Cathodic Protection Report

ZAMZAMA CONDENSATE
PIPELINE CP SYSTEM
FOR
BHP BILLITON
BY
NURICON PETROSERVICES
(PTE.) LIMITED
4th Floor, Mubarak Manzil, 39 Garden Road, Karachi, Pakistan
Phn : 92-21-273 5051 ( 4 Lines )
Fax : 92-21-273 4162 Email : karachi@nuricon.com
Report for:
Client:
Doc. Title
Project:
BHP BILLITON
NPSL Reference:
PETROCHEM ENGG. & IND. CONSULTANTS
Contract No:
CP SYSTEM OF 6 DIA 28 Km PIPELINE
Zamzama Condensate Pipeline CP System Design for BHP BILLITON
PETROCHEM:07/002
PEC/NU-2006/002
Doc. No.:
Main Report
CATHODIC PROTECTION
SURVEY RESULTS & SYSTEM DESIGN
FOR:
BHP BILLITON
FACILITIES:
BHP GAS FIELDS, SIND, PAKISTAN
PROJECT:
ZAMZAMA CONDENSATE PIPELINE CP SYSTEM

DESIGN REVIEW
CLIENT:
PETROCHEM ENGG. & INDUSTRIAL

CONSULTANTS
CONTRACT DOC NO.
PEC/NU-2006/002
CONTRACT DATE:
APRIL 10, 2006
FIELD SURVEY BY:
MAQSOOD-UZ-ZAMAN, NPSL, KARACHI

ASIF SIDDIQUI, NPSL, KARACHI
TARIQ JAMEEL, NPSL, KARACHI
PERVAIZ ABBASI, NPSL, KARACHI
BURHAN, NPSL, KARACHI
REPORT BY:
MAQSOOD-UZ-ZAMAN, NURICON
PETROSERVICES, KARACHI, PAKISTAN
FINAL REPORT DATE:
DECEMBER 2006
NPSL REFERENCE NO.
PETROCHEM :07/002
NURICON PETROSERVICES (PTE.) LTD.

4th Floor, Mubarak Manzil, 39 Garden Road, Karachi
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E-mail : karachi@nuricon.com
Report for:
Client:
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Project:
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NPSL Reference:
Contract No:
PETROCHEM:07/002
PEC/NU-2006/002
Doc. No.:
Main Report
TABLE OF CONTENTS
LIST OF ABBREVIATIONS............................................................................................. 3
INTRODUCTION & BACKGROUND ............................................................................. 5
SCOPE OF WORK............................................................................................................. 6
OBJECTIVE ....................................................................................................................... 6
SOIL RESISTIVITY SURVEY ......................................................................................... 6
DESIGN CONCEPTS ........................................................................................................ 7
BILL OF QUANTITIES ................................................................................................... 10
APPENDIX:
SOIL RESISTIVITY
APPENDIX:
SOIL CONDUCTIVITY / RESISTIVITY
APPENDIX:
DESIGN CALCULATIONS
APPENDIX:
DRAWINGS
1. Schematic Arrangement of CP System Along

Pipeline ROW ..........................................................................Drawing No. CP-LAY-01
2. Typical Shallow Vertical Groundbed Details ....................Drawing No. SVGB-LAY-01
3. Typical Anode Junction Box (AJB) Details .........................Drawing No. TYP-AJB-01
4. Typical Burial Detail for Pair of Earthing Electrodes & their Cable Connections to
Insulating Flanges ............................................................................ Drawing No. EE-01
5. Typical Cable Connections to the Pipeline ........................Drawing No. TYP-CCON-01
6. Test Post Details ............................................................Drawing No. TP-01sheets 1 & 2
7. Typical Cable Trench Details ...........................................................Drawing No. CT-01
8. Current Measuring Test Station.................................................. Drawing No. CMTS-01

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LIST OF ABBREVIATIONS
3.14.... (a constant)
Backfill resistivity (ohm-m)
Soil resistivity (ohm-m)
A
AC or ac
AP
BHPB
BHPBP
Ampere
Alternating Current
Anodic protection.
BHP Billiton
BHP Billiton Pakistan
CP
CPP
CPS
da
Cathodic Protection
Casing potential profile
Cathodic Protection System.
Casing to Soil Potential (with respect to Saturated Cu-CuSO 4
Reference Electrode)
Diameter of anode.
db
DC or dc
Dia
ft, in,
ICCP
Diameter of anode column/canister inclusive of backfil.

Direct Current
Diameter
Foot, inch
Impressed Current Cathodic Protection
ICCPS
KM or km
La
Lb
m
Impressed Current Cathodic Protection System

Kilometer
Length of anode.
Length of anode column/canister including backfil
Meter
mA
MV or mv
cm
mm
Na
Miliampere
Milivolt
Centimeter
Millimeter
No of anodes
NPSL
PE
Petrochem
Nuricon Petroservices (Pte.) Limited

Polyethylene
Petrochem Engineering (Pvt.) Limited
Polarization Potential (with respect to Saturated Cu-CuSO 4
CSP
Potential

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PVC
Rc
Rg
Pipe to Soil Potential (with respect to Saturated Cu-CuSO 4

Polyvinyl Chloride Compound
Cable resistance
Resistance of single anode
Rgt
ROW
Rs
Rt
S
Resistance of multiple anodes to remote earth

Right of way
Resistance of structure to remote earth
Total circuit resistance
Spacing between the anode columns (wherever applicable)
Sa
Sav
SCP
SCPS
sqm
Spacing between bottom and top of consecutive anodes

Center to center spacing between vertical anode/backfill columns
Sacrificial Cathodic Protection
Sacrificial Anode Cathodic Protection System
Square meter
SSP
Structure to Soil Potential (with respect to Saturated Cu-CuSO4

TEG
Thermo-electric generator
PSP

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DESIGN REPORT FOR 6 X 28 KM CONDENSATE

PIPELINE FROM BHPS ZAMZAMA GAS FIELD
TO PARCOS BUBAK STATION
This document outlines the Cathodic Protection System Design and Engineering for the
6x 28 km 3LPE coated Condensate Pipeline from BHP Billitons Zamzama Gas Field to
Parco Booster Pumping Station at Bhubak. Petrochem Engineering is the consultant for
design and engineering of the pipeline for BHP and they acquired the services of Nuricon
Petroservices (Pte.) Limited (NPSL) to Design and Engineer the CP system for this pipeline
and to carry out pre design surveys for this purpose.
Zamzama is located near Dadu, Sind and is about 330 km northwest of Karachi, Pakistan.
The pipeline would carry gas condensate from condensate tanks at Zamzama to condensate
storage tanks at Bhubak for onward sale and distribution.
INTRODUCTION & BACKGROUND
Before carrying out the actual Soil Resistivity Survey by NPSL, the BHPB provided some
soil resistivity data of the surrounding areas and sought NPSL advice whether a sacrificial
anode system based on zinc ribbon can be designed for the pipeline or not. In response NPSL
recommended an Impressed Current CP system as it was most suitable for that environment
though they did not rule out the possibility of a Sacrificial CP system based on the zinc anode
ribbon. BHPB in response advised to design a zinc ribbon based system and on NPSLs
recommendation they agreed on the discrete anode system as in NPSLs opinion ribbon
system did not prove successful in that area for other BHPB lines.
After agreement for the type of CP system based on the BHPB provided data, NPSL team
mobilized to the site and collected soil resistivity measurement data. The data showed that
the soil resistivity in the upper layer is generally high averaging 52.87 ohm- m with few
locations suitable for making the groundbeds. Preliminary design and the groundbed
calculations including proposed groundbed locations were reported to BHPB that were in
principal, agreed by them with few changes.
Subsequently NPSL team was again mobilized to site to mark the precise groundbed
locations on the drawings and also to confirm the resistivities. It was found that the
resistivities of the upper layer have been changed that necessitated to take the resistivities of
the deeper soil layers which were taken by using Geonics Model EM34 Soil Conductivity
Meter. It is noted that the upper soil stratum is susceptible to the seasonal changes due to
varying degrees of rain fall and cultivation cycles. Fertilizer, irrigation, seasonal water ponds
are responsible for changes in the resistivities.

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As a result of the resistivity changes the finally proposed groundbeds are kept deeper. Since
higher resistivity reduces the groundbed current output therefore higher number of anodes is
required but higher number of anodes would increase the installation cost therefore two
anodes per anode column are proposed to limit the installation cost by reducing the boreholes
to half.
Total four groundbeds are proposed, two at the ends and two in between. Test Posts are
designed to reduce the risk of vandalism which is a common problem in that area. NPSL
proposed the average distance between test stations as 1.0 km to facilitate coating and Close
Interval Potential Surveys (CIPS) in future however BHPB opted for a distance of 2.5 km
between the subsequent test stations. To our understanding BHPB would install some Radio
Transmitter test stations on experimental basis along the pipeline. Grounding or Earthing
zinc electrodes are also proposed along with the surge diverters, to be installed across the
insulating flanges.
SCOPE OF WORK
The detailed design report shall comprise the minimum requirement for the design, material,
installation and commissioning for the external cathodic protection system to be installed for
6x28 km Condensate pipeline from ZamZama to Parcos Bubak Station.
The Cathodic Protection System shall be designed as a stand alone system capable for
operating independently of any other existing cathodic protection systems and shall be a
sacrificial anode system.
OBJECTIVE
The cathodic protection system objective is to prevent pipeline from corrosion by making it
sufficiently cathodic by supplying current to the pipeline from anodes so that the polarization
potential along the whole pipeline is between -850 to -1200 mv with respect to the Cu-CuSO4
half cell.
SOIL RESISTIVITY SURVEY
Soil Resistivity survey was done by Wenner 4 Pin Method at 1.25 m and 2.5 m pin spacing at
every 500 m along the entire pipeline right of way (ROW). The average resistivity is
estimated to be 52.87 ohm- m and the data is appended at Appendix-Soil Resistivity. There
were very few low resistivity locations where groundbed could be suitably placed.
After acquiring this resistivity data and the approval of preliminary calculations, 4 Pin
method was repeated at the precise groundbed locations however it was revealed that the
resistivities have been changed and resistivities of deeper soil layers would need to be
surveyed that may be less susceptible to the environmental changes. For this purpose Geonics
Model EM34 was used to measure the soil conductivities that were converted to resistivities.
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This method induces electromagnetic current into the soil and measures the induced current,
knowing that the induction is proportional to the conductivities. This data is given at
Appendix-Soil Conductivity/Resistivity.
The analyses of all the acquired data lead to the conclusion that deeper groundbeds would be
required to get the sufficient amount of protection current. It also necessitated the use of
additional anodes than the required by anode weight calculations.
DESIGN CONCEPTS
The system design considerations are:
Pipeline Information
Diameter:
Length:
Wall Thickness:
Coating Type:
Coating Conductance:
Isolation:
The pipeline has a nominal diameter of 6 inches and outer

diameter of 6.625 (0.168 meter).
The length of pipeline is about 28 km.
The minimum wall thickness of the pipeline is 6 mm.
3 Layer Polyethylene
Has an average coating conductance of 1.89x10-4 S/m2 at the
end of its design life of 25 years.
Electrically isolated from metallic structures along the ROW as
well as at both the ends.
CP System Information
Type:
Anodes Material:
Anode Size:
Anode Weight:
Package:
Sacrificial Groundbeds
Zinc
2x2x60 long (50x50x1500 mm)
60 lbs (27.27 kg)
The anodes are to be packaged in 50% hydrated gypsum
(CaSO4) and 50% bentonite clay mixture. Package dimensions
are given in the relevant drawing.
No. of Groundbeds:
Four: A, B, C and D
Anode Columns:
Each groundbed has 6 anode columns and 2 anodes per
column. This is to reduce the installation complexities and
costs since the holes are deeper than the normal for sacrificial
anodes.
Location of Groundbeds: See following table.

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Serial
Groundbed
Identification
1.
0+556
Zamzama Plant, near grave yard. Anodes and

junction box to be installed within the plant
fencing. Depth of inactive column: 26 meters.
2.
8+375
This location is near Goath (village) Gullan

Punhwar. Depth of inactive column:
26 meters.
3.
19+318
This location is near the back of grid station.

Depth of inactive column: 15 meters.
4.
27+720
Preferably within the Parco boundary wall

where the pipeline enters the pumping station
boundary. BHPB to decide with PARCO.
Depth of inactive column: 10 meters.
Test Stations:
Serial
Chainage
Location/Remarks
See the following table. Test Stations with only two wires for only
potential monitoring purpose are identified as TS whereas test
stations having four or more wires, intended for potential monitoring
as well as Line Current measuring, are identified as TS/CMP. Test
stations are designed to reduce the risk of vandalism.
Type
Chainage
Identification
1.
Potential Monitoring 0+000

& Current Measuring
2.
Potential Monitoring
2+500
TS
3.
5+000
TS/CMP
4.
7+500
TS
5.
10+000
TS
6.
12+500
TS/CMP
7.
15+000
TS
TS/CMP Across insulating flange; can

also measure current

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Chainage
Identification
Serial
Type
8.
17+500
TS
9.
20+000
TS
10.
20+950
TS
11.
21+100
TS
12.
23+500
TS/CMP
13.
26+000
TS
14.
27+700
TS
15.
Potential Monitoring N/A

& Current Measuring
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Remarks
TS/CMP Across insulating flange; can

also measure current
Cased Crossings:
There are no cased crossings along the pipeline ROW.
Earthing Electrodes:
Earthing electrodes are used at insulating flanges to shunt the

electric surges as well as to bypass the lightening surge. This
may also provide a little protection on the non-protected side of
the insulating flange. Four electrodes, 1.4x1.4x60 each, are to
be packaged in 50-50 bentonite/gypsum mixture. Electrodes are
to be paired diagonally and joined diagonally.
Surge Diverters:
To diffuse the electric and lightening surges across the insulating

flanges the surge diverters are proposed to supplement the action
of earthing electrodes.
Cables:
All the proposed cables would have PVC insulation & sheath
having stranded high purity annealed copper conductor and a
voltage grade of 600/1000. Anode cable s would have 16 mm2
conductors, whereas negative cable would have a 50 mm2
conductor. All cables for test stations and earthing electrodes
would have conductor size of 6 mm2 .
Each anode of a particular groundbed is proposed to have equal
anode-cable lengths to keep the cable resistance and hence the
anode output, uniform.

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BILL OF QUANTITIES
Serial
Description
Unit
Quantity
1a.
Zinc anodes of 50x50x1500 mm having net metal weight of

27.27 kg (60 lb) with carbon steel insert and zinc
conforming to American Military standard for pure zinc.
Anode cable, 25 sqmm x 41 meter long, single core stranded
copper with PVC insulation and PVC sheath of 600/1000
volt grade should be mechanically tightened to the steel
insert and should also be brazed to it. This joint should be
potted with the epoxy and top of the anode around this joint
to be coated with epoxy to avoid preferential corrosion.
Also, the joint should be strong enough to hold the weight of
the anode and packaged backfill.
Each
24
1b.

Anode cable, 16 sqmm x 31 meter, single core stranded
copper with PVC insulation and PVC sheath of 600/1000
Each
12
1c.

Anode cable, 16 sqmm x 26 meter, single core stranded
copper with PVC insulatio n and PVC sheath of 600/1000
Each
12
2.
4-Electrode Zinc Earthing Cell (each electrode of size

1.4x1.4x60) packaged in 50-50 bentonite/gypsum
mixture. Electrodes to be diagonally paired and connected
and each pair to have 5 meter cable to connect to the
insulating flanges.
Package

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Unit
Quantity
3.
Cadweld Charges, 15 gram
Each
40
4.
Cadweld Mould
Each
5.
Test Stations (see drawing No. TYP-TP-01).
Each
10
6.
Test Station/Current Measuring Post having 6 each M6

Terminals. Terminals to be of stainless steel, copper or
brass, complete with terminal box, fixtures and accessories.
Each
7.
Anode bond box, to be able to accommodate 13 shunts, 12

anode cables, one No. Negative Cable and one Test Cable.
Junction box to be complete with all fixtures and accessories
including bus bar.
Each
8.
Royston Handy Caps with primer or Raychem's Perp Repair

system for coating repair, and covering of cadweld.
Each
40
9.
Stubs, 50x50x6 mm each (to be cut from ? 6 pipe piece), to

be welded on the pipeline for cadwelding/cable connections
to the pipe. Welding to be done by the pipeline contractor.
Each
40
10.
Negative cable, 50 mm2 Cu/PVC/PVC, single core stranded,

600/1000 volt grade.
Meter
40
11.
Test cable, 6 mm2 Cu/PVC/PVC, single core stranded,

600/1000 volt grade. Black Color.
Meter
550
12.

600/1000 volt grade. Red Color.
Meter
500
13.

600/1000 volt grade. Blue Color.
Meter
40
14.
Miscellaneous items e.g., cable lugs, nut-bolts, negative &

test cables, coating repair material, sand, cement, crush for
junction boxes grouting, etc.
Lot
15.
SERVICES - Installation, Test and Commissioning
Lump
Sum
16.
Surge Diverters ( see attached data sheet )
Each

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POWER SUPPLY SYSTEMS

Isolating spark gaps
Dimension drawing EXFS
EXFS L / EXFS KU
EXFS L200
Installation of EXFS
For indirect connection/earthing of functionally

separate parts of installations when being
affected by lightning
EXFS L ...: Ex Isolating spark gap for aboveground installation
Unit for lightning equipotential bonding

according to IEC 62305 for hazardous areas (Zone
2)
Corresponds to "ATEX Directive" 94/9/EC
Corrosion-resistant enclosure of zinc die casting
with plastic cover and flexible conductor
connection
For bridging insulating pieces, insulating flanges,
etc. in cathodic protected pipe sections
EXFS L200
Lightning impulse current (10/350 s) current (10/350)
Classfication of lightning current carrying capability acc. to prEN
50164-3
Nominal discharge current (8/20 s) current (8/20)
50 kA
N
100 kA
100% lightning impulse sparkover voltage Lightning impulse

sparkover voltage
<= 2.5 kV
Power frequency sparkover voltage (50 Hz) sparkover voltage (50

Hz)
<= 1.2 kV
Type of protection according to EN 50014, EN 50021 acc. to EN

50014, 50021
Operating temperature range
Degree of protection
Approvals, Certifications
Length of enclosure length
Diameter of enclosure
Enclosure material material
Connecting cable cable
Cable length
Suitable for flange size size
[TU]
II 3 G EEx nC II T4
-20C...+80C
IP 54
ZELM 03 ATEX 3192X
90 mm
63 mm
zinc die casting, plastic
H01N2-D 25 mm2 with cable lug and M10 screw/nut
200 mm
120-230 mm
Ordering information
Type
Part No.
Packing unit
EXFS L200
923 061
1 pcs.
Change in form and technology, with masses, weights and materials we reserve ourselves in the sense of the progress of the technology. The illustrations are noncommittal.
Seite 1 Copyright 2005 DEHN + SHNE GmbH + Co. KG Hans-Dehn-Str. 1 Postfach 1640 D-92306 Neumarkt Tel. 09181 906-0 www.dehn.de info@dehn.de
APPENDIX: SOIL RESISTIVITY
BHP BILLITON PAKISTAN
Appendix-Soil Resistivity
CP of Dia. 6"x28 km
Zamzama-Bhubak Condensate Pipeline
SOIL RESISTIVITY OBSERVATIONS DATA SHEET

Cathodic Protection System for 6''dia 28km Condensate Pipeline
Resistivites taken from BHP Zamzama plant to Parco Bubak station
S. No Pin Spacing Ohms
Pin Spacing Ohms
Remarks
1
1.25
4.8
37.70
2.5
3.3
51.84
Farms (June 5, 2006)
2
1.25
1.4
11.00
2.5
0.4
6.28
- do 3
1.25
6.16
48.38
2.5
4.71 73.98
- do 4
1.25
3.67
28.82
2.5
0.67 10.52
- do 5
1.25
2.4
18.85
2.5
2
31.42
- do 6
1.25
1.8
14.14
2.5
1.5
23.56
- do 7
1.25
7.1
55.76
2.5
5.3
83.25
- do 8
1.25
0.4
3.14
2.5
0.2
3.14 straws & bushes
9
1.25
3.8
29.85
2.5
0.4
6.28 smooth surface
10
1.25
2.2
17.28
2.5
0.9
14.14
Farms
11
1.25
9.4
73.83
2.5
8.9 139.80
- do 12
1.25
5.1
40.06
2.5
4.9
76.97
- do 13
1.25
13.1 102.89
2.5
12.7 199.49
- do 14
1.25
3.3
25.92
2.5
1.4
21.99 Wadara Swalah Goth
15
1.25
0.3
2.36
2.5
0.2
3.14 Farm - Proposed Groundbed Location
16
1.25
155 1217.37
2.5
140 2199.11 dry land greaveyard June 6,2006
17
1.25
5.1
40.06
2.5
1.6
25.13
Farms
18
1.25
15
117.81
2.5
12
188.50
- do 19
1.25
7
54.98
2.5
5
78.54
- do 20
1.25
10
78.54
2.5
7
109.96
- do 21
1.25
8
62.83
2.5
6
94.25
- do 22
1.25
0.3
2.36
2.5
0.2
3.14
- do 23
1.25
4.4
34.56
2.5
1.6
25.13
- do 24
1.25
4.1
32.20
2.5
3.1
48.69
- do 25
1.25
7
54.98
2.5
2
31.42
- do 26
1.25
0.76
5.97
2.5
0.67 10.52
- do 27
1.25
0.68
5.34
2.5
0.42
6.60
- do 28
1.25
2.7
21.21
2.5
2.4
37.70 wet soil
29
1.25
3.6
28.27
2.5
1.6
25.13 farms
30
1.25
2.6
20.42
2.5
1.2
18.85 turning point road crossing
31
1.25
1.6
12.57
2.5
1.1
17.28 farms
32
1.25
1.2
9.42
2.5
0.58
9.11 saikh colony/ road crossing
33
1.25
0.84
6.60
2.5
0.77 12.10
Farms
34
1.25
6.8
53.41
2.5
3.5
54.98
- do 35
1.25
2.4
18.85
2.5
1.8
28.27
- do 36
1.25
3
23.56
2.5
1
15.71
- do 37
1.25
4
31.42
2.5
2
31.42 water chanel SNG pipeline crossing
38
1.25
2
15.71
2.5
0.9
14.14
Farms
39
1.25
5
39.27
2.5
3
47.12
- do 40
1.25
4
31.42
2.5
1
15.71
- do 41
1.25
4
31.42
2.5
2
31.42
- do 42
1.25
0.6
4.71
2.5
0.4
6.28
- do -

4th Floor Mubarak Manzil 39 Garden Road, Karachi
Tel. (+92-21) 273 5051-4 Lines, Fax: 273 4162
Page 1 of 2
BHP BILLITON PAKISTAN
Appendix-Soil Resistivity

Pin Spacing Ohms
43
1.25
0.9
7.07
2.5
0.3
44
1.25
8
62.83
2.5
5.2
45
1.25
3.8
29.85
2.5
0.2
46
1.25
5.1
40.06
2.5
1.8
47
1.25
5.1
40.06
2.5
3.1
48
1.25
6.1
47.91
2.5
3
49
1.25
1.4
11.00
2.5
0.7
50
1.25
4
31.42
2.5
2
51
1.25
5
39.27
2.5
0.3
52
1.25
0.77
6.05
2.5
0.72
53
1.25
0.65
5.11
2.5
0.29
54
1.25
0.6
4.71
2.5
0.4
55
1.25
3.1
24.35
2.5
2.4
56
1.25
2.8
21.99
2.5
1.7
57
1.25
2.5
19.63
2.5
1.8
58
1.25
4
31.42
2.5
3
59
1.25
7
54.98
2.5
3
60
1.25
6
47.12
2.5
4
61
3
3.1
58.43
4
2.6
62
1.25
10
78.54
2.5
7.9
63
3
5.5
103.67
4
4.6
Average 52.8673
Average
6-Nov-06
Data acquired on 6 Nov 2006
1
2.0
3
37.70
2
2.0
1.4
17.59
3
4
5
6
7
2.0
2.0
2.0
2.0
2.0
0.8
3.2
0.7
0.4
1.2
10.05
40.21
8.80
5.03
15.08
4.71
81.68
3.14
28.27
48.69
47.12
11.00
31.42
4.71
11.31
4.56
6.28
37.70
26.70
28.27
47.12
47.12
62.83
65.35
124.09
115.61
75.71
CP of Dia. 6"x28 km
Remarks
Farm - Proposed Groundbed Location
Farms
- do - do - do - do - do - do - do - do cotton factory
Farms
- do - do Parco bubak outside boundary wall
inside Parco Bubak
inside Parco Bubak
outside Zamzama plant near fencing
June 7,2006
outside Zamzama plant near fencing
Pin Spacing Ohms
Remarks
4.0
4.0
3.5
1
87.96
25.13
4.0
4.0
4.0
4.0
4.0
0.5
1.6
1
0.5
0.9
12.57
40.21
25.13
12.57
22.62
At chainage 7+000
8.375 km near Graveyard (Gullan
Punhwar Goth)
"
"
Near grid station's back
"
"
10-Nov-06
Serial
1.
2.
3.
4.
5.
6.
Pin Spacing (m)

2
4
6
Resistivities (ohm-m)
24.20 30.40
36.50
31.90 82.20 140.60
2.61 3.69
29.30 27.30
29.70
20.40 22.00
27.00
25.90 29.30
29.20
Remarks
Zamzama plant grave yard
Chainage 7+000
Corner of Jiven Khan Jamali goath road
100 meter inside from corner
Near grid station
Outside Parco bhubak terminal

4th Floor Mubarak Manzil 39 Garden Road, Karachi
Tel. (+92-21) 273 5051-4 Lines, Fax: 273 4162
Page 2 of 2
APPENDIX:
SOIL CONDUCTIVITY /
RESISTIVITY
BHP BILLITON, PAKISTAN
CP of Dia. 6"x28 km
Appendix - Soil Conductivity/Resistivity
APPARENT SOIL CONDUCTIVITY / RESISTIVITY ACQUIRED BY GEONICS MODEL EM34

Apparent Soil Conductivity (mS/m)
Coil Spacing
10 m
20 m
40 m
Location
Dipole=>
HD
VD
HD
VD
HD
VD
Depth=>
7.5 m 15 m 15 m 30 m 30 m 60 m
Behind Grid Station
E/W
60.00 55.00 89.00 100.00 90.00 167.00
N/S
70.00 70.00 82.00 107.00 68.00 162.00
Averages
65.00 62.50 85.50 103.50 79.00 164.50
7+00 km from Zamzama
E/W
26.00 16.00 24.00 40.00 48.00 74.00
N/S
17.00 32.00 26.00 42.00 52.00 71.00
* Averages
BHP Plant, outside fencing near graveyard
38.00 41.00 47.00 52.00 72.00 104.00
Averages
Outside Bhubak west wall
N/S
88.00 118.00 111.00 264.00
E/W
70.00 59.00 75.00 75.00
Averages
Apparent Soil Resistivity (ohm-m)

Coil Spacing
10 m
20 m
40 m
HD
VD
HD
VD
HD
VD
7.5 m 15 m 15 m 30 m 30 m 60 m
Layer Resistivities (ohm-m)

0 - 10 m 10 - 20 m 20 - 40 m
16.67 18.18 11.24 10.00 11.11

14.29 14.29 12.20 9.35 14.71
15.85
10.69
5.99
6.17
9.49
15.85
8.07
8.54
38.46 62.50 41.67 25.00 20.83

58.82 31.25 38.46 23.81 19.23
47.76
32.23
13.51
14.08
16.92
47.76
24.33
11.47
26.32 24.39 21.28 19.23 13.89

25.35
20.25
9.62
11.75
25.35
16.86
8.28
12.77
8.04
11.36 8.47 9.01 3.79

14.29 16.95 13.33 13.33
12.77
9.87
* At all groundbed locations resistivity is lower than 8.54 ohm-m below the depth of 26 m
Nuricon Petroservices (Pte.) Ltd.
Page 1 of 1
APPENDIX: DESIGN CALCULATIONS
Appendix - Design Calculations Rev1
CP Design Calculations for Dia. 6" x 28 km Codensate Pipeline

Formulae:
= sqrt(r * g)
Equation-1
Rg = sqrt (r/g)
Equation-2
Ed = Ex Cosh ( * x)
Equation-3
Ex = Ed / Cosh ( * x)
Equation-4
Ix = Id * Exp(-a*x)
Equation-5
Rso = Rg * Coth (*x)
Equation-6
1/2
Equation-7
Rg = (r/g)
Where:
= Attenuation Constant
Rg = Characteristic Resistance of the pipeline, ohm
r = Unit lineal resistance, ohms/unit length
g = Unit lineal conductance to earth, S/unit length
x = No. of unit lengths (distance, in meters here)
Ed = Potential rise at drain point, v
Id = Current at drain point or Initial point, A
Rso = Open circuit resistance of the finite or isolated pipeline, ohm
Resistivity of steel =
r = * L/A
13.4 ohm-cm
0.134 ohm-m
Equation-8
Where:
= resistivity, ohm-meter
L = Length of pipe or rod, meter
2
A = Crossectional Area of Casing, m
r = Resistance of Casing of Length L
1/r = Conductance along 1 meter of casing/pipe, S
CP of Dia. 6"x28 km Zamzama-Bhubak

Condensate Pipeline

Condensate Pipeline
Calculations
System
Pipe OD (m)
Wall Thickness (m)
Average Soil Resistivity along ROW (ohm-m)
2
Crossectional area (m )
Pipeline Resistance (ohm/m)
Specific coating conductance (S/sqm)
Lineal coating conductance (S/m)
Lineal resistance of Pipeline (ohm/m)
Lineal conductance (S/m)
Rg (sqrt(r/g))
x
Rso (ohm)
Zn
0.168
0.006
52.870
0.00325
4.12E-05
1.89E-04
9.98E-05
4.12E-05
9.98E-05
6.42E-05
0.643
8375 m
1.309
Zn
0.168
0.006
52.870
0.00325
4.12E-05
1.89E-04
9.98E-05
4.12E-05
9.98E-05
6.42E-05
0.643
19318 m
0.760
Zn
0.168
0.006
52.870
0.00325
4.12E-05
1.89E-04
9.98E-05
4.12E-05
9.98E-05
6.42E-05
0.643
28000 m
0.679
Zn
0.168
0.006
52.870
0.00325
4.12E-05
1.89E-04
9.98E-05
4.12E-05
9.98E-05
6.42E-05
0.643
28000 m
0.679
Zn
0.168
0.006
52.870
0.00325
4.12E-05
1.89E-04
9.98E-05
4.12E-05
9.98E-05
6.42E-05
0.643
8375 m
1.309
Zn
0.168
0.006
52.870
0.00325
4.12E-05
1.89E-04
9.98E-05
4.12E-05
9.98E-05
6.42E-05
0.643
10943 m
1.061
Zn
0.168
0.006
52.870
0.00325
4.12E-05
1.89E-04
9.98E-05
4.12E-05
9.98E-05
6.42E-05
0.643
19625 m
0.755
Zn
0.168
0.006
52.870
0.00325
4.12E-05
1.89E-04
9.98E-05
4.12E-05
9.98E-05
6.42E-05
0.643
28000 m
0.679
Zn
0.168
0.006
52.870
0.00325
4.12E-05
1.89E-04
9.98E-05
4.12E-05
9.98E-05
6.42E-05
0.643
19318 m
0.760
Zn
0.168
0.006
52.870
0.00325
4.12E-05
1.89E-04
9.98E-05
4.12E-05
9.98E-05
6.42E-05
0.643
10943 m
1.061
Zn
0.168
0.006
52.870
0.00325
4.12E-05
1.89E-04
9.98E-05
4.12E-05
9.98E-05
6.42E-05
0.643
8682 m
1.271
Zn
0.168
0.006
52.870
0.00325
4.12E-05
1.89E-04
9.98E-05
4.12E-05
9.98E-05
6.42E-05
0.643
28000 m
0.679
Zn
0.168
0.006
52.870
0.00325
4.12E-05
1.89E-04
9.98E-05
4.12E-05
9.98E-05
6.42E-05
0.643
19625 m
0.755
Zn
0.168
0.006
52.870
0.00325
4.12E-05
1.89E-04
9.98E-05
4.12E-05
9.98E-05
6.42E-05
0.643
8682 m
1.271
8.54
3
0.01
6
6
0
0.616
8.54
3
0.01
6
6
0
0.616
8.54
3
0.01
6
6
0
0.616
8.54
3
0.01
6
6
0
0.616
8.54
3
0.01
6
6
0
0.616
8.54
3
0.01
6
6
0
0.616
8.54
3
0.01
6
6
0
0.616
8.54
3
0.01
6
6
0
0.616
8.54
3
0.01
6
6
0
0.616
8.54
3
0.01
6
6
0
0.616
8.54
3
0.01
6
6
0
0.616
8.54
3
0.01
6
6
0
0.616
8.54
3
0.01
6
6
0
0.616
8.54
3
0.01
6
6
0
0.616
0.28 v
1.10 v
0.60 v
0.00 v
B-D
0.36 A
0.62 A
0.26 v
1.10 v
0.60 v
0.00 v
C
0.39 A
0.28 v
1.10 v
0.60 v
0.00 v
C-A
0.36 A
0.32 v
1.10 v
0.60 v
0.00 v
C-B
0.30 A
0.34 v
1.10 v
0.60 v
0.00 v
C-D
0.27 A
0.63 A
0.26 v
1.10 v
0.60 v
0.00 v
D-A
0.39 A
0.28 v
1.10 v
0.60 v
0.00 v
D-B
0.36 A
0.145 v
0.10 A
0.085 v
0.06 A
0.952 v
0.148 v
0.11 A
0.252 v
0.15 A
0.291 v
0.15 A
0.085 v
0.06 A
0.698 v
0.145 v
0.10 A
0.34 v
1.10 v
0.60 v
0.00 v
D-C
0.27 A
0.39 A
2.03 A
0.291 v
0.15 A
0.052
27.27
0.0840
0.8
35.2
0.052
27.27
0.0840
0.8
35.0
Groundbed Resistance
Soil resistivity (ohm-m)
Anode/bfill length (m)
Anode diameter after 80% consumed ( m)
Annode spacing (m)
No. of anodes
Internal resistance (ohm)
Groundbed resistance (ohm)
Potential Attenuation & Groundbed Output

Voltage swing at drain point based on Rso & Id, Ed
0.34 v
0.28 v
0.26 v
0.26 v
0.34 v
0.32 v
Anode Potential (v)
1.10 v
1.10 v
1.10 v
1.10 v
1.10 v
1.10 v
Pipeline Potential (v)
0.60 v
0.60 v
0.60 v
0.60 v
0.60 v
0.60 v
Anode Polarization (v)
0.00 v
0.00 v
0.00 v
0.00 v
0.00 v
0.00 v
A-B
A-C
A-D
B
B-A
B-C
Groundbed No.
Current returned by each side of groundbed, Id (A)
0.26 A
0.36 A
0.39 A
0.39 A
0.26 A
0.30 A
Total current output of one groundbed (A)
0.39 A
Total current output of all groundbeds (A)
Ex 0.296 v
0.148 v
0.085 v
0.085 v 0.296 v
0.252 v
Ix
0.15 A
0.11 A
0.06 A
0.06 A
0.15 A
0.15 A
* Total Potential Shifts at A, B, C & D Locations (v) 0.869 v
0.955 v
* The limit ofactual Potential is -1.10 volt, the Anode Open Circuit Potential
Groundbed Life
Output/anode (A) put/anode (A)
0.032
Anode weight (kg)
27.27
Anode capacity(A-y/kg) 0.0840
Anode utilization factor
0.8
Life (y)
57.0
0.052
27.27
0.0840
0.8
35.0
0.032
27.27
0.0840
0.8
57.0
Current Requirement
Room Temp. Current Density (A/sqm)
0.025
Current adjustment for temp. (A/sqm/C)
0.001
Current Density at 40 Celsius (A/sqm)
0.040
Initial Coating Breakdown
0.05%
Yearly increase in Coating Breakdown
0.02%
Coating Breakdown after 20 years
0.55%
Current density for coated pipe after 25 years (A/sqm) 0.00022
Initial Current Density for coated pipe (A/sqm) 0.00002
Average Current Density for coated pipe (A/sqm) 0.00012
Pipe OD (m)
0.168
Pipeline length (m) 30,000
Pipeline area (sqm) 15,860
Required current based on average density (A)
1.90
Anode Requirement (Zn)
Anode consumption (kg/A-y)
Utilization factor
Required current output (A)
Desired minimum life (y)
Required anode metal weight (kg)
Weight of one anode
Required anodes based on weight (ea)
Required No. of anodes based on current output
Required No. of Groundbeds
Proposed No. of anodes (ea)
Recommended No. of groundbeds (ea)
11.90
0.80
1.90
25.00
707.73
27.27
26.00
40.00
4
48
4

Condensate Pipeline
APPENDIX: DRAWINGS
Insulating Flange
Near
Graveyard
Surge Diverter &

Earthing Electrodes
8375
Groundbed
See Drg. No.
SVGB-01 for
details.
Pchem:07/002
N.T.S.
REF:
SCALE:
Rev No:
DESIGNED BY:
Rev. Dt:
MZT
Drawn by:
mzt
Nov 6, 2006
Aug 10, 2006
CP-LAY-01
Design & Engg. of CP System for 6"x28 km Condensate Pipeline

DRAWING NO:
Test Stations at every

2.5km. See drg. No.
TP-01 for details
8682
Parco
Boundary
Wall
Surge Diverter &

Earthing Electrodes
Sheet No: 1 of 1
APPROVED BY:
MZT
SMZ
Within or outside
the wall of PARCO
Terminal
CHECKED BY:
BHP BILLITON
DATE:
Schematic arrangement of CP system along pipeline ROW
HONOR:
PETROCHEM
Groundbed
See Drg. No.
SVGB-01 for
details.
PROJECT:
TITLE:
CLIENT:
Current Measuring
Test Station
See Drg. No. CMTS-01
for details.
10943
Pipeline
Insulating Flange
50x50x1500 Zn Anode
Native Backfill
Bore hole
50x50x1500 Zn Anode
Anode Cable
Packaged Backfill
PACKAGE
DETAIL
Cables in the
trench to AJB
Di = Inactive Depth
NGL
Pipeline
Anode
Cables
SCALE:
N.T.S.
Pchem:07/002
Rev No:
DESIGNED BY:
Rev. Dt:
MZT
mzt
Nov 06, 2006
Drawn by:
SVGB-LAY-01
REF:
DRAWING NO:
Design & Engg. of CP System for 6"x28km Condensate Pipeline

July 31, 2006
PROJECT:
DATE:
6000
Sheet No: 1 of 1
APPROVED BY:
CHECKED BY:
BHP BILLITON
6000
HONOR:
TITLE: Typical Shallow Vertical Groundbed Details
CLIENT:
5. All dimensions are in mm

unless specified otherwise.
4. Negative (50 sqmm)cable is to

be cadwelded to the pipeline.
3. Refer to drawing No. AJB-01

for Anode Junction Box details.
AJB
PETROCHEM
Negative
Cable from
AJB
2. Refer to drawing No. CT-01 for

trenching detail.
1. See Detail A for anode burial.
NOTE
Anode
Column
6000
Anode
Junction
Box
MZT
SMZ
N.T.S.
Pchem:07/002
SCALE:
Rev No:
DESIGNED BY:
Rev. Dt:
MZT
mzt
Nov 6, 2006
Drawn by:
TYP-AJB-01
REF:
DRAWING NO:

Aug 14, 2006
PROJECT:
DATE:
Sheet No: 1 of 1
APPROVED BY:
CHECKED BY:
HONOR: BHP BILLITON

PETROCHEM
TITLE: Typical Anode Junction Box (AJB) Details
CLIENT:
MZT
SMZ
Bore hole
To Insulating Joint
NGL
Erthng Electrode Burial Detail
Native Backfill
Electrode Cables
50x50x1500 Zn Earthing Electrodes
Packaged Backfill
BHP BILLITON
N.T.S.
Rev No:
DESIGNED BY:
Rev. Dt:
MZT
Drawn by:
Pchem:07/002
SCALE:
REF:
EE-01
July 31, 2006
DATE:
DRAWING NO:
MZT
Sheet No: 1 of 1
APPROVED BY:
CHECKED BY:
Typical Burial Detail for Pair of Earthing Electrodes & their Cable Connections to Insulating Flanges
HONOR:
PETROCHEM
PROJECT:
TITLE:
CLIENT:
MZT
SMZ
HONOR:
PETROCHEM
N.T.S.
Pchem:07/002
SCALE:
Rev No:
DESIGNED BY:
Rev. Dt:
MZT
mzt
Nov 28 ,2006
Drawn by:
TYP-CCON-01
REF:
DRAWING NO:

July 31, 2006
PROJECT:
Sheet No: 1 of 1
APPROVED BY:
CHECKED BY:
BHP BILLITON
DATE:
TITLE: Typical Cable Connections to the pipeline
CLIENT:
MZT
SMZ
Pipeline
Detail AA
Cadweld
Concrete Block
NGL
See detail B
on Sheet 2
N.T.S.
Rev No:
DESIGNED BY:
MZT
Rev. Dt:
Drawn by:
Pchem:07/002
TP-01
REF:
DRAWING NO:

July 31, 2006
PROJECT:
DATE:
SCALE:
Pipeline
mzt
Sheet No: 1 of 2
APPROVED BY:
CHECKED BY:
HONOR: BHP BILLITON

PETROCHEM
TITLE: Test Post Details
CLIENT:
Cadweld
Cable
1:2:6 Lean Concrete
1m x 1m x 1m Concrete Block
Tinned Bush
MZT
SMZ
DETAIL B
Test Cable
Cable Strands
Cable Insulation
Heat shrink tube
N.T.S.
Rev No:
DESIGNED BY:
MZT
Rev. Dt:
Drawn by:
Pchem:07/002
SCALE:
TP-01
REF:
DRAWING NO:

July 31, 2006
PROJECT:
DATE:
mzt
Sheet No: 2 of 2
APPROVED BY:
CHECKED BY:
HONOR: BHP BILLITON

PETROCHEM
TITLE: Test Post Details
CLIENT:
Tinned Bush
MZT
SMZ
N.T.S.
Rev No:
DESIGNED BY:
MZT
Rev. Dt:
Drawn by:
Pchem:07/002
SCALE:
CT-01
REF:
DRAWING NO:

July 31, 2006
PROJECT:
DATE:
mzt
Sheet No: 1 of 1
APPROVED BY:
CHECKED BY:
HONOR: BHP BILLITON

PETROCHEM
TITLE: Typical Cable Trench Details
CLIENT:
Sand
Cables
MZT
SMZ
Backed Clay Tiles or Bricks
Warning Tape
Native Soil Backfill
NGL
Pchem:07/002
N.T.S.
SCALE:
Rev No:
DESIGNED BY:
Rev. Dt:
MZT
Drawn by:
CMTS-01
REF:
DRAWING NO:
July 31, 2006
DATE:
mzt
Sheet No: 1 of 1
APPROVED BY:
CHECKED BY:
BHP BILLITON
Current Measuring Test Station
HONOR:
PETROCHEM
PROJECT:
TITLE:
CLIENT:
MZT
SMZ

Cathodic Protection Report

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ZAMZAMA CONDENSATE

BHP GAS FIELDS, SIND, PAKISTAN

ZAMZAMA CONDENSATE PIPELINE CP SYSTEM

PETROCHEM ENGG. & INDUSTRIAL

CONTRACT DOC NO.

APRIL 10, 2006

FIELD SURVEY BY:

MAQSOOD-UZ-ZAMAN, NPSL, KARACHI

FINAL REPORT DATE:

NPSL REFERENCE NO.

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SOIL CONDUCTIVITY / RESISTIVITY

1. Schematic Arrangement of CP System Along

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Backfill resistivity (ohm-m)

Soil resistivity (ohm-m)

Diameter of anode column/canister inclusive of backfil.

Impressed Current Cathodic Protection System

Nuricon Petroservices (Pte.) Limited

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Pipe to Soil Potential (with respect to Saturated Cu-CuSO 4

Resistance of multiple anodes to remote earth

Spacing between bottom and top of consecutive anodes

Structure to Soil Potential (with respect to Saturated Cu-CuSO4

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DESIGN REPORT FOR 6 X 28 KM CONDENSATE

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The pipeline has a nominal diameter of 6 inches and outer

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Zamzama Plant, near grave yard. Anodes and

This location is near Goath (village) Gullan

This location is near the back of grid station.

Preferably within the Parco boundary wall

Potential Monitoring 0+000

TS/CMP Across insulating flange; can

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Potential Monitoring N/A

TS/CMP Across insulating flange; can

There are no cased crossings along the pipeline ROW.

Earthing electrodes are used at insulating flanges to shunt the

To diffuse the electric and lightening surges across the insulating

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Zinc anodes of 50x50x1500 mm having net metal weight of

Zinc anodes of 50x50x1500 mm having net metal weight of

Zinc anodes of 50x50x1500 mm having net metal weight of

4-Electrode Zinc Earthing Cell (each electrode of size

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Cadweld Charges, 15 gram

Test Stations (see drawing No. TYP-TP-01).

Test Station/Current Measuring Post having 6 each M6

Anode bond box, to be able to accommodate 13 shunts, 12

Royston Handy Caps with primer or Raychem's Perp Repair

Stubs, 50x50x6 mm each (to be cut from ? 6 pipe piece), to

Negative cable, 50 mm2 Cu/PVC/PVC, single core stranded,

Test cable, 6 mm2 Cu/PVC/PVC, single core stranded,

Test cable, 6 mm2 Cu/PVC/PVC, single core stranded,

Test cable, 6 mm2 Cu/PVC/PVC, single core stranded,

Miscellaneous items e.g., cable lugs, nut-bolts, negative &

SERVICES - Installation, Test and Commissioning

Surge Diverters ( see attached data sheet )

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POWER SUPPLY SYSTEMS

Dimension drawing EXFS

For indirect connection/earthing of functionally