte to apply Cathodic

protection to the structure

2 BackfillLow resistance material surrounding the anode to reduce the

anode to electrolyte resistance

3 Cathode The structure that is to be protected by Cathodic protection

4Cathodic

Protection

The prevention or reduction of corrosion of metal by making the

metal the cathode in a galvanic or electrolytic cell

5 CorrosionThe deterioration of metal caused by its electrochemical reaction

with its environment

6Corrosion

Current

The current flowing in a corrosion cell & which is

electrochemically equivalent to the anode & cathode reactions

7 Current DensityCurrent flowing into the cathode divided by cathode surface

area.

8 ElectrolyteA liquid or the liquid component in a composite material such assoil, in which electric current may flow by ionic charge transfer

9 Instantaneousoff potential

A potential substantially free of voltage gradients

10 PolarizationA change in the potential of a metal from its natural steady state

value as a result of current flow

11Polarized

Potential

The potential value of a metal after polarization reaches the

steady state

12ReferenceElectrode

An electrode that has a stable potential in one or more

electrolytes at a given temperature, thus enabling it to be usedfor the measurement of other reference electrode

13 Structure A metal which has a surface in contact with an electrolyte

14 Dia Diameter

15 Ch Chainage

16 Km Kilometer

17 m Meter

18 mm Millimeter

19 Nos Number

20 V Voltage


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SN Terms Description

21 mV Milivolts

21 m2 Square meter

22 mg miligrams

23 Amps Ampere

24 PSP Pipe to Soil potential

25 CPS Cathodic Protection Station

26 HPCL Hindustan Petroleum Corporation Limited

27 KazStroy KSS Petron Private Limited

28 Raychem RPG Raychem RPG Pvt. Ltd.


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5.0 CORROSION SURVEY REPORT5.1 OBJECTIVE OF THE SURVEY

The survey aim to generate sufficient data and correlated information which will provide the

basis for designing of cathodic protection system. The same information shall be used as

input parameters with which the C.P. system has to eventually cope with.

The basic data and generated information shall be comprehensively analysied and

interpreted to lay down the guidelines for the C.P. system Design and Engineering.

5.2 SCOPE OF WORK

The Corrosion Survey includes,

Soil Resisitivity survey

Additional data collection to generate design data for evaluation of interaction

possibilities due to presence of other services in ROU.

Soil samples shall be collected on an average for every 10 km along ROU.

5.3 SOIL RESISTIVITY SURVEYThe Soil resistivity measurements have been carried out using 4 pins WENNER method. The

measurements were carried out at pin spacing of 1, 1.5 and 2.5 m.

INSTRUMENT USED FOR THE SURVEYSoil Resistivity meter

Make: Nilsson Electrical Lab, INC. USA/MC Miller USA, NILSSON 400 & Motwane-DET-20

RESISTIVITY CALCULATIONSd = 2 x x a x R

Where:

a = Consecutive distance in cm

R = Resistance measured as indicated by unit in ohms

d = Resistivity (ohm-cm)


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Chainage wise chemical analysis report readings are tabulated below:

Sr.No.

Chainage(Km)

Chloride (ppm) Sulphate (ppm) pH (Digital mtr)

1.0 Mtr 2.0 Mtr 1.0 Mtr 2.0 Mtr 1.0 Mtr 2.0 Mtr

1 0 749 649 93 86 7.13 6.95

2 10 949 949 33 17 7.18 7.23

3 20 1199 1449 123 153 6.93 7.48

4 30 200 150 167 93 7.03 7.96

5 40 120 180 123 153 6.93 7.48

6 50 250 210 167 93 7.03 7.96

7 60 135 140 123 153 6.93 7.48

8 70 899 949 167 93 7.03 7.96

9 80 749 899 123 153 6.93 7.48

10 90 300 450 33 27 7.18 7.23

11 100 227 230 123 153 6.93 7.48

12 110 999 1049 18 9 7.4 4.14

13 120 1199 1449 123 153 6.93 7.48

14 130 200 250 167 93 7.03 7.69

15 140 649 699 227 212 7.6 7.5816 150 600 500 19 41 7.01 7.05

17 160 200 150 5 6 8.08 8.03

18 170 250 899 17 95 7.31 7.21

19 180 500 350 123 153 6.93 7.48

20 190 150 150 123 153 6.93 7.48

21 200 250 253 167 93 7.03 7.96

22 210 200 300 123 153 6.93 7.48

23 220 200 250 167 93 7.03 7.96

24 228 699 550 123 153 6.93 7.48

As per the chemical analysis report attached in Annexure A we can conclude the following

points:

The Chloride content was less than 520 PPM.

The Sulphate content was less than 109 PPM.

The pH value varies from 6.93 to 8.8

The soil resistivity report, its graphs and soil samples chemical analysis report and

its graph are attached in Annexure A.


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5.6 ADDITIONAL DATA COLLECTIONAdditional data has been collected from Various sources like owner, consultant, contractor,

aligment sheet and from the field survey.

List of Major Road, River & Canal Crossings IN Phase-1 are as follows:

1) RKPL Ph-1 Rewari Dispatch Terminal to SV-4, Ch:228 km:

MAJOR RAILWAY CROSSING

Sr.No.

Chainage(km)

DESCRIPTIONLength Of

Crossing (Km)

1 98.111 RAILWAY XING (NCR) 35

2 141.972 WEASTERN CENTRAL RAILWAY 55

3 158.470 MATHUTA ACHNERA RAILWAY XING 30

4 162.395 CENTRAL RAILWAY CROSSING 47

5 163.213 RAILWAY XING-MATHURA TO FARAH 47



8 216.534 NORTHAN RAILWAY MAINLINE XING 74


MAJOR HT LINE CROSSING

Sr. No. Chainage (km) DESCRIPTION

1 2.885 110 KVA HT CROSSING

2 5.151 132 KVA HT LINE CROSSING

3 10.765ASPHALTED ROAD GUJAR MAJARI TO GUJARI & 132 KVA

CROSSING

4 19.774 220 KVA HT LINE XING

5 33.054 220 KVA HT LINE XING NEAR BRICK KILN

6 34.248 220 KVA HT XING

7 34.850 110 KVA HT CROSSING, NEAR CHAMBORDA VILLAGE


9 134.851 220KVA LINE XING NEAR ASPHALTED ROAD


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MAJOR HT LINE CROSSING

Sr. No. Chainage (km) DESCRIPTION

10 145.049 400KV HT LINE XING

11 158.270 400 KV HT LINE XING

12 166.385 440KVA HT LINE XING

13 177.354 220KV HT XING NEAR KHADERA VILLAGE


15 199.079 200 KV HT LINE XING

16 201.754 220 KVA HT LINE XING17 217.007 400KVA HT XING, NEAR GOWAL VILLAGE


MAJOR ROAD CROSSING

Sr. No. Chainage (km) Crossing

1 0.577 NH-71

2 3.387 NH-08

3 4.018 NATIONAL HIGHWAY JAIPUR-DELHI

4 33.876 STATE HIGHWAY-25

5 62.608 SH-35 XING

6 82.564 SH-45


8 99.961 SH-14 XING




12 161.957 NH-02 Farah To Mathura



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NACE RP-10A190 Measurement technique related to criteria for CP of Undergroundor Submerged steel piping system

NACE RP-0177 Recommended Practice Mitigation of AC and Lighting Effects

on Metallic Structures and Corrosion Control Systems

NACE No. 54276 Cathodic Protection Monitoring For Buried Pipelines

NACE RP-0572 Recommended Practice Design, Installation, Operation and of

Impressed Current Deep Ground Beds

DNV RP-B403 Recommended Practice Monitoring of CP System

DNV RP-B401 Recommended Practice Cathodic Protection Design

IS 8062 Recommended Practice ICCP for Underground Pipe

VDE 0150 Protection against Corrosion due to stray current from DC

Installation

IS: 1554 Part1 PVC insulated (Heavy Duty) Cables.

BS:7361 Part I Code of Practice for Cathodic Protection for Land and

Marine applications

6.5 PHILOSOPHY OF CATHODIC PROTECTION SYSTEMAs provided in the enquiry specifications, the cathodic protection system shall be a Galvanic/

Sacrificial Anodes system and shall be designed using pre-packed Magnesium anodes. The

prepacked Magnesium anodes shall be installed in a horizontal configuration in a trench of

depth 2 M. to ensure that it reach moist soil and it should be 2 to 5 M. away from the edge of

pipeline.Considering Minimum 2 Nos. of 2.5 Kg prepacked magnesium anode for soil

resistivity upto 90 ohm-M. and Minimum 3 Nos. of 2.5 Kg prepacked magnesium anode for

soil resistivity above 90 ohm-M. and upto 110 ohm-M.,for carrier pipe protection along the

pipeline route at every 1 km interval. However any unprotected Pipeline area is observedduring construction the same shall be protected by providing additional anodes.


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6.6 PROTECTION CURRENT DENSITYThe Pipeline is coated with 3 layer PE Coating and the minimum protective current density for

Temporary Cathodic Protection system as per the Specification no: MH2145-C000-EL-SPC-

0025 RevA is as given below.

Pipeline SurroundingMinimum Protection

Current Density (mA / m2)

Soil Resistivity < 10 ohm-m 0.075

Soil Resistivity 10 ohm-m to 100 ohm-m 0.055

Soil Resistivity > 100 ohm-m 0.035

A safety margin of 1.3 i.e. 30% has been provided for in the current calculations over and

above the specified protective current density.

Soil Resistivity in phase 1 of RKPL is in the range of 10 ohm-m to 100 ohm-m, The Average

soil resistivity at 2 m depth is 22.23 ohms-m in Phase1 of RKPL, hence current density of

0.055 mA / m2 is considered.

6.7 CATHODIC PROTECTION DESIGN CRITERIA

Cathodic Protection system shall be designed to meet the following any one of the criteria: The pipe to Soil Potential measurements shall be in between (-) 0. 95 V ON to (-) 1.5

V ON as measured between the pipe surface and a saturated copper - copper sulfate

reference electrode.

The pipe to Soil Potential measurements shall be in between (-) 0. 95 V (IR Free) to (-)

1.18 V (IR Free) as measured between the pipe surface and a saturated copper -

copper sulfate reference electrode.

A positive potential swing of 100 mV or more shall be considered as the criteria for

presence of an interaction / interference situation requiring investigation and

incorporation of mitigation measures.


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7.0 DESIGN CALCULATIONThe following calculations have been used to design the Temporary Cathodic Protection

system.

7.1 TOTAL CURRENT REQUIREMENT

Surface Area

Where:Sa =Surface area of Pipeline (m

2)

D = Diameter of pipeline (m)

L = Length of pipeline (m)

The surface area calculations are tabulated as under:

Pipeline SectionDia.(m)

PipelineLength (m)

CoatingSurface

Area (m2)

Rewari Dispatch terminal to SV-

6(Ch:228 km)0.457 228000 3LPE 327341.3


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7.2 CURRENT REQUIREMENT

The Pipeline is coated with 3 layer PE Coating and the current density considered for the

Temporary Cathodic Protection design is 0.055 mA / m2

Based on the above current density, the total current requirement as per soil resistivity span is

calculated as follows:

WhereIt = C.P. current requirement (Amp)

Sa = Surface area of Pipeline (m2)

Cd= C.P. protective current density (mA/m2)

1.3 = Safety Margin

ChainageSpan

Soilresistivity(Ohms-m)

Dia(m)

PipelineLength (m)

SurfaceArea (m2)

ProtectiveCurrent Density

(mA/ m2)

CurrentRequired(Amp.)

Rewari Dispatch terminal to SV-6(Ch:228 km)

.00-228 Km 22.23 0.457 228000 327341.3 0.055 23.40


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7.3 ANODE WEIGHT REQUIREMENTThe total anode weight requirement is calculated using the following formula:

Where

Wt= Total Anode Weight (Kg.)

It = C.P. current requirement (Amps)

Ct=Consumption Rate of Anode (7.9 Kg/Amp-Year)

L = Design Life (2 years)

Uf= Anode Utilisation factor (0.85)

PipelineSection

Individual

AnodeWeight

(Kgs) (W)

Total

Current(Amp)

(It)

Total Anode

Requirement(Kgs)(Wt)

Total Anode

Requirement(Nos)(Na)

Total No.

of AnodeProposed

(Nos)

Rewari Dispatch terminalto SV-6(Ch:228 km)

2.5 23.40 434.96 174 458


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7.4 HORIZONTAL GROUNDBED RESISTANCEa) Resistance of Single horizontal anode

Where:

Rah= Resistance of Single horizontal anode

Ps = Soil Resistivity in (5 ohm-m)

L= Length of prepackaged anode in (1.5 m)

d = diameter of prepackaged anode in (0.15 m)

t = Depth of Anode in (2 m)

Rah = 1.068 ohms

b) Resistance of multiple horizontal

Where

Rgbh= Resistance of multiple horizontal anodes in (ohms)

Rah = Resistivity of single horizontal anode in (1.068 ohms)

N = Number of anodes (2 Nos.)

F = Crowding Factor (1.134)

Rgbh=0.606 ohms

c) Crowing Factor

Where:

F = Crowding Factor

Rah= Resistance of Single horizontal anodes (1.068 ohms)

Ps = Soil Resistivity in (5 ohm-mtr.)

S = End to End spacing of Anode (3 mtr.)

N = Number of Anodes (2 Nos.)

F=1.134


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d) Cable ResistanceFor the ground bed using 1 horizontal anode, the longest anode tail cable of 9 m ofPVC/PVC

single core copper conductor 6mm2cable shall be used.

The cable resistance of copper conductor single core 6 mm2size is 3.08 ohm/Km.

Therefore the cable resistance for 1 No. Anode tail cables of 9 mtr. Length shall be,

Where:

RC = Total Cable Resistance (ohms)

Ra = Cable Resistance (0.00308 ohm-m)

L = Length of the Cable (9 m)

N = Number of anodes (2 Nos.)

RC = 0.0139 ohms

e) Total Circuit Resistance

The total circuit resistance for each anode bed

Where:

Rt = Total circuit resistance (ohms)

Rgbh= Resistance of multiple horizontal anodes (0.606 ohms)

RC = Total Cable Resistance (0.0139 ohms)

Rt= 0.620 ohms

f) The current output at each ground bed

Where:

I= Current Output per anode bed (Amps.)

V= Driving potential for Mg anodes with line polarized is

=1.55 - 0.95 = 0.6 V

Rt= Total circuit resistance (0.620 ohms)

I=0.967 Amps


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Pipeline Coverage by Anodes at various Soil Resistivities for RKPL is as below:

Soil Resistivityrange Ohm-m

Using 2Nos of MG anode Using 3Nos of MG anode

Total Circuit

Resistance

CurrentO/P of

Anode(Amps)

KMCoverageof Pipeline

Total Circuit

Resistance

CurrentO/P of

Anode(Amps)

KMCoverageof Pipeline

1 0.135 4.439 43.26 0.104 5.74 55.98

1-3 0.377 1.58 15.48 0.294 2.034 19.83

3-5 0.620 0.967 9.42 0.485 1.23 12.05

5-8 0.984 0.610 5.94 0.771 0.778 7.59

8-10 1.227 0.489 4.77 0.961 0.624 6.08

10-15 1.833 0.327 3.19 1.43 0.417 4.07

15-20 2.44 0.246 2.40 1.91 0.314 3.06

20-25 3.04 0.197 1.92 2.389 0.251 2.45

25-30 3.65 0.164 1.60 2.86 0.209 2.04

30-35 4.25 0.141 1.37 3.34 0.180 1.75

35-40 4.86 0.123 1.20 3.81 0.157 1.53

40-50 6.07 0.099 0.96 4.77 0.126 1.23

50-60 7.29 0.082 0.80 5.722 0.105 1.02

Hence, The anode ground bed locations and the number of anodes to be used for each location

has been decided considering 2 Nos. of 2.5 Kg prepacked magnesium anode for soil resistivity

upto 90 ohm-m. and 3 Nos. of 2.5 Kg prpacked magnesium anode for soil resistivity above 90

ohm-m and upto 110 ohm-m, for carrier pipe protection along the pipeline route at every 1

km interval.

However any unprotected pipeline area is obsreved during construction time, The same shall

be protected by providing additional anodes.

R-1


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The ground bed details are mentioned in the enclosed Schedule. The actual chainages mayvary as per actual site conditions at the time of selection of locations during installation.


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8.0 EHV / HV CROSSINGSZinc earthing anode & polarization cell shall be provided as per Project Specification MH2145-

C000-EL-SPC-0025 RevA.

For earthing of pipeline at the 66KV and above HT Line crossings, at 1 km interval of parallel

run (if horizontal distance of HT line is within 25 m. of the pipeline) and at the departure

points from the parallel run for earthing purpose Zinc ribbon anode so that the earthing

resistance is restricted within acceptable limit of 5 ohm.

The total meter of Zinc ribbon anode proposed (Size 12.7 X 14.28 mm) = 110 m

Sample calculation of resistance of Horizontal anode bed for Zinc Ribbon anode:

Where:

Rb= Anode to Earth resistance (ohm)

Ps = Soil Resistivity in ohm-M (2.885 ohm-m)

L = Length of prepackaged anode in m (3 m)

D = Diameter of prepackaged anode in m (0.15 m)

S = Twice the Depth of Anode (4 m)

Rb=2.425 ohms

ii) Resistance of the anode to backfill:

Where:Rbs = Resistance of anode to backfill in ohms (ohms)

Ps = Resistivity of backfill material (0.5 ohm-m)

L = Length of anode in m (3 m)

d = Effective diameter of anode in m (0.0151 m)

Rbs=0.108 ohms


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iii) Cable resistance:For the groundbed using 1 Zinc Ribbon anode of 10 m. Length, the anode tail cable of 8 m.

Of PVC/PVC single core copper conductor 25 mm2cable shall be used.

The cable resistance of copper conductor single core 25 mm2size is 0.727 ohm/Km.

Therefore, the cable resistance for 1 No. anode tail cables of 8 m. Length shall be calculated

as follow:

Where:

RC = Total Cable Resistance (ohms)

Ra = Cable Resistance (0.000727 ohm-m)

L = Length of the Cable (8 m)

Rc=0.0058 ohms

iv) Total circuit resistance:

Where:

RT= Total circuit resistance (ohms)

Rb= Resistance of horizontal anode to electrolyte (2.425 ohms)

Rbs= Resistance of Anode to backfill (0.108 ohms)

RC= Cable Resistance (0.0058 ohms)

N = Number of Anodes (2 No)

RT=1.270 ohms

R-1


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Detail calculation for zinc grounding anode for HT Line Xings are tabulated below:

SNChainage

(km)

SoilResistivity (Ohm-

M)

No. ofAnode

s (Zn)

Lengthof thePre-

Packe

dAnode

(Mt)

AnodeDia

(mt)

Lengthof

Bare

Anode(mt)

Dia ofBare

Anode(mt)

Twicethe

Depth

ofAnode

Anode toearth

Resistance (ohm

Anode tobackfill

Resistance (ohms)

CableResistanc

e (ohms)

Totalcircuit

Resistance

No of Zinc

anode

Totalweigh

t of

Anode

Polarisation cell(Solid

State-5.0KA)

N L D l d S Rb Rbs Rc RT Nos (Kg) Nos

1 2.885 12.230 2 3 0.150 3 0.151 4.0 2.425 0.108 0.0058 1.270 3mtr x 2Nos 5.1 1

2 5.151 64.995 2 5 0.150 5 0.151 4.0 9.218 0.073 0.0058 4.648 5mtr x 2Nos 8.5 1

3 10.765 32.905 2 3 0.150 3 0.151 4.0 6.526 0.108 0.0058 3.320 3mtr x 2Nos 5.1 1

4 19.774 31.870 2 3 0.150 3 0.151 4.0 6.320 0.108 0.0058 3.217 3mtr x 2Nos 5.1 15 33.054 26.875 2 3 0.150 3 0.151 4.0 5.330 0.108 0.0058 2.722 3mtr x 2Nos 5.1 1

6 34.248 19.310 2 3 0.150 3 0.151 4.0 3.830 0.108 0.0058 1.972 3mtr x 2Nos 5.1 1

7 34.850 27.315 2 3 0.150 3 0.151 4.0 5.417 0.108 0.0058 2.765 3mtr x 2Nos 5.1 1

8 63.010 51.855 2 5 0.150 5 0.151 4.0 7.354 0.073 0.0058 3.716 5mtr x 2Nos 8.5 1

9 134.851 20.515 2 3 0.150 3 0.151 4.0 4.068 0.108 0.0058 2.091 3mtr x 2Nos 5.1 1

10 145.049 15.840 2 3 0.150 3 0.151 4.0 3.141 0.108 0.0058 1.627 3mtr x 2Nos 5.1 1

11 158.270 19.090 2 3 0.150 3 0.151 4.0 3.786 0.108 0.0058 1.950 3mtr x 2Nos 5.1 1

12 166.385 13.655 2 3 0.150 3 0.151 4.0 2.708 0.108 0.0058 1.411 3mtr x 2Nos 5.1 1

13 177.354 8.895 2 3 0.150 3 0.151 4.0 1.764 0.108 0.0058 0.939 3mtr x 2Nos 5.1 114 197.417 18.550 2 3 0.150 3 0.151 4.0 3.679 0.108 0.0058 1.896 3mtr x 2Nos 5.1 1

15 199.079 25.900 2 3 0.150 3 0.151 4.0 5.136 0.108 0.0058 2.625 3mtr x 2Nos 5.1 1

16 201.754 24.565 2 3 0.150 3 0.151 4.0 4.872 0.108 0.0058 2.493 3mtr x 2Nos 5.1 1

17 217.007 9.370 2 3 0.150 3 0.151 4.0 1.858 0.108 0.0058 0.986 3mtr x 2Nos 5.1 1

Total Length of Zinc Ribbon anode=110Mtrs

-


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9.0 CATHODIC PROTECTION AT CASED CROSSINGSAs per specification no MH2145-C000-EL-SPC-0025 RevA, Cathodic protection to casing shall

be provided if casing is coated. In This project all cased crossing are uncoated, therefore

additional protection is not Provided.

9.1 CATHODIC PROTECTION FOR CARRIER PIPE

Carrier pipe inside casing shall be protected by Zinc ribbon anodes well connected to the

outer surface of bottom of carrier pipe extending between hour hand positions of 4 and 8 o

clock. The anodes shall be placed at close intervals as per design calculations and sized

based on the permanent CP design parameters for 35 years.

The calculations are as below,

i)Surface Area

Where:

Sa =Surface area of Pipeline(m2)

D = Diameter of pipeline (m)

L = Length of pipeline (m)

ii) Current requirement

Where:

It = Current requirement (Amps)

Sa =Surface area of Pipeline(m2)

Cd = CP protective current density (mA/m2)

1.3 = Safety factor


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The surface area & current requirement calculations are tabulated as under:

Chainage(km)

Dia.(m)

PipelineLength (m.)

Surface Area(m2)

CurrentDensity (mA/m2)

Current Required(Amps)

0.577 0.457 27 38.76 0.055 0.0028

3.387 0.457 74 106.24 0.055 0.0076

10.747 0.457 18 25.84 0.055 0.0018

22.865 0.457 18 25.84 0.055 0.0018

33.876 0.457 25 35.89 0.055 0.0026

62.608 0.457 32 45.94 0.055 0.0033

82.564 0.457 14 20.10 0.055 0.0014

92.680 0.457 20 28.71 0.055 0.0021

98.076 0.457 35 50.25 0.055 0.0036

99.961 0.457 22 31.59 0.055 0.0023

122.770 0.457 17 24.41 0.055 0.0017

127.241 0.457 16 22.97 0.055 0.0016

136.215 0.457 22 31.59 0.055 0.0023

140.377 0.457 36 51.69 0.055 0.0037

141.917 0.457 55 78.96 0.055 0.0056

158.440 0.457 30 43.07 0.055 0.0031

161.957 0.457 30 43.07 0.055 0.0031

162.348 0.457 47 67.48 0.055 0.0048

163.166 0.457 47 67.48 0.055 0.0048

164.684 0.457 47 67.48 0.055 0.0048

165.712 0.457 47 67.48 0.055 0.0048

216.460 0.457 74 106.24 0.055 0.0076

226.000 0.457 29 41.64 0.055 0.0030


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iii) Anode required by weight

Where:

Wt = Weight of anode required (kg)

It = Current requirement (Amps)

Ct =Consumption rate of anode(11.24 Kg/Amp-Year)

L = Design Life (35 years)

Uf = Anode Utilisation factor (0.5)

Type of anode: Zinc Ribbon Anode

Totalcurrentrequired(Amps)

AnodeWeight as per

design (Kgs)

WeightOf Anode

per mtr.

Total Length ofAnode required as

per design (m)

Individual lengthof Anode proposed(Between 2 spacer)

(m)

Total Length of Ribbonproposed considering

1no zinc ribbon inbetween 2 spacer (m)

0.0028 2.18 0.850 2.57 0.48 6.46

0.0076 5.98 0.850 7.03 0.48 17.71

0.0018 1.45 0.850 1.71 0.48 4.31

0.0018 1.45 0.850 1.71 0.48 4.310.0026 2.02 0.850 2.38 0.48 5.98

0.0033 2.58 0.850 3.04 0.48 7.66

0.0014 1.13 0.850 1.33 0.48 3.35

0.0021 1.62 0.850 1.90 0.48 4.79

0.0036 2.83 0.850 3.33 0.48 8.37

0.0023 1.78 0.850 2.09 0.48 5.26

0.0017 1.37 0.850 1.62 0.48 4.07

0.0016 1.29 0.850 1.52 0.48 3.83

0.0023 1.78 0.850 2.09 0.48 5.26

0.0037 2.91 0.850 3.42 0.48 8.61

0.0056 4.44 0.850 5.23 0.48 13.16

0.0031 2.42 0.850 2.85 0.48 7.18

0.0031 2.42 0.850 2.85 0.48 7.18

0.0048 3.80 0.850 4.47 0.48 11.25

0.0048 3.80 0.850 4.47 0.48 11.25

0.0048 3.80 0.850 4.47 0.48 11.25

0.0048 3.80 0.850 4.47 0.48 11.25

0.0076 5.98 0.850 7.03 0.48 17.71

0.0030 2.34 0.850 2.76 0.48 6.94

Total 187.12


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10.0 INSULATION JOINTSThe Surge Diverter Flame Proof type shall be connected across each Isolation Joints.

The proposed locations of IJ are as follows:

Sr.No.

Pipeline SectionChainage

(Km)Location

Qty(Nos.)

1

RKPL-Phase I

00 Rewari Dispatch Terminal 1

2 141.80 Bharatpur Terminal Receiver Side 1

3 141.80 Bharatpur Terminal Launcher Side 1

4 164.378 Mathura Terminal Receiver Side 1

5 164.378 Mathura Terminal Launcher Side 1

11.0 EARTHING ELECTRODE

The above ground unprotected portion of the pipeline at the pipeline terminal and

intermediate station shall be earthed through earthing system consisting of earth electrodes

and earthing conductor. All flanges on unprotected pipe shall be shorted with 25 Sq. mm

copper cables.The resistance of grounding shall be limited to 5 ohms.

The motor operated valves located on cathodically protected pipeline shall be separately

grounded with the help of 20kg zinc anode.


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12.0 POLARISATION COUPONSThe Polarisation coupons of pipeline material shall be provided along the pipeline to monitor

the adequacy of the cathodic protection. The Polarisation coupon shall be made as per

drawing no 06-10-1403-PCC & specification MH2145-C000-EL-SPC-0025 RevA

The coupon shall be installed as per table given below:

RKPL Ph-1 Pipeline Section:

Sr.

No.

Chainage

(Km)Location

Test Station

Type

Qty

(Nos.)

1 5.151 132 KVA HT LINE CROSSING ML 1

2 158.270 400 KV HT LINE XING ML 1

13.0 REFERENCE CELL ACCESS POINTS

Reference cell access points shall be provided near insulating joint locations at SV stations

where the ground is paved, for measurement of pipe to soil potentials. A perforated PVC

pipe filled with native soil and buried at the location shall be provided for measurement

purpose. The length of the PVC pipe shall be adequate to reach the native soil below the

paving.

14.0 ER PROBE & READER

Electrical Resistance Probe and Reader shall be provided along the pipeline ROU for

monitoring the rate of metal loss due to corrosion. The ER Probes shall be implemented for

external corrosion monitoring. The lead wires of the probe shall be connected to pipeline

through test station and terminated inside test station enabling periodic resistancemeasurement of the probe using a portable probe-measuring instrument.

The material of the E/R probe element shall be of same alloy as of the pipeline material.

Probe shall be provided preferably at the bottom portion of pipeline.

2 Nos ER Probe shall be considered with 2 Nos. Of Reader for pipeline in Phase I.

The location for installation of ER probe has been proposed, however exact location shall be

decided at site after post commissioning survey in consultation with consultant/owner.

The Proposed location of ER probe is as below:


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RKPL Ph-1 Pipeline Section:

SNChainage

(Km)Location

Test StationType

Qty (Nos.)

1 33.054 220 KVA HT LINE XING NEAR BRICK KILN M 1

2 217.007 400KVA HT XING, NEAR GOWAL VILLAGE ML 1

15.0 TEST STATION

Test Station shall be provided along the pipeline ROU for monitoring the performance of the

Cathodic protection system at an interval of about 1000 m in inhabited areas and 2000 m in

Un-inhabited areas such as forests / deserts etc.

In addition to the above Test Stations shall be provided at the following points,

At the locations of Anode ground beds.

At all Insulation Joints.

At vulnerable locations with drastic changes in Soil Resistivity.

At locations of Surge diverters, Polarisation Coupons, pipeline grounding through

polarization cells, Zinc & Mg Anodes.

At EHV/HV AC/DC overhead line crossings and selected locations where EHV/HV

overhead lines are in the vicinity of the pipeline.

At Railway Line crossing and at selected location along lines running parallel to

pipeline.

At both sides of major river crossings.

At EHV/HV cable crossings or along routes where EHV/HV cables are running in

parallel.

In the vicinity of DC network or grounding systems and HVDC grounding systems

where interference problems are suspected. At crossing of other pipelines / structures

At the Location of Reference cell and ER Probe Installation.

At both sides of Cased crossings.

Locations where interference is expected.

At locations of Sectionalizing Valves (SV) Stations.

At any other locations considered necessary by Owner/Owners Representative.


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Test Station Connection Scheme as given below:

Purpose Type

Pipe to soil potential measurement A

Pipe to soil potential measurement with Galvanic Anode Connection AL

Line Current measurement B

Line Current measurement with Galvanic Anode Connection BL

Isolating Joint, Line Current measurement with Galvanic Anode Connection BFL

Cased crossing with uncoated casing C

Uncoated cased crossing with Galvanic Anode Connection CL

Cased crossing with coated casing D

coated cased crossing with Galvanic Anode Connection DL

Insulating Joint F

Intermediate CP station impressed current drainage point. G

Intermediate CP station impressed current drainage point with galvanic anodeconnection.

GL

Intermediate CP station impressed current drainage point with Insulating Jointand galvanic anode connection.

GFL

Foreign pipeline crossing E

Foreign pipeline crossing with Galvanic Anode Connection EL

HT Line crossings Grounding Through Polarisation Cell and Zinc ribbon anode M

HT Line crossings Grounding Through Polarisation Cell, Zinc ribbon anode withGalvanic Anode Connection

ML

HT line crossing & cased crossing with uncoated casing CM

HT line crossing & cased crossing with coated casing DM

HT Line crossings Grounding Through Polarisation Cell, Zinc ribbon anode &foreign pipeline crossing

ME

Cased Crossing with uncoated casing & foreign pipeline crossing CE


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Cased Crossing with coated casing & foreign pipeline crossing DE

HT Line crossings Grounding Through Polarisation Cell and Zinc ribbon anode

& Foreign pipeline crossing with Galvanic Anode ConnectionMEL

Coated cased crossing with HT Line crossings Grounding Through PolarisationCell, Zinc ribbon anode with Galvanic Anode Connection

DML

Un-Coated cased crossing with HT Line crossings Grounding ThroughPolarisation Cell, Zinc ribbon anode with Galvanic Anode Connection

CML

Test Station installation chainage & types are mentioned in the schedule. All the chainage are

indicative only. The test stations shall be installed as per the actual details like HT Line/

Pipeline crossings, cased crossings, MOV etc., at site during actual execution of the job.


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1) The Schedule of Test stations for RKPL Ph-1 are as follows:

SN LocationChainage

(km)

Test

StationType

(TS)

CPStatio

n SizeTest

station(ICTS)

(Nos.)

NormalSize

Teststation

(TS)(Nos.)

Polcell

SizeTest

Station(PCTS)

(Nos.)

CTSUSize

TestStation

(CTS)(Nos.)

Perman

ent Ref.Cell

CuCuSo4 (Nos)

Mg

Anode(2.5KG)

(Nos.)

Mg

Anode(10KG)

(Nos.)

Bare ZnRibbon

Anodefor HTLine

crossing

(m.)

ZN

Anode(20KG)

(Nos.)

Polarisa

tion cell(solidstate)(Nos.)

Polaris

ationCoupon

(Nos.)

ERprobe(Nos.)

1 HPCL Rewari Terminal 0.000 GFL 1 2 2 1

2 NH-71 0.577 C 1

3 NH-71 0.604 C 1

4 IN FIELD 1.000 AL 1 2

5 KARNAWAS TO DODHI ROAD XING 2.000 AL 1 2

6 110 KVA HT CROSSING 2.885 M 1 4 1

7 IN FIELD 3.000 AL 1 2

8 NH-08 3.387 C 1

9 NH-08 3.461 C 1

10 NATIONAL HIGHWAY JAIPUR-DELHI 4.018 AL 1 3

11 132 KVA HT LINE CROSSING 5.151 ML 1 1 3 24 1 1

12 IN FIELD NEAR DHANI VILLAGE 6.151 AL 1 3

13 KHERIMOLTA DISTRIBUTORY 7.167 AL 1 2

14 IN FIELD 8.167 AL 1 2

15 IN FIELD 9.167 AL 1 2

16 NEAR GUJRAS CART TRACK 10.000 AL 1 2

17ASPHALTED ROAD GUJAR MAJARI

TO GUJARI10.747 C 1

19HPCL PIPELINE CROSSING, NEAR

GUJARI BUS11.851 EL 1 2


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SN LocationChainage

(km)

TestStation Type(TS)

CPStation SizeTest

station

(ICTS)(Nos.)

NormalSizeTest

station(TS)

(Nos.)

PolcellSizeTest

Station

(PCTS)(Nos.)

CTSUSizeTest

Station(CTS)

(Nos.)

Permanent Ref.

Cell

CuCuSo

4 (Nos)

MgAnode(2.5

KG)

(Nos.)

MgAnode

(10

KG)

(Nos.)

Bare ZnRibbonAnodefor HT

Line

crossing(m.)

ZNAnode

(20

KG)

(Nos.)

Polarisation cell(solid

state)

(Nos.)

Polarisation

Coupon(Nos.)

ERprobe

(Nos.)

20 IN FIELD 12.851 AL 1 2

21 CART TRACK JAKAPUR BHAGANA 13.778 AL 1 2

22 IN FIELD 14.778 AL 1 2

23 IN FIELD 15.778 AL 1 2

24 IN FIELD 16.778 AL 1 2

25 IN FIELD 17.778 BL 1 1 2

26 NEAR SAHIBI RIVER 18.691 AL 1 3

27 220 KVA HT LINE XING 19.774 ML 1 2 8 1

28 IN FIELD 20.774 AL 1 2

29 IN FIELD 21.774 AL 1 2

30 MAJOR DISTRICT ROAD XING-61 22.865 CL 1 3

31 MAJOR DISTRICT ROAD XING-61 22.883 C 1

32 CART TRACK JAKAPUR BHAGANA 23.883 AL 1 2

33IN FIELD NEAR PUR VILLAGE &

BHADUKA24.883 AL 1 2

34 IN FIELD 25.883 AL 1 2

35 IN FIELD NEAR KASWAR VILAGE 26.883 AL 1 2

36 NEAR NALLAH XING 27.883 AL 1 2

37 HPCL PIPELINE CROSSING, NEAR 28.754 EL 1 2

38 IN FIELD 29.754 AL 1 2

39 IN FIELD 30.754 AL 1 2

R-1

-


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SN LocationChainage

(km)

Test

Station Type(TS)

CPStatio

n SizeTest

station(ICTS)

(Nos.)

NormalSize

Teststation

(TS)

(Nos.)

Polcell

SizeTest

Station(PCTS)

(Nos.)

CTSUSize

TestStation(CTS)

(Nos.)

Perman

ent Ref.Cell

CuCuSo4 (Nos)

Mg

Anode(2.5KG)

(Nos.)

Mg

Anode(10KG)

(Nos.)

Bare ZnRibbon

Anodefor HTLine

crossing

(m.)

ZN

Anode(20KG)

(Nos.)

Polarisa


Polarisa

tionCoupon(Nos.)

ERprobe(Nos.)

40 IN FIELD AFTER METALLED ROAD 31.754 AL 1 2

41 IN FIELD 32.754 AL 1 2

42220 KVA HT LINE XING NEAR BRICK

KILN33.054 M 1 1 6 1 1

43 STATE HIGHWAY-25 33.876 CL 1 2

44 STATE HIGHWAY-25 33.901 C 1

45 220 KVA HT XING 34.248 M 1 4 1

46110 KVA HT CROSSING, NEAR

CHAMBORDA VILLAGE34.850 M 1 6 1

47 SV-1 34.913 GL 1 2 2 1

48 IN FIELD 35.913 AL 1 2

49 IN FIELD 36.913 AL 1 2

50 IN FIELD 37.913 AL 1 2

51IN FIELD NEAR BAMBREADY

VILLAGE38.913 AL 1 2

52 IN FIELD NEAR MANDPUR VILLAGE 39.913 AL 1 2

53IN FIELD BEFOR MANPUR VILLAGE

RD40.913 AL 1 2

54 NEAR DHAMUKAD VILLAGE 41.913 AL 1 2

55 DHAMUKAD VILLAGE NER MASJID 42.913 AL 1 2

56 DHAMUKAD VILLAGE 43.913 AL 1 2

57 IN FIELD NEAR CHACHARA VILLAGE 44.913 AL 1 2

58 IN FIELD NEAR BAGODA VILLAGE 45.913 AL 1 2

59IN FIELD NEAR BAYADIWAS 7

JHAMPADIWAS VILLAGE46.913 BL 1 1 2


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SN LocationChainage

(km)

TestStationType(TS)

CPStation SizeTest

station

(ICTS)(Nos.)

NormalSizeTest

station(TS)

(Nos.)

PolcellSizeTest

Station

(PCTS)(Nos.)

CTSUSizeTest

Station(CTS)

(Nos.)

Permanent Ref.

Cell

CuCuSo

4 (Nos)

MgAnode(2.5

KG)

(Nos.)

MgAnode

(10

KG)

(Nos.)


Line

crossing(m.)

ZNAnode

(20

KG)

(Nos.)


state)

(Nos.)

Polarisation

Coupon(Nos.)

ERprobe

(Nos.)

80 IN FIELD NEAR TIKRI VILLAGE 66.022 AL 1 2

81ASPHALTED RD XING, NEAR

SHERPUR VILLAGE67.008 AL 1 2

82 IN FIELD NEAR SUNERA VILLAGE 68.022 AL 1 2

83IN FIELD NEAR BORE WELL &

SUNERA VILLAGE69.022 AL 1 2

84 IN FIELD NEAR RAWAKA VILLAGE 70.022 AL 1 2

85ASPHALTED ROAD, NEAR RAWAKA


86 IN FIELD NEAR INDPWARA VILLAGE 72.128 AL 1 2

87CART TRACK NEAR INDPWARA


88ASPHALTED ROAD, NEAR SHERPURA


89NEAR ASPHATED RD XING

(JOTHPUR-SHERPUR)75.165 AL 1 2

90 IN FIELD DAYANA KAWAS VILLAGE 76.165 BL 1 1 2

91IN FIELD DAYANA KAWAS VILLAGE

AFETR METALICA RD XING77.165 AL 1 2

92 METEL ROAD, KHELI VILLAGE 78.087 AL 1 2

93 IN FIELD KHELI VILLAGE 79.165 AL 1 2

94 METEL ROAD, KHELI VILLAGE 80.129 AL 1 2

95 RUPARE RIVER 80.522 B 1 1 2

96 RUPARE RIVER 80.742 B 1 2


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SN

LocationChainage

(km)

Test

StationType(TS)

CPStatio

n SizeTest

station(ICTS)

(Nos.)

NormalSize

Teststation

(TS)

(Nos.)

Polcell

SizeTest

Station(PCTS)

(Nos.)

CTSUSize

TestStation(CTS)

(Nos.)

Perman

ent Ref.Cell

CuCuSo4 (Nos)

Mg

Anode(2.5KG)

(Nos.)

Mg

Anode(10KG)

(Nos.)

Bare ZnRibbon

Anodefor HTLine

crossing

(m.)

ZN

Anode(20KG)

(Nos.)

Polarisa


Polaris

ationCoupon(Nos.)

ERprobe(Nos.)

97 NEAR CHAMARBARA VILLAGE 81.342 AL 1 3

98IN FIELD BETWEEN BARDI-

CHAMARBARA VILLAGE82.378 AL 1 3

99 SH-45 82.564 C 1

100 SH-45 82.578 C 1

101AFTER SH-4X, NEAR BAROLI


102 IN FIELD NEAR DOMRAKI VILLAGE 84.578 AL 1 2

103BFOR METALIC ROAD XING NEAR

KHESTI VILLAGE85.578 AL 1 2

104ASPHALTED ROAD XING NEAR

KHESTI VILLAGE86.500 AL 1 2

105 IN FIELD NEAR KHESTI VILLAGE 87.500 AL 1 2

106 IN FIELD NEAR DHUTKA VILLAGE 88.500 AL 1 2

107 IN FIELD BEFORE REVER 89.400 AL 1 2

108 RUPARE RIVER 89.485 B 1 1 2

109 RUPARE RIVER 89.695 B 1 2

110 IN FIELD AFTER RIVER 90.395 AL 1 2

111 MUD ROAD XING NEAR BOARWELL 91.448 AL 1 2

112 IN FIELD 92.448 AL 1 2




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SN LocationChainage

(km)

TestStationType(TS)

CPStation SizeTest

station

(ICTS)(Nos.)

NormalSizeTest

station(TS)

(Nos.)

PolcellSizeTest

Station

(PCTS)(Nos.)

CTSUSizeTest

Station(CTS)

(Nos.)

Permanent Ref.

Cell

CuCuSo

4 (Nos)

MgAnode(2.5

KG)

(Nos.)

MgAnode

(10

KG)

(Nos.)


Line

crossing(m.)

ZNAnode

(20

KG)

(Nos.)


state)

(Nos.)

Polarisation

Coupon(Nos.)

ERprobe

(Nos.)

115 SV-3 93.532 GL 1 2 2 1

116IN FIELD KUTAKPUR TO ARSI


117ASPLATED ROAD XING ARSI TO

NAGAR MARKET95.643 AL 1 2

118METAL ROAD XING BHUKI TO ARSI


119 IN FIELD 97.700 AL 1 2

120 RAILWAY XING (NCR) 98.076 C 1

121 RAILWAY XING (NCR) 98.111 C 1

122 METAL ROAD XING 98.805 AL 1 2

123 SH-14 XING 99.961 CL 1 2

124 SH-14 XING 99.983 C 1

125IN FIELD AFTER SH-14, NEAR BURJA

VILLAGE

100.983 AL 1 2

126 IN FIELD NEAR GANGABAK VILLAGE 101.983 AL 1 2

127IN FIELD AFTER RD, NR GANGABAK


128 KENDALE TO MOBAI RD XIG 103.933 AL 1 2

129METAL ROAD XING DABHARA TO

WOBAI105.088 BL 1 1 2

130NEAR MORLI VILLAGE & BADESRA

ROAD106.000 AL 1 2

131NEAR MOBAIT TOMORALI

ASPHALTED RD107.000 AL 1 2


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SN LocationChainage

(km)

Test

StationType(TS)

CPStatio

n SizeTest

station(ICTS)

(Nos.)

NormalSize

Teststation

(TS)

(Nos.)

Polcell

SizeTest

Station(PCTS)

(Nos.)

CTSUSize

TestStation(CTS)

(Nos.)

Perman

ent Ref.Cell

CuCuSo4 (Nos)

Mg

Anode(2.5KG)

(Nos.)

Mg

Anode(10KG)

(Nos.)

Bare ZnRibbon

Anodefor HTLine

crossing

(m.)

ZN

Anode(20KG)

(Nos.)

Polarisa


Polaris

ationCoupon(Nos.)

ERprobe(Nos.)

132 NEAR BOAR WELL 108.000 AL 1 2

133 IN FIELD NEAR 11 KV LINE 109.000 AL 1 2

134 IN FIELD NEAR JANUTHER VILLAGE 110.000 AL 1 2

135 IN FIELD NEAR JANUTHER VILLAGE 111.000 AL 1 2

136 METALICA ROAD XING 111.958 AL 1 2

137 METALED ROAD XING 113.184 AL 1 2

138 IN FIELD SINSINI VILLAGE 114.184 AL 1 2

139 IN FIELD NEAR SONGAANB VILLAGE 115.184 AL 1 2

140 IN FIELD NEAR SONGAANB VILLAGE 116.184 AL 1 2

141IN FIELD NEAR BADANGASH


142 SV-4 118.254 GL 1 2 2 1

143 IN FIELD 119.190 AL 1 2

144 IN FIELD PALA VILLAGE 120.190 AL 1 2145 IN FIELD PALA VILLAGE 121.190 AL 1 2

146 NEAR CART TRACK PALA VILLAGE 122.190 AL 1 2


148 STATE HIGHWAY-14 122.787 C 1 2

149 ASPHALTED ROAD XING 123.190 AL 1 2

150 IN FIELD, NEAR SAINTHRI VILLAGE 124.190 AL 1 2

151AFTER MUD ROAD, NEAR KUMHER



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SN LocationChainage

(km)

TestStationType(TS)

CPStation SizeTest

station

(ICTS)(Nos.)

NormalSizeTest

station(TS)

(Nos.)

PolcellSizeTest

Station

(PCTS)(Nos.)

CTSUSizeTest

Station(CTS)

(Nos.)

Permanent Ref.

Cell

CuCuSo

4 (Nos)

MgAnode(2.5

KG)

(Nos.)

MgAnode

(10

KG)

(Nos.)


Line

crossing(m.)

ZNAnode

(20

KG)

(Nos.)


state)

(Nos.)

Polarisation

Coupon(Nos.)

ERprobe

(Nos.)

152 IN FIELD, NEAR SAINTHRI VILLAGE 126.100 AL 1 2

153 MAJOR DISTRICT ROAD-71 127.241 CL 1 2

154 MAJOR DISTRICT ROAD-71 127.257 C 1

155 IN FIELD BEFORE ASPHALTED ROAD 128.257 AL 1 2

156 IN FIELD 129.257 AL 1 2

157NAAR ALEYA VILLAGE & BOMBO

PLACE130.024 B 1 1

158 IN FIELD 130.257 AL 1 2

159 IN FIELD NEAR DERAA VILLAGE 131.257 AL 1 2

160 DERAA VILLAGE ROAD XING 132.159 AL 1 2

161 IN FIELD 133.159 AL 1 2

162 ASPHALTED ROAD 134.057 AL 1 2

163

220KVA LINE XING NEAR

ASPHALTED ROAD 134.851 ML 1 2 4 1164 ASPHLATED ROAD XING 135.894 AL 1 2



167 IN FIELD NEAR MEGHAYA VILLAGE 136.894 AL 1 2

168 FOREGIN PL XING (WRPL IOCL) 137.705 EL 1 2

169 CART TRACK 138.724 AL 1 2

170 IN FIELD 139.724 AL 1 2


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SN LocationChainage

(km)

TestStationType(TS)

CPStation SizeTest

station

(ICTS)(Nos.)

NormalSizeTest

station(TS)

(Nos.)

PolcellSizeTest

Station

(PCTS)(Nos.)

CTSUSizeTest

Station(CTS)

(Nos.)

Permanent Ref.

Cell

CuCuSo

4 (Nos)

MgAnode(2.5

KG)

(Nos.)

MgAnode

(10

KG)

(Nos.)


Line

crossing(m.)

ZNAnode

(20

KG)

(Nos.)


state)

(Nos.)

Polarisation

Coupon(Nos.)

ERprobe

(Nos.)



173 IOCL MBPL P/L XING 141.136 E 1

174 BPCL MBPL P/L XING 141.369 EL 1 2

175 BHARATPUR TERMINAL 141.800 GF 1 2

176 BHARATPUR TERMINAL 141.800 GF 1 2

177 WEASTERN CENTRAL RAILWAY 141.917 C 1

178 WEASTERN CENTRAL RAILWAY 141.972 CL 1 2

179 NEAR DAURAMKI VILLAGE 142.972 AL 1 2

180 NEAR DAURAMKI VILLAGE 143.972 AL 1 2

181 400KV HT LINE XING 145.049 ML 1 2 4 1

182 NEAR BILOTHI VILLAGE 146.049 AL 1 2

183 HPCL P/L XING 147.051 EL 1 2

184NEAR KARAUTI VILLAGE &

BILWATHI VILLAGE148.051 AL 1 2

185 IN FIELD 149.051 AL 1 2

186 NEAR SANTRAUK VILLAGE 150.051 AL 1 2

187 NEAR OLL VILLAGE 151.051 AL 1 2

188 NEAR HASANPUR VILLAGE 152.051 AL 1 2

189 NEAR HASANPUR VILLAGE 153.051 BL 1 1 2

190 NEAR IKDONIA VILLAGE 154.051 AL 1 2


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SN LocationChainage

(km)

Test

StationType(TS)

CPStatio

n SizeTest

station(ICTS)

(Nos.)

NormalSize

Teststation

(TS)

(Nos.)

Polcell

SizeTest

Station(PCTS)

(Nos.)

CTSUSize

TestStation(CTS)

(Nos.)

Perman

ent Ref.Cell

CuCuSo4 (Nos)

Mg

Anode(2.5KG)

(Nos.)

Mg

Anode(10KG)

(Nos.)

Bare ZnRibbon

Anodefor HTLine

crossing

(m.)

ZN

Anode(20KG)

(Nos.)

Polarisa


Polaris

ationCoupon(Nos.)

ERprobe(Nos.)

191 NEAR PILWA VILLAGE 155.051 AL 1 2

192 NEAR PILWA VILLAGE 156.051 AL 1 2

193 NEAR BORI VILLAGE 157.150 AL 1 2

194 400 KV HT LINE XING 158.270 ML 1 1 2 4 1 1

195 MATHUTA ACHNERA RAILWAY XING 158.440 C 1

196 MATHUTA ACHNERA RAILWAY XING 158.470 C 1

197 IN FIELD 159.261 AL 1 2

198 NEAR DHAMA SHASABAD VILLAGE 160.261 AL 1 2


200 NH-02 Farah To Mathura 161.957 C 1

201 NH-02 Farah To Mathura 161.987 C 1

202 CENTRAL RAILWAY CROSSING 162.348 CL 1 2

203 CENTRAL RAILWAY CROSSING 162.395 C 1204 RAILWAY XING-MATHURA TO FARAH 163.166 C 1

205 RAILWAY XING-MATHURA TO FARAH 163.213 CL 1 2

206 NEAR LADPUR VILLAGE 164.213 AL 1 2

207 MATHURA TERMINAL 164.378 GF 1 2

208 MATHURA TERMINAL 164.378 GF 1 2

209 RAILWAY XING-MATHURA TO FARAH 164.684 C 1

210 RAILWAY XING-MATHURA TO FARAH 164.731 C 1


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SN LocationChainage

(km)

Test

Station

Type(TS)

CPStatio

n SizeTest

station(ICTS)

(Nos.)

NormalSize

Teststation

(TS)

(Nos.)

Polcell

SizeTest

Station(PCTS)

(Nos.)

CTSUSize

TestStation(CTS)

(Nos.)

Perman

ent Ref.Cell

CuCuSo4 (Nos)

Mg

Anode(2.5KG)

(Nos.)

Mg

Anode(10KG)

(Nos.)

Bare ZnRibbon

Anodefor HTLine

crossing

(m.)

ZN

Anode(20KG)

(Nos.)

Polarisa


Polarisa

tionCoupon(Nos.)

ERprobe(Nos.)

211 NEAR LADPUR VILLAGE 165.213 AL 1 2

212RAILWAY XING-MATHURA TO

FARAH165.712 C 1

213RAILWAY XING-MATHURA TO

FARAH165.759 C 1

214 IOCL P/L CROSSING 166.018 E 1

215 440KVA HT LINE XING 166.385 ML 1 2 4 1

216 NEAR BHADURI VILLAGE 167.385 AL 1 2

217BEFORE ASPHALTED ROAD

NATHALA-LADPUR168.385 AL 1 2

218 KARNAWAL MINOR CANEL 169.426 AL 1 2


220 YAMUNA RIVER XING 170.486 B 1 1 2

221 YAMUNA RIVER XING 170.876 B 1 2

222 AFTER YAMUNA RIVER XING 171.400 AL 1 2

223 BEFORE NABIPUR MINOR CANAL 172.400 AL 1 2

224AFTER ASPHALTED RD XIN

HAIBPUR-NABIPPUR173.400 AL 1 2

225 NEAR PIMPARI VILLAGE 174.400 AL 1 2

226 NEAR PIMPARI VILLAGE 175.400 AL 1 2

227BEFORE YAMUNA EXPRESS

HIGHWAY176.400 BL 1 1 2

228220KV HT XING NEAR KHADERA

VILLAGE177.354 ML 1 2 4 1

229 AFTER CANEL, KHANGARI GRAM 178.354 AL 1 2


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SN LocationChainage

(km)

Test

Station

Type(TS)

CPStatio

n SizeTest

station(ICTS)

(Nos.)

NormalSize

Teststation

(TS)

(Nos.)

Polcell

SizeTest

Station(PCTS)

(Nos.)

CTSUSize

TestStation(CTS)

(Nos.)

Perman

ent Ref.Cell

CuCuSo4 (Nos)

Mg

Anode(2.5KG)

(Nos.)

Mg

Anode(10KG)

(Nos.)

Bare ZnRibbon

Anodefor HTLine

crossing

(m.)

ZN

Anode(20KG)

(Nos.)

Polarisa


Polarisa

tionCoupon(Nos.)

ERprobe(Nos.)

230ASPHALTED ROAD XING KILONI-

PATLONI VILLAGE179.354 AL 1 2

231 IN FIELD 180.354 AL 1 2

232 NEAR JATERA KILONI VILLAGE 181.354 AL 1 2


BAMARASPUR VILLAGE182.214 AL 1 2

234 NEAR PATLONI VILLAGE 183.214 AL 1 2

235 NEAR PATLONI VILLAGE 184.214 AL 1 2

236 AWERNI MINOR CANEL 185.271 AL 1 2

237 NEARM BAHARATIYA VILLAGE 186.271 AL 1 2


PAUCHAVARI VILLAGE187.382 AL 1 2

239 SV-5 188.058 G 1 2 1

240AFTER ROAD XING, PANCHWARI-

BISAWAR188.382 AL 1 2

241 METTALLED ROAD XING 189.233 AL 1 2242 NEAR BHILAHAR VILLAGE 190.233 AL 1 2

243ASPHALTD ROAD, BHILARAH-

GARHI191.331 AL 1 2

244 IN FIELD 192.331 AL 1 2

245 NEAR CHIRAWALI VILLAGE 193.331 AL 1 2

246NEAR MAI VILLAGE BEFORE

ASPHALTED RD194.331 AL 1 2

247 ASPHALTED RD XING 195.337 AL 1 2

248 KHANDAULI DISTRIBUTION 196.442 AL 1 2


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SN LocationChainage

(km)

Test

Station

Type(TS)

CPStatio

n SizeTest

station(ICTS)

(Nos.)

NormalSize

Teststation

(TS)

(Nos.)

Polcell

SizeTest

Station(PCTS)

(Nos.)

CTSUSize

TestStation(CTS)

(Nos.)

Perman

ent Ref.Cell

CuCuSo4 (Nos)

Mg

Anode(2.5KG)

(Nos.)

Mg

Anode(10KG)

(Nos.)

Bare ZnRibbon

Anodefor HTLine

crossing

(m.)

ZN

Anode(20KG)

(Nos.)

Polarisa


Polarisa

tionCoupon(Nos.)

ERprobe(Nos.)


250 NEAR NAGIRIA VILLAGE 198.417 AL 1 2

251 200 KV HT LINE XING 199.079 M 1 6 1


253 IN FIELD AFTER NH 200.600 AL 1 2


255 IN FIELD NEAR SEMRA VILLAGE 202.754 AL 1 2

256 IN FIELD 203.754 BL 1 1 2

257ASPHALTED ROAD NEAR MAHARA

GHARI VILLAGE204.839 AL 1 2

258IN FIELD NEAR RAGALA RAMBAL


259 IN FIELD NEAR SIRAIKA VILLAGE 206.839 AL 1 2

260ASPHALTED ROAD NEAR SIRAKA

VILLAGE

207.941 AL 1 2

261IN FIELD NEAR AKBAR BURJ


262 IN FIELD USMANPUR VILLAGE 210.000 AL 1 2

263IN FIELD NEAR HOGIGHARI


264 IN FIELD NEAR BENAI VLLAGE 212.000 AL 1 2

265IN FIELD AFTER ASPHALTED RD,

NEAR BENAI VLLAGE213.000 AL 1 2

266IN FIELD NEAR GHARI HARPAL



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SN LocationChainage

(km)

Test

StationType(TS)

CPStatio

n SizeTest

station(ICTS)

(Nos.)

NormalSize

Teststation

(TS)

(Nos.)

Polcell

SizeTest

Station(PCTS)

(Nos.)

CTSUSize

TestStation(CTS)

(Nos.)

Perman

ent Ref.Cell

CuCuSo4 (Nos)

Mg

Anode(2.5KG)

(Nos.)

Mg

Anode(10KG)

(Nos.)

Bare ZnRibbon

Anodefor HTLine

crossing

(m.)

ZN

Anode(20KG)

(Nos.)

Polarisa


Polaris

ationCoupon(Nos.)

ERprobe(Nos.)

267 IN FIELD NEAR MUKHBAR VILLAGE 215.000 AL 1 2

268 IN FIELD NEAR GOWAL VILLAGE 216.000 AL 1 2

269 NORTHAN RAILWAY MAINLINE XING 216.460 C 1

270 NORTHAN RAILWAY MAINLINE XING 216.534 C 1

271400KVA HT XING, NEAR GOWAL

VILLAGE217.007 ML 1 1 2 4 1 1

272ASPHALTED ROAD, NEAR

HEMRAJPUR VILLAGE218.039 AL 1 2

273 SV-6 218.859 G 1 2 1

274 IN FIELD, NEAR ETA VILLAGE 219.000 AL 1 2

275 IN FIELD NEAR SALEMPUR VILLAGE 220.000 AL 1 2

276IN FIELD DEVKHERA VILLAGE

BEFORE ASPHALTED RD221.000 AL 1 2

277 IN FIELD DEVKHERA VILLAGE 222.000 AL 1 2

278 IN FIELD DEVKHERA VILLAGE 223.000 AL 1 2

279 NEAR DYAGHARI VILLAGE 224.000 AL 1 2

280NEAR DYAGHARI VILLAGE MINOR

CANNEL225.016 AL 1 2



283 IN FIELD NEAR GHARIJORI VILLAGE 227.029 AL 1 2

284IN FIELD NEAR TARANAGAR


TOTAL 10 245 17 12 36 468 12 116 7 17 2 2


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16.0 CABLE LAYING DETAILSAll cables shall be laid in accordance with approved layout drawings. Half-meter cable slack

shall be provided near anodes, pipeline and test station in account for any settling.

All cable inside plant/station area shall be laid at a depth of 0.75 m and cables outside

station area shall be laid at a depth of minimum 1.5 m.

The buried cables laid outside the Station area shall be mark with Polyethylene warning mats

placed at 60 % of depth from the finished ground.

All cable shall be laid in sand under brick cover and back filled with normal soil as per cable

laying details drawing no. 06-10-1403-CLD.

17.0 CABLE TO PIPE CONNECTIONS

Connections of all CP cables to the charged pipelines shall be made by Pin Brazing and for

uncharged pipeline by Thermit weld.

Pipe coating shall be repaired after connection of cable to pipeline and the coating repair

material shall cover, exposed portion of the pipeline against ingress of water/moisture.


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18.0 INSTALLATION PROCEDURE

18.1 FOR TEST STATION

a) Introduction This procedure covers installation of the Test Station.

b) Materials and reference

Sr. No. Material/Tool Make Application/Purpose

1 Test Station along with Bend RaychemFor Erection of teststation

2 Pharma Standard For Casting

3PCC materials like cement, Stonechips & sand

Standard For Casting

4MS Sheet for Mixing of PCCmaterials

Standard For Mixing PCC material

5Tools such as Hammer, Spannersets, Pliers

Standard For Casting

6 Water cans Standard For Casting

Drawings:06-10-1403-TS, 06-10-1403-PCTS, 06-10-1403-CTSUTS

WORLEYPARSONS Reference MH2145-C000-EL-SPC-0025 RevA.

c) ProcedureThe location of the test stations shall be marked on row as per approved design with their

connection scheme and other related information on alignment sheet.

Foundation shall be cast at site location. The overall dimensions of foundations shall

be 600 mm x 600 mm x 800 mm. As shown in the standard drawing No. 06-10-1403-

TS. The foundation cast should be properly watered and cured.

Excavate 1m x 1 m x 1 m where the foundation is to cast.

Prepare PCC for height of 600+200 mm as per installation drawing &

WORLEYPARSONS standard drawing.

Placed TS bend (Bottom) above PCC.

Take MS shuttering and placed it in right position.

The PCC (M-15) mixture shall be constantly rammed for proper compaction.

Remove the shuttering after 24 hrs.

The foundation shall be cured by proper curing for minimum 7 days

Placed the TS boxes on the studs of the bend cast in concrete foundation and tighten

the bolts.

50 mm PCC shall be done on the top of foundation after installation of Test Station.


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The bolts shall then be distorted by hitting with a heavy hammer to make theinstallation vandal proof and also to ensure that the installation becomes theft proof.

Bottom Cable entry of Test station Foundation shall be closed/Sealed by using

Bitumen Compound to prevent water entry.

The test station shall be installed in front side of the test station facing the pipeline &

left hand side of the product flow in the pipeline.

The name plate of test station (Black background with white letters) shall in min.

carry following information:

Test Station Number, Chainage in Km

Test Station Connection Scheme Type

Distance from Pipeline in mtrs

Direction of Product flow

d) PRECAUTIONS:

Cables used shall be of sufficient length so as to reach termination point without any

joint. Provide sufficient slack for future maintenance purpose (Loop shall be 1mtr

before Test station).

All the connections should be checked for proper tightening and tagged.

Cable tags are to be provided at end before final termination

Cable should be neatly dressed inside the trench and to be terminated inside test

station.

In case of location, where sacrificial anode is to be installed, the same should be

taken parallel and the anode cable to be terminated at test station.

20% of Spare terminal shall be provided in Test Stations.

Test station used for sacrificial anodes shall have shunt for measurement of anodes

current and provision for resistance insertion to limit the anode current output.

Test Station shall be installed at left side of the pipeline towards flow.

Test report Record and document all the inspection results obtained in the below

inspection report format.

e) FORMATS

Inspection & Test Plan :06-10-1403-ITP-TS,

Installation report : 06-10-1403-IR-TS,

NOTE: In case of any conflict between the above procedures and contract specifications, thelater shall be governed.


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INSPECTION AND TEST PLAN FOR TEST STATION

PROJECT EPMC SERVICES FOR REWARI-KANPUR PIPELINE PROJECT

OWNER HINDUSTAN PETROLEUM CORPORATION LIMITED.

CONSULTANT WORLEYPARSONS SEA INDIA PVT. LTD.

CONTRACTOR KSS PETRON PRIVATE LIMITED

CP CONTRACTOR RAYCHEM RPG PVT. LTD.

REF. DRG. 06-10-1403-TS, 06-10-1403-PCTS, 06-10-1403-CTSUTS

REPORT NO. 06-10-1403-ITP-TS

WORLEYPARSONS STD. DWG

2-D-109-P CEL TS/ 2-D-110-TS

PERSONNELRESPONSIBLE

RAYCHEM RPG: SITE ENGINEER / SUPERVISOR

HPCL/WORLEYPARSONS: INSPECTOR

SR.NO.

ACTIVITYRAYCHEM

RPG

WORLEYP

ARSONS/KSS

HPCL

1 Check Location P RM RM

2 Concrete Foundation Size, PCC Mixture, & Curing P S RM

3 Installation Test Post Mounting Above Foundation P S RM

4 Termination Of Cables In The Test Station P S RM

5 Check Proper Sealing Of Cable Entry At Foundation P RM RM

6 Cable Height Above Ground Level P RM RM

LEGEND:

A : APPROVAL R : REVIEW OF RECORD

P : PERFORM RM : RANDOM CHECK

W : WITNESS ALL S : SUBMISSION

RAYCHEM RPG WORLEYPARSONS KSS HPCL

Name: Name: Name: Name:

Sign: Sign: Sign: Sign:

Date: Date: Date: Date:


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INSTALLATION REPORT FOR TEST STATION






REF. DRG. 06-10-1403-TS, 06-10-1403-PCTS, 06-10-1403-CTSUTS

WORLEYPARSON

S STD. DWG

2-D-109-P CEL TS/

2-D-110-TS

REF. SPECIFICATION

REPORT NO. 06-10-1403-IR-TS, Date

Test station Location (Chainage in Km)

Test Station Type

Distance from the pipeline (m)

Foundation

Test Station Mounting

Test station Doors / Locks /Gasket

Cable entry sealing

Cable Termination

NOTES:






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18.2 FOR SACRIFICIAL ANODES

a) Introduction:

This procedure covers installation of the prepackaged Sacrificial Anode assemblies.

b) Materials required

Sr. No. Material/Tool Make Application/Purpose

1Magnesium Anode with

cotton bag

Scientific Metal / YuxiChina/Xiang Metal,China

For Protection of Pipeline

2 Backfill Powder Standard For Installation

3 Water can Standard For Installation

4 Excavation tools Standard For excavation

Drawings:06-10-1403-MG2.5, 06-10-1403-MG10, 06-10-1403-ZN20 & 06-10-1403-

GAI

c) Responsibility:

It is the responsibility of the contractors engineer to ensure that the Anodes, cables and the

associated test station are correctly installed. The responsibility shall also cover the proper

supervision in excavation, backfilling and concreting work as required.

d) Detailed Procedure:

The Anodes shall be suitably located as enumerated in the Design Package to provide

the adequate levels of corrosion protection.

The installation procedure is as follows:

The Mg anode groundbed shall be located at 5 mtrs away from the pipeline

For Zinc anode groundbed shall be located at 2 mtrs away from the pipeline.

For Zinc anode installed for HT line crossing shall be located at 5 mtrs away from the

pipeline.

The anodes shall be installed in Horizontal configuration perpendicular to the pipeline.

The anodes shall be installed in suitable trench at min 1.5 Mtrs depth. The Spacing

between consecutive Anodes shall be 5 Mtrs as per the standard procedure.

The top of the anode shall be at the bottom of the pipeline

The prepacked anodes shall be lowered inside the trench and the balance spaced

around the anodes shall be filled with native soil. After installing the anode the soil

surrounding the anode shall be compacted. While lowering, the anode should not be

suspended or lowered by its lead wire. In dry locations water shall be poured directly

on the anode.


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Wherever Hard Rock / Hard Soil Observed Depth of Anode bed shall be installed at aminimum depth equal to bottom level of the pipeline.

The anode installation shall be checked by measuring the potential of the pipeline

against a standard Cu-Cu So4 reference cell before and after connection of the

anodes.

e) Backfill:

Anodes shall be packaged in a cotton bag and shall be surrounded by a low resistivity rapid

wetting chemical backfill of the following composition:

Gypsum : 75%

Bentonite : 20%Sodium Sulphate : 5%

f) Precautions:

Cables used shall be of sufficient length so as to reach termination point without any

joint. Provide sufficient slack for future maintenance purpose.

All the connections should be checked for proper tightening and tagged.

Cable tags are to be provided at end before final termination

Cable should be neatly dressed inside the trench and to be terminated inside test

station

e) FORMATS

Inspection & Test Plan :06-10-1403-ITP-ANODES,

Installation report :06-10-1403-IR-ANODES,

NOTE: In case of any conflict between the above procedures and contract specifications, thelater shall be governed.


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INSPECTION AND TEST PLAN FOR ANODES






REF. DRG. 06-10-1403-MG2.5, 06-10-1403-MG10, 06-10-1403-ZN20 & 06-10-1403-GAI

REPORT NO. 06-10-1403-ITP-ANODES


2-D-103-106-MG 2.5 KG/ 2-D-107-MG 20-10KG

PERSONNELRESPONSIBLE

RAYCHEM RPG: SITE ENGINEER / SUPERVISOR

HPCL/WORLEYPARSONS: INSPECTOR

SRNO

ACTIVITYRAYCHEM

RPG

WORLEYPARSONS/

KSS

HPCL

1 Check Location P RM RM

2 Check Depth P RM RM

3 Open Circuit Potential Measurement P S RM

4 Natural PSP Measurement P S RM

5 Anode Open circuit potential(Before Connecting With PL) P RM RM

6 PSP Measurement (After Connecting With Anode) P RM RM

7 Anode Condition (Backfill, Cable, Bag) P S RM

8 Spacing Between Anodes P RM RM

9Cable Connection & Connector Assembly With Anode Continuity Check

P S RM

10 Check cable termination & tagging P RM RM

LEGEND:

A : APPROVAL R : REVIEW OF RECORD

P : PERFORM RM : RANDOM CHECK

W : WITNESS ALL S : SUBMISSION





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INSTALLATION REPORT FOR ANODES







2-D-103-106-MG 2.5 KG/ 2-D-107-MG 20-10KG

REF. DRG. 06-10-1403-MG2.5, 06-10-1403-MG10,06-10-1403-ZN20 & 06-10-1403-GAI

REPORT NO. 06-10-1403-IR-ANODES, DATE

Anode Location (Chainage in Km)

Test Station Type

Test Station No.

Type of Sacrificial Anode Mg Anode/ Zinc Anode

Distance from Pipeline (Mtr)

No. Of AnodesSpacing Between Anodes

Current Output of Anode mA

Anode Condition & Anode Laying &Termination with Test station

OK/NOT OK

Anode Tail Cable Length (Mtr) A1 A2 A3

Anode Open circuit potential w.r.tCu / CuSO4Ref. Cell ( Before connecting to PL)

PSP w.r.to Cu/CuSO4Ref.Cell (Before Connecting Anode)

PSP w.r.to Cu/CuSO4Ref. Cell

(After Connecting Anode)

Instrument Details (Make/ model / Sr. No.) Calibration certificate. No. & validity





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18.3 FOR CABLE LAYINGa) Introduction:

This procedure covers the method of under ground cable laying with proper related activities

to be performed.

b) Materials

Sr. No Material/Tool Make Application/Purpose

1 Crimping Tool Standard For Crimping of cable

2 Sand, Bricks Standard For Installation

3 Excavation tools Standard For Excavation

Drawings:06-10-1403-CLD

c) Procedure:

All cables shall be laid in accordance with approved layout drawings. There shall be

no joints in a single run of cable.

Warning Mats should be placed at 60% of depth from finished ground level.

The cables shall be laid at a depth of 0.75 m inside Station / Plant area and at 1.5 m

outside station / Plant area with a layer of sand or soft soil as per spec A027-010-06-

45-SW-01, Rev.4

Second Class Bricks shall be placed over the sand spread as per the drawing and

backfill with normal soil.

Cable tags for buried cables/PVC ferrule are attached to each cable at termination

point for identification of individual cable.

Crimping the cable to proper sized crimping lugs does termination of cable. Before

Documents

Tcp Docs Rkpl