SABP-X-001_Cathodic Protection Design Package Preparation

Previous Issue: New Next Planned Update: TBD Page 1 of 16 Primary contact: Khan, Naeem Ahmad on 966-3-8747951 Copyright©Saudi Aramco 2007. All rights reserved. Best Practice SABP-X-001 12 September 2007 Cathodic Protection Design Package Preparation Document Responsibility: Cathodic Protection Standards Committee Saudi Aramco DeskTop Standards Table of Contents 1 Introduction.................................................... 2 1.1 Purpose.................................................. 2 1.2 Scope…………....................................... 2 1.3 Conflict with Mandatory Standards......... 2 1.4 Disclaimer……….................................... 2 2 References……............................................. 2 3 General.......................................................... 3 4 CP Design Package Formats........................ 3 Appendix A – Format for “Detailed Design Package for Buried Pipelines”................ 4 Document Responsibility: Cathodic Protection Standards Committee SABP-X-001 Issue Date: 12 September 2007 Next Planned Update: TBD Cathodic Protection Design Package Preparation Page 2 of 16 1 Introduction 1.1 Purpose The purpose of this Best Practice is to establish a format for a cathodic protection (CP) design package, for use by design engineers working on Saudi Aramco projects and Saudi Aramco engineers. It shall be used where applicable unless otherwise specified. 1.2 Scope The material in this Best Practices document provides a streamlined format for a design package for CP systems to be installed to protect Saudi Aramco facilities. It covers designs prepared for the structures covered by the Index X Saudi Aramco Engineering Standards and Standard Drawings, and the class 17 CP Materials Specifications. 1.3 Conflicts with Mandatory Standards In the event of a conflict between this Best Practice and other Mandatory Saudi Aramco Engineering Requirement, the Mandatory Saudi Aramco Engineering Requirement shall govern. 1.4 Disclaimer This material is being provided for the general guidance and benefit of the CP Designer. Use of the Best Practices in designing projects for Saudi Aramco, however, does not relieve the Designer from his responsibility to verify the accuracy of any information presented or from his contractual liability to provide safe and sound designs that conform to Mandatory Saudi Aramco Engineering Requirements (MSAER). Use of the information or material contained herein is no guarantee that the resulting product will satisfy the applicable requirements of any project. Saudi Aramco assumes no responsibility or liability whatsoever for any reliance on the information presented herein or for designs prepared by Designers in accordance with the Best Practices. Use of the Best Practices by Designers is intended solely for, and shall be strictly limited to, Saudi Aramco projects. Saudi Aramco® is a registered trademark of the Saudi Arabian Oil Company. Copyright, Saudi Aramco, 2007. 2 References This Best Practice requires the use of the latest edition of the applicable CP Mandatory Saudi Aramco Engineering Requirements. Document Responsibility: Cathodic Protection Standards Committee SABP-X-001 Issue Date: 12 September 2007 Next Planned Update: TBD Cathodic Protection Design Package Preparation Page 3 of 16 3 General This best practice is divided into sections, each of which contains an example of a typical design package for facilities such as land pipelines, well casings, plant piping, etc. As the CP designs for different types of facilities vary based on the specific requirements for each type of structure, it is important that the particular typical design package be used for a specific type of structure. 4 CP Design Package Formats Sample design package formats are attached to this Best Practice as Appendices. The first page of the design package shall be a cover sheet, giving the BI title and Pipeline name. The second page is a design package quality assurance check list that will be completed for each package and signed by the CP designer and the PMT engineer responsible for the project. Subsequent pages and sections form the body of the design package, and are self explanatory, as seen in the Appendix A. Pipeline names and other information shown in Appendix A is given as illustrative examples only. Instructions for each section are given in italicized font. Revision Summary 12 September 2007 New Saudi Aramco Best Practice. Document Responsibility: Cathodic Protection Standards Committee SABP-X-001 Issue Date: 12 September 2007 Next Planned Update: TBD Cathodic Protection Design Package Preparation Page 4 of 16 A p p e n d i x A Format for “Detailed Design Package for Buried Pipelines” (Cover sheet) BI-10-10101 56” QUAD-2 & 64” ADKHS-1 Pipeline CP Systems Document Responsibility: Cathodic Protection Standards Committee SABP-X-001 Issue Date: 12 September 2007 Next Planned Update: TBD Cathodic Protection Design Package Preparation Page 5 of 16 Detailed Design Package Quality Assurance Check List for Pipeline CP Systems BI-10-10101 Pipeline: 56”QUAD-2 Item Yes No N/A Design Package Contents 1 Review schedule complies with SAEP-303 2 Package contents comply with requirements of SAES-X-400 3 Appendices noted in design document are attached 4 Design calculations printouts are attached and legible 5 Design drawings are attached and legible Design Basis & Compliance with SAES-X-400 6 Design basis review meeting held prior to start of design by Contractor 7 Design based on existing capacity , or new CP systems 8 If using existing capacity, are details of all existing systems included and approval letter for use of spare capacity has been obtained from the Proponent 9 If installing new CP systems or upgrading existing systems, has location and sizing been reviewed and approved by Proponent 10 Remote monitoring equipment interface with existing Saudi Aramco Wireless Remote Monitoring System (design to be reviewed & approved by IT/CIED/WEG) Review of Design Details & Calculations 11 Correct CP design current requirement calculations 12 Correct sizing of new CP power sources, if being installed 13 Calculated surface anode bed resistance based on soil resistivity measurements taken at site (not normally required for deep anode bed) 14 Correct type and placement of anodes for SSD fences and thrust anchors 15 Maximum allowable anode bed resistance for new anode beds 16 Maximum allowable CP system resistance for new CP systems 17 Replacement anode beds (due to proximity to new pipeline) comply with distance and anodebed sizing requirements 18 Materials List (if included) complies with materials requirements listed in design document Please provide remarks below for any item from above that is applicable but not done: Item ___ Item ___ Designer Signature and Date PMT Engineer Signature and Date Document Responsibility: Cathodic Protection Standards Committee SABP-X-001 Issue Date: 12 September 2007 Next Planned Update: TBD Cathodic Protection Design Package Preparation Page 6 of 16 DESIGN INFORMATION 1.0 Pipeline Name 1. 56” QUAD-2 2. 64” AKDHS-1 2.0 Pipeline Routing & Length No. Pipeline Name Diameter (in) Length (KM) From To CP Current Requirement (A) 1 QUAD-2 56 78 QSTP ANDR WIPS-1 34.86 2 ADKHS-1 64 142 ANDR WIPS-1 KHRS CPF 72.52 The main characteristics of the Pipelines are as follows: No. Pipeline Name Material Wall Thickness External Corrosion Coating 1 QUAD-2 API 5L GRADE X-65 SAW PIPE 0.344/0.375/0.500/0.5 62/0.625 inch FBE as per 09-SAMSS-089 2 ADKHS-1 API 5L GRADE X-65 SAW PIPE 0.344/0.375/0.500/0.5 62/0.625 inch FBE as per 09-SAMSS-089 3.0 CP Design Basis No. Pipeline KM (Location) Rectifier Tag/ Identification No. Ground bed Type Ground bed Status No. of Ground beds Rated Output V/A 1 QUAD-2 0.5 (QSWTP) QSTP-1 Surface New 1 50/35 2 QUAD-2 89.2 (ADWIPS-1) ADWIPS-1 Surface New 1 50/50 3 ADKHS-1 142.0 (KHCPF) KHCPF-1 Deep New 1 50/50 Document Responsibility: Cathodic Protection Standards Committee SABP-X-001 Issue Date: 12 September 2007 Next Planned Update: TBD Cathodic Protection Design Package Preparation Page 7 of 16 4.0 Reference Documents 4.1 Project Drawings List all drawings here and attach copies of drawings as Appendix There should be at least one drawing showing the overall CP layout (map) of the new pipeline(s), with all existing and proposed CP stations clearly marked on it. 4.2 Applicable Saudi Aramco Standards List all Standards and Standard Drawings including latest applicable revision date and revision number. Document Number Date Rev Document Title SAES-X-400 2005 Cathodic Protection of Buried Pipelines SAES-X-600 2004 Cathodic Protection of Plant Facilities SAES-B-064 2005 Onshore and Near shore Pipeline Safety 17-SAMSS-004 2005 Conventional (Tap Adjustable) Rectifiers for C.P. 17-SAMSS-006 2005 Galvanic Anodes for Cathodic Protection 17-SAMSS-007 2004 Impressed Current Anodes for Cathodic Protection 17-SAMSS-008 2004 Junction Boxes for Cathodic Protection 17-SAMSS-017 2004 Impressed Current Cathodic Protection Cables 17-SAMSS-018 2004 Remote Monitoring System (RMS) for Cathodic Protection Applications AA-036069 1998 Cathodic Protection Galvanic Anodes Installation Details at Thrust Anchors AD-036132 2003 Cable Identification Termination Details AB-036273 2001 C.P. Surface Marker, Underground Electric Cables AB-036274 2003 C.P. Junction Box - 5 Terminal AB-036275 2003 C.P. Junction Box - 12 Terminal AA-036276 2003 C.P. Multi-purpose Junction Box AA-036277 2003 C.P. Bond Box - 5 Terminal AA-036346 1995 C.P. Surface Anode Bed Details, Horizontal & Vertical Anodes Sheet 1 & 2 AA-036349 2003 C.P. 3 Terminal Bond Box Details AA-036350 2003 C.P. 2 Terminal Bond Box Details AB-036351 2003 C.P. Marker Plate Details AA-036352 1998 Galvanic Anodes for Roads & Camel Pipeline Crossing AA-036378 2004 Rectifier Installation Details Sheet 1 & 2 AB-036381 2007 10 Thermite Welding of Cables to Pipelines and Structures AA-036385 1998 Deep Anode Bed AB-036540 2004 Mounting Support - Junction Box AA-036674 1999 C.P. Bonding Details for Onshore Pipelines & Flow lines Document Responsibility: Cathodic Protection Standards Committee SABP-X-001 Issue Date: 12 September 2007 Next Planned Update: TBD Cathodic Protection Design Package Preparation Page 8 of 16 Document Number Date Rev Document Title AA-036675 1999 C.P. Installation Details, Direct Buried Cable AE-036785 2003 Symbols for Cathodic Protection AB-036787 1995 Cathodic Protection Plant Road Crossing AB-036907 1999 KM Marker and CP Test Stations for Buried Pipelines Saudi Aramco Engineering Drawing Preparation SAES-A-2002 5.0 Design Basis & Calculations 5.1 Design Basis: List all design basis variables (protective criteria, current density, design life, anode consumption rates, etc.) 5.2 Design Calculations Attach calculation spreadsheet (as Appendix 1) 6.0 Field Survey Data All of the information below should be presented in tabular format, as shown in the examples below. 6.1 Existing CP Facilities CPS No. Km Chainage of P/L (approx) Ground Bed Type No. of Ground Beds Actual Output (V/A) Rating Output (V/A) Distance from P/L (m) (approx) QRT-8-1 1.700 Distributed 8 9/23 50/250 - QRT-3 3.500 Surface 1 6.4/28.5 50/50 000 JRTNGL-2 3.500 Surface 1 23/169 50/250 225 + GART-88 3.500 Surface 1 17/160 40/250 225 + JJHEX-1-8 17.545 Surface 1 4.5/15.9 18/40 50 + UBTG-203 18.345 Surface 1 16/220 100/250 225 + QJ-0A 48.150 Surface 1 0/0 50/250 125 UBTG-173A 48.800 Surface 1 7.1/130 50/250 120 UBTG-173 48.950 Surface 1 11.6/144 50/200 120 QA 3-7 Solar Surface 1 4/16 6/30 35 + DR 1-4 101.400 Surface 1 26.5/49 50/50 52 DHWL-1 103.800 Deep well 1 29/36 100/250 000 AB-1 104.850 Surface 1 92/21 100/150 25 Document Responsibility: Cathodic Protection Standards Committee SABP-X-001 Issue Date: 12 September 2007 Next Planned Update: TBD Cathodic Protection Design Package Preparation Page 9 of 16 6.2 Replacement of Existing Facilities/Anodebeds The following existing groundbeds are to be relocated because of their distance from pipeline is less than the required as per SAES-X-400. CPS No. Km Chainage of P/L (approx) Ground Bed Type No. of Ground Beds Actual Output (V/A) Rating Output (V/A) Distance from P/L (m) (approx) QRT-8-1 1.700 Distributed 8 9/23 50/250 - QRT-3 3.500 Surface 1 6.4/28.5 50/50 000 QJ-0A 48.150 Surface 1 0/0 50/250 125 UBTG-173A 48.800 Surface 1 7.1/130 50/250 120 UBTG-173 48.950 Surface 1 11.6/144 50/200 120 DR 1-4 101.400 Surface 1 26.5/49 50/50 52 DHWL-1 103.800 Deep well 1 29/36 100/250 000 AB-1 104.850 Surface 1 92/21 100/150 25 6.3 Other Pipeline Features 6.3.1 Road Crossings 6.3.2 Pipeline Crossings 6.3.3 Parallel Pipelines 6.3.4 Overhead Pipelines 6.3.5 Main Valves 6.3.6 Thrust Anchors 6.3.7 SSD Fences 6.3.8 Induced AC Mitigation 6.4 Soil Resistivity Attach as Appendix -2. Should include survey data and site sketch of the surveyed location showing where the resistivity readings were taken. 7.0 Remote Monitoring Systems Give details of the RMU type, application/system operating software and the communication system that will be used. Document Responsibility: Cathodic Protection Standards Committee SABP-X-001 Issue Date: 12 September 2007 Next Planned Update: TBD Cathodic Protection Design Package Preparation Page 10 of 16 8.0 Temporary CP System Give details of proposed temporary CP system. 9.0 Installation Guidelines 9.1 General In all cases, the cathodic protection system installation works would be carried out in a manner such that the requirements of the applicable Saudi Aramco Standard drawings and specifications, and the Project drawings and specifications are met. 9.2 Additional Bonding At various locations along the pipeline, additional bonding is required. This is to ensure that parallel and crossing buried pipelines are made continuous. This is required not only to avoid the risk of stray current interaction, but also to enable the cathodic protection applied to the pipeline, and any cathodic protection on existing parallel or crossing buried pipelines to remain as uniform as possible. Bonding is required at all pipeline crossing and at pipeline parallelisms (if the spacing is up to 50 m) at 10 km intervals. Bonding is also required where parallelisms begin and end. Bonding of parallel lines would be carried out at new and existing drain point locations, which can be achieved via the negative junction box already installed if spare cable terminal is available. The bonding facilities would be installed in accordance with Saudi Aramco drawing AA-036674. Where foreign pipelines (non-Saudi Aramco) are bonded to the system, resistors may be required across the bonds. This requirement would be determined on site. Bonding facilities should be installed across above grade insulating devices in accordance with the applicable Saudi Aramco specifications and drawings. All cable connections and materials associated with bonding requirements should conform to the applicable Saudi Aramco standards and drawings. 9.3 Additional Cathodic Protection by Galvanic Anodes Galvanic anode facilities will be installed along the pipeline at such as road crossings, SSD fence crossings, thrust anchor blocks and main line valve locations along the pipeline routes, per SAES-X-400. These should be Document Responsibility: Cathodic Protection Standards Committee SABP-X-001 Issue Date: 12 September 2007 Next Planned Update: TBD Cathodic Protection Design Package Preparation Page 11 of 16 installed to conform with the applicable specifications and to standard drawings AA-036352, AA-036069 as applicable. 9.4 Monitoring Facilities Monitoring facilities are already provided as a component of galvanic anode facilities, and all bonding facilities. Where these are installed, stand- alone testing stations would not be required in addition. Where bonding is achieved via junction boxes, additional monitoring stations will be provided. 9.5 Surface Anode Groundbeds The horizontal and vertical surface anode groundbeds shall be constructed as specified on the Project cathodic protection station Layout drawing and shall conform with the applicable requirements of SAES-X-400 and Saudi Aramco drawing AA-036346 sheets 1 and 2. The anodes shall be installed with or without coke breeze backfill at specified depth as shown in the project drawings. Prior to installation, the location for the groundbed shall be verified as meeting the design soil resistivity, and that it is sufficiently distant from buried structures to meet the requirements of SAES-X-400, paragraph 4.6.5. Any requirement for modification to the groundbed design to meet the design requirements shall be resolved prior to installation works taking place. Following verification of the design, or modified design, the groundbed shall be installed to include the indicated anode quantity. The anode quantity shall not be less than that provided in the design. In subkha area no watering facility is required. Anodes shall be installed without using the anode tail cables. The surface anode groundbed resistance shall be measured and verified prior to backfilling the groundbed with native soil. 9.6 Deep Anode Groundbeds The deep anode groundbeds shall be constructed as specified on the Project cathodic protection system layout drawings and shall conform to the applicable requirements of SAES-X-400 and Saudi Aramco Standard Drawing Nos. AA - AA-036385. Prior to installation, the location of the Groundbed shall be verified as meeting the design soil resistivity, and that it is sufficiently distant from buried structures to meet the requirements of SAES-X-400, paragraph 4.6.5. Document Responsibility: Cathodic Protection Standards Committee SABP-X-001 Issue Date: 12 September 2007 Next Planned Update: TBD Cathodic Protection Design Package Preparation Page 12 of 16 Any requirement for modification to the groundbed design to meet the design requirements shall be resolved prior to installation works taking place. Following verification of the design, or modified design, the groundbed shall be installed to include the indicated anode quantity. The anode quantity shall not be less than that provided in the design. The following procedures shall be followed during the construction: • The borehole shall initially be drilled at the location designated in the applicable project drawing or as per modification. The deep groundbed field location shall be verified and approved by CPOD/CSD prior to construction. Initially the boreholes shall be drilled to designed depth. As the borehole is developed, drill stem and test anode resistance would be measured. The measured drill stem and test anode resistance values shall be advised to CPOD/CSD to determine the most appropriate depth for the active length, top of coke breeze column, location, number and spacing of anodes. Drilling shall be continued, if required so, to a maximum required depth, or to a depth indicated by resistance measurements to provide a suitable active length. The designed/modified anode quantity shall be installed at a uniform separation to fill the active length or at the separation as per the requirement of test anode resistance. • Each anode shall be centrally located within the hole, and shall be fully surrounded with the calcined petroleum coke breeze backfill according to the standard specification and drawing requirements. 9.7 Distributed Anode Groundbeds The vertical distributed anode groundbeds shall be constructed as specified on the Project cathodic protection system layout drawings and shall conform with the applicable requirements of SAES-X-600 and Saudi Aramco Standard Drawing AA-036346 sheets 1 and 2. The anodes shall be installed as per Type ‘G’ of the above drawing. Each hole shall be 6 m deep, and a minimum of 250 mm in diameter. Anode shall be installed at a depth between 3 m to 6 m. Prior to installation, the location of each anode shall be verified as meeting the design soil resistivity, and that it is sufficiently distant from buried structures to meet the requirements of SAES-X-600, paragraph 4.6.6. Document Responsibility: Cathodic Protection Standards Committee SABP-X-001 Issue Date: 12 September 2007 Next Planned Update: TBD Cathodic Protection Design Package Preparation Page 13 of 16 Any requirement for modification to the groundbed design to meet the design requirements shall be resolved prior to installation works taking place. Following verification of the design, or modified design, the groundbed shall be installed to include the indicated anode quantity. The anode quantity shall not be less than that provided in the design. Each anode shall be centrally located within its hole, and shall be fully surrounded with the calcined petroleum coke breeze backfill according to the standard specification and drawing requirements. The backfill column shall be a minimum of 3 m in height. Anodes shall only be lowered into their augers using the rope, specifically designed for this purpose. 9.8 Induced AC Mitigation – Zinc Grounding Facilities When pipelines share their right of way with high-tension power lines, there may be a risk of hazardous induced voltages. The maximum acceptable induced voltage is 12 VAC under normal conditions (SAES-B- 064). Site measurements shall be carried out during and after installation works to ensure that hazardous voltages are not approached. Wherever AC voltages over buried pipeline sections exceeds 12 volts, zinc grounding facilities will be installed in accordance with a dedicated Project drawing. Document Responsibility: Cathodic Protection Standards Committee SABP-X-001 Issue Date: 12 September 2007 Next Planned Update: TBD Cathodic Protection Design Package Preparation Page 14 of 16 10.0 Bill of Materials Material List for New CP Station at KM 89.2 of QUAD-2 Pipeline ITEM DESCRIPTION UNIT QTY 1 Transformer Rectifier: Oil Cooled, silicon stack as per Aramco standard Input: AC 3 phase, 480 V, 60 Hz. Output: 50 VDC max. 50 Amp max. Ea. 1 2 Remote Monitoring Units c/w Junction Box and support Ea. 1 3 Three Phase 480V, 20 A AC circuit breaker c/w conduit & support Ea. 1 4 TA-4 Silicon Iron Chrome Anode - C/W 15 M 16mm² Kynar/HMWPE Cable Ea. 4 5 TA-4 Silicon Iron Chrome Anode - C/W 23 M 16mm² Kynar/HMWPE Cable Ea. 4 6 TA-4 Silicon Iron Chrome Anode - C/W 30 M 16mm² Kynar/HMWPE Cable Ea. 4 7 12 Terminal Junction Box - Aramco Dwg. AB-036275 c/w support & conduits Ea. 1 8 5 Terminal Junction Box - Aramco Dwg. AB-036274 c/w support & conduits Ea. 2 9 Single Test Point - Aramco Dwg. AB-036907 c/w support & conduit Ea. 7 10 Cable - 10mm² Single core THHN-THWN Insulated (Test Cables) M 100 11 Cable - 70mm² Single core HMWPE Insulated M 350 12 Cable - 16mm² Single core HMWPE Insulated M 225 13 Cable - 10mm² four core XLPE Insulated PVC sheathed for AC power supply M 100 14 Cable - 3 Pair x 16 AWG shielded wire M 100 15 Cable/anode markers: Redwood timber 100x100x1350 c/w identification marker and directional marker. Ea. 12 16 Warning tape-18” x 250m roll Ea. 2 17 Fencing around Transformer Rectifier, Concrete Pad for Transformer Rectifier, Circuit Breaker and other ancillary materials for installation of Transformer Rectifier as per Saudi Aramco Standard Drawing Nos. AA-036378 Sht. 1 & 2 Lot 1 Document Responsibility: Cathodic Protection Standards Committee SABP-X-001 Issue Date: 12 September 2007 Next Planned Update: TBD Cathodic Protection Design Package Preparation Page 15 of 16 Appendices Appendix 1 – Design Calculation Excel Sheet(s) Should be a simple 1 or 2 page Excel sheet with all the necessary variables and calculations shown in a concise manner. Appendix 2 – Soil Resistivity Field Data & Survey Location Sketch(es) Soil resistivity survey is only required for surface anode bed locations. No soil resistivity survey is required for deep anode beds if previous information/data suggests that surface anode bed will not work at this location. Survey location sketch(es) for surface anode bed(s), and a site sketch for proposed deep anode bed location(s) should be included in this Appendix. Appendix 3 – Cathodic Protection System Facilities List & Locations Item Chainage KM Facilities Location Align. Sheet XXXXX-1 PIPELINE 1 0.004 Two terminal bond station, Insulating flanges Insulating flange at Scraper Launcher at km 219.147 of SRG-1 001 2 0.030 Galvanic installation, test station Anchor Block at Scraper Launcher at km 219.147 of SRG-1 001 3 0.049 Galvanic installation, test station SSD fence crossing at Scraper Launcher at km 219.147 of SRG-1 001 4 1.000 KM marker & test station 001 5 2.000 KM marker & test station 001 6 3.000 KM marker & test station 001 7 4.000 KM marker & test station 002 8 4.485 KM marker & test station HT line crossing 002 9 4.432 KM marker & test station HT line crossing 002 10 5.000 KM marker & test station 002 11 6.000 KM marker & test station 002 12 6.221 2 terminal bond station Pipeline crossing 002 13 6.274 Galvanic installation, test station Asphalt Road (Dammam-Riyadh express high way) 002 14 6.375 Galvanic installation, test station Asphalt Road (Dammam-Riyadh express high way) 002 15 7.000 KM marker & test station 003 16 8.000 KM marker & test station 003 17 9.000 Galvanic installation, 2 terminal bond station, test station Main Line Valve 003 18 10.000 KM marker & test station 003 19 11.000 KM marker & test station 004 20 12.000 KM marker & test station 004 Document Responsibility: Cathodic Protection Standards Committee SABP-X-001 Issue Date: 12 September 2007 Next Planned Update: TBD Cathodic Protection Design Package Preparation Page 16 of 16 Appendix 4 - CP Construction Drawings a. Overall CP layout map b. CP detail drawings of each CP Station (new or replacement) c. CP layout drawings for other CP installations (e.g., negative connections at pipeline terminations, distributed anodes, etc.) d. CP detail drawings of major pipeline crossings, road crossings, and other significant installations other than CP stations