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SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - JUNE 2008)

REV 3

SAUDI ARAMCO INSPECTION CHECKLIST

SAIC NUMBER

Impressed Current CP Cable Installation, Termination, and


Pre-Commissioning
PROJECT TITLE

SAIC-X-3207
WBS / BI / JO NUMBER

EQUIPMENT ID NUMBER(S)

EQUIPMENT DESCRIPTION

LAYOUT DRAWING NUMBER

REV. NO.

SCHEDULED INSPECTION DATE & TIME

ACTUAL INSPECTION DATE & TIME

CPCONTRACTOR / SUBCONTRACTOR

EQPT CODE

SYSTEM ID.

PURCHASE ORDER NUMBER

MH's SPENT

TRAVEL TIME

SAUDI ARAMCO USE ONLY

SAUDI ARAMCO ACTIVITY NUMBER

SAUDI ARAMCO INSPECTION LEVEL

CONTRACTOR INSPECTION LEVEL

ACCEPTANCE CRITERIA

REFERENCE

A.

Installation

A1

IT IS MANDATORY that proposed construction drawings and the related


cathodic protection design information for every design package be
submitted to the proponent cathodic protection organization and the
Cathodic Protection & Coatings Unit of CSD for review and approval.

SAES-X-600
Sec. 4.1.1

A2

The design agency shall not issue drawings for construction that have
not been approved in writing by the proponent cathodic protection
organization and the Cathodic Protection & Coatings Unit of CSD.

SAES-X-600
Sec. 4.1.1

A3

The minimum size for the primary positive and negative DC cables from
the rectifier shall be 25 mm (#4 AWG).

SAES-X-600
Sec. 4.2.7.2

A4

All cathodic protection cables including the primary positive and negative
cables shall be sized to comply with the most recent edition of the
National Fire Protection Association NFPA 70, National Electric Code
(NEC).
Commentary Note:
Use Table 310-16, Column for 90C rated cables of the latest NEC
Handbook to calculate the ampacity of HMWPE cables, and consider an
ambient temperature of 40C.

SAES-X-600
Sec. 4.2.7.3

A5

Cables installed for, or associated with electrical grounding or electrical


ground continuity purposes shall not be used to achieve the required
electrical continuity for cathodic protection.

SAES-X-600
Sec. 4.2.8.2

A6

Identify and locate all bonding connections on the cathodic protection


drawings.

SAES-X-600
Sec. 4.2.8.3

A7

The bond conductor shall be sized to achieve a voltage drop across the
conductor of less than 0.05 volt and shall be minimum 16 mm (#6
AWG).

SAES-X-600
Sec. 4.2.10.2

A8

Provide an above-grade bond box for all isolating devices. Construct the
box according to Standard Drawings
AA-036277, AA-036349 or AA-036350.

SAES-X-600
Sec. 4.2.11.4

A9

Impressed Current Anodes:


Do not roll, pull or twist the anode and anode cable or lower the anode,
with the anode cable or perform any other action that may strain the
cable where the cable protrudes from the anode.

SAES-X-600
Sec. 5.2.1

Page 1 of 8

PLANT NO.

EC / PMCC / MCC NO.


QUANTITY INSP.

SAUDI ARAMCO TIP NUMBER

ITEM
No.

30-Jun-08
DATE APPROVED
QR NUMBER

WORK PERMIT REQUIRED?

PASS

FAIL

N/A

RE-INSP DATE

A10

Inspect the ICCP anode cables for below grade usage for insulation
damage just before installation. Conduct the inspection with a pulse type
holiday detector set at 18,000 volts DC. Saudi Aramco or it's designated
agent shall witness the inspection. Do not use anodes with the cables
that fail the dielectric test.

Page 2 of 8

SAES-X-600
Sec. 5.2.3

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - JUNE 2008)

REV 3

SAUDI ARAMCO INSPECTION CHECKLIST


Impressed Current CP Cable Installation, Termination, and
Pre-Commissioning
PROJECT TITLE

SAIC NUMBER

SAIC-X-3207
WBS / BI / JO NUMBER

ITEM
No.

ACCEPTANCE CRITERIA

REFERENCE

A11

Do not use repaired anode cables, repaired anodes, or anodes with


repaired anode-to-cable connections.
Exception:
You may repair an anode cable provided all splices are made in above
ground junction boxes. Two boxes are required with one box at each end
of the repaired section of cable. New cable of similar or larger size to the
anode cable shall then be installed to connect the two boxes. Use cable
splice boxes constructed according to Standard Drawing AA-036145.

SAES-X-600
Sec. 5.2.4

A12

Each impressed current anode shall be connected to the positive circuit


of the respective rectifier through an individual anode lead wire
connected through a dedicated shunt mounted in an appropriately sized
anode junction box.

SAES-X-600
Sec. 5.2.6

A13

Each junction box shall be constructed according to one of the following


Standard Drawings: AB-036274, AB-036275 or AA-036347 and Saudi
Aramco Materials System Specification 17-SAMSS-008.
Exception:
Shunts are not required for the individual anode connection in the
individual anode boxes (GUB boxes) installed at the tank shell (Standard
Drawing AA-036355, Sheet 1).

SAES-X-600
Sec. 5.2.6

A14

Install the anodes according to Standard Drawing AA-036355, or


Standard Drawing AA-036346. The cathodic protection design shall
provide the hole depth and other installation details that are job specific.

SAES-X-600
Sec. 5.2.7

A15

DC Cables-Install all plant area buried DC cables in trenches


constructed according to Standard Drawing AD-036874.

SAES-X-600
Sec. 5.4.1

A16

Identify all underground DC cables (anode, bond, positive, and negative)


with cable route markers constructed and installed according to
Standard Drawings AB-036351 and AB-036273.

SAES-X-600
Sec. 5.4.2

A17

Inspect positive cables for insulation damage immediately prior to the


burial of the cables. Conduct the inspection with a pulse type holiday
detector set at 18,000 volts DC. Repair of the insulation for buried
positive cable by any method is prohibited. Above-grade repair
connections for anode bed positive cables in splice boxes are
acceptable. See Standard Drawing AA-036145 for cable splice box
details.

SAES-X-600
Sec. 5.4.3

A18

Limit buried main positive cable runs (e.g., between rectifier and anode
bed junction box) to 150 meters. Make all splices in above-grade splice
boxes. For sections of cable between 150 meters and 300 meters in
length, locate the splice box approximately at the midpoint. See
Standard Drawing AA-036145 for cable splice box details.

SAES-X-600
Sec. 5.4.4

A19

Negative cables and bond cables to be used for buried service need to
be only checked visually for obvious insulation defects. Repair cables
with visible insulation damage with 3 half-lap layers of plastic vinyl tape
over 3 half-lap layers of rubber tape.

SAES-X-600
Sec. 5.4.5

A20

Use thermite welds for all negative drain cable and bond connections to
steel pipes and structures according to Standard Drawing AB-036381.

SAES-X-600
Sec. 5.4.6

A21

Above-grade cables shall be armored or run in covered cable trays or


steel conduit. Negative cables attached to above-grade structures may
extend out of the conduit for up to 500 mm between the conduit and the
structure connection.

SAES-X-600
Sec. 5.4.7

Page 3 of 8

30-Jun-08
DATE APPROVED
QR NUMBER

CPCONTRACTOR / SUBCONTRACTOR

PASS

FAIL

N/A

RE-INSP DATE

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - JUNE 2008)

REV 3

SAUDI ARAMCO INSPECTION CHECKLIST


Impressed Current CP Cable Installation, Termination, and
Pre-Commissioning
PROJECT TITLE

SAIC NUMBER

SAIC-X-3207
WBS / BI / JO NUMBER

ITEM
No.

ACCEPTANCE CRITERIA

REFERENCE

A22

Wire Termination-All wiring terminations shall be either solderless


crimped connectors, or shall be tinned (AC input does not require
tinning) and terminated in a captivating compression type terminal block
or lug.

17-SAMSS-004
Sec. 5.4.8.2

A23

Grounding Terminal-Each rectifier shall be provided with an external


ground terminal (corrosion resistant) sized for a 25 mm (#4 AWG)
copper ground conductor. Each rectifier shall also be provided with an
internal equipment grounding terminal adjacent to the AC terminal block.

17-SAMSS-004
Sec. 5.4.8.6

A24

Install test stations, bond boxes, and junction boxes on supports


constructed according to Standard Drawing AB-036540. Show all test
stations and box locations on the design and construction drawings.

SAES-X-600
Sec. 5.6.1

A25

Identify all cables inside test stations, bond boxes, and junction boxes
with durable tags according to Standard Drawing AD-036132. Label the
cable and the terminals to indicate the structures to which they are
connected.
Exception:
Cable identification is not required inside one pin test station.

SAES-X-600
Sec. 5.6.2

A26

Install an inside and outside nameplate for all junction and bond boxes
indicating the identifying number of the structure and/or the rectifier unit
to which they are connected. If specified in the design documents by the
proponent organization, a location schematic shall be engraved on the
nameplate of the positive and negative junction boxes.

SAES-X-600
Sec. 5.6.3

A27

Negative and bond cables shall be HMWPE, THHN, THWN, RHH-RHW,


or USE type. The copper conductor sizes, and number of strands shall
be per Table 2 and shall be concentric-lay stranded, Class C per ASTM
B8 or Class 2 per IEC 60228. THHN, THWN, RHH-RHW, and USE type
cables shall be UL 83 or approved equivalent labeled or listed. HMWPE
type cables shall comply with Table 2 and Table 3 of this specification.

17-SAMSS-017
Sec. 5.3

A28

Anode cables for onshore cathodic protection systems include anode


cables for:
Buried Pipelines (SAES-X-400)
Vessel and Tank Internals (SAES-X-500)
Plant Facilities (SAES-X-600)
Onshore Well Casings (SAES-X-700)
Anode cables for onshore cathodic protection systems shall be
manufactured with stranding and double insulation in accordance with
the details specified in Table 1 and Table 3.

17-SAMSS-017
Sec. 5.4.1

A29

Conductors of all impressed current cathodic protection cable types shall


be annealed copper per ASTM B3 or IEC 60228, and shall be
concentric-lay stranded per ASTM B8 class B or C, or per IEC 60228
class 2.

17-SAMSS-017
Sec. 5.1.2

A30

The cable outer insulation layer or jacket for impressed current cathodic
protection cables shall be permanently marked at intervals of no greater
than one meter with the manufacturer's name or trademark, the
conductor size, and the type of insulation. The print color shall contrast
with the jacket color.

17-SAMSS-017
Sec. 5.1.3

Page 4 of 8

30-Jun-08
DATE APPROVED
QR NUMBER

CPCONTRACTOR / SUBCONTRACTOR

PASS

FAIL

N/A

RE-INSP DATE

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - JUNE 2008)

REV 3

SAUDI ARAMCO INSPECTION CHECKLIST


Impressed Current CP Cable Installation, Termination, and
Pre-Commissioning
PROJECT TITLE

ITEM
No.

SAIC NUMBER

SAIC-X-3207
WBS / BI / JO NUMBER

ACCEPTANCE CRITERIA

REFERENCE

A31

Cable Reel Labeling:


A permanent stainless steel or aluminum tag shall be firmly attached on
the outsides of the cable reel. Cable reel tag engraving or stamping
shall include the following data:
Destination
Purchase Order Number
Type and Size of Cable (identified as per this specification)
Length of Cable on Reel
Saudi Aramco Specification #_________, Dated___________
Date of Manufacture and Batch Number

17-SAMSS-017
Sec. 5.1.4

A32

Positive cables shall be HMWPE insulated in accordance with Table 3 of


this specification. The copper conductor sizes, and number of strands
shall be per Table 2 of this specification and shall be concentric-lay
stranded, Class C per ASTM B8 or Class 2 per IEC 60228.

17-SAMSS-017
Sec. 5.2

A33

The cable tag shall contain the following information:


a) Cable identification number from construction drawing or anode
number or structure number/description or D.C. power source number.
Std. Dwg No. AD-036132 Note.1

SAES-X-600
Sec. 3.1

A34

The cable tag shall be either:


a) Stainless steel tapewriter tape embossed using tapewriter or
b) White polyolefin sleeve material with permanent labeling.
Std. Dwg No. AD-036132 Note.2

SAES-X-600
Sec. 3.1

A35

Ensure that the cable tag & cable ties do not have any sharp exposed
edges.
Std. Dwg No. AD-036132 Note.3

SAES-X-600
Sec. 3.1

B.

Pre-Commissioning

B1

Achieve cathodic protection within 30 (thirty) days of commissioning of


the facility. For new or upgraded CP systems, conduct all precommissioning and commissioning in accordance with GI-0002.710 and
SAEP-332.

B2

Prepackaged anodes shall have two lifting eyes or polypropylene rope


handles installed at the cable end to allow for vertical installation.

B3

Before the start of construction, the construction agency shall notify


Project Inspection and/or the proponent Operations Inspection Unit so
that full inspection coverage can be provided during construction and
especially during anode installations. The Construction agency shall
provide test data sheets to the inspection agency for review at least
three days, but not more than one week, prior to the start of construction.

SAES-X-600
Sec. 6.2

B4

The Design agency or Construction agency shall update all Construction


Drawings for any field modifications to the original design to show the
detailed "as-built" cathodic protection system. The as-built drawings shall
accurately illustrate the type and location of cathodic protection
equipment & cables including every cathodic protection rectifier, cable,
junction box, bond box, negative cable termination, anode, etc. The
Design agency or Construction agency shall provide copies of these
updated drawings to the cathodic protection proponent department and
the Consulting Services Department within sixty (60) days of project
completion. Reported corrections (if any) shall be completed and
resubmitted within thirty days.

SAES-X-600
Sec. 7

Page 5 of 8

30-Jun-08
DATE APPROVED
QR NUMBER

SAES-X-600
Sec. 6.1

17-SAMSS-007
Sec. 6.1.1.2

CPCONTRACTOR / SUBCONTRACTOR

PASS

FAIL

N/A

RE-INSP DATE

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - JUNE 2008)

REV 3

SAUDI ARAMCO INSPECTION CHECKLIST

SAIC NUMBER

Impressed Current CP Cable Installation, Termination, and


Pre-Commissioning
PROJECT TITLE

SAIC-X-3207
WBS / BI / JO NUMBER

ITEM
No.

ACCEPTANCE CRITERIA

30-Jun-08
DATE APPROVED
QR NUMBER

REFERENCE

CPCONTRACTOR / SUBCONTRACTOR

PASS

FAIL

N/A

RE-INSP DATE

REMARKS:

REFERENCE DOCUMENTS:
1.
2.
3.
4.
5.
6.

Schedule G -- Material, Tools and Equipment (Pro Forma MP-IK-LS Contract), March 2006
Schedule Q -- Quality Requirements (Pro Forma Contract), February 2008
17-SAMSS-007 Impressed Current Anodes for Cathodic Protection, 17 January, 2007
17-SAMSS-017 Impressed Current Cathodic Protection Cables, 31 March, 2008
17-SAMSS-004 Conventional (Tap Adjustable) Rectifiers for Cathodic Protection, 30 March, 2005
SAES-X-600 Cathodic Protection of Plant Facilities 25 June, 2007

NOTES:
1. Approved - Acceptable to the authority having jurisdiction (i.e., Saudi Aramco ID).
2. Identified - Recognizable as suitable for the specific application by a qualified testing laboratory (i.e., listing and/or labeling).
3. Listed - Equipment and materials included in a list published by an approved qualified organization concerned with evaluation of products
or services, that maintains periodic inspection of production of listed equipment or materials or periodic evaluation of services, and whose listing
states
that the equipment, material, or services either meets appropriate designated standards or has been tested and found suitable for a specified
purpose.
4. Labeled - Equipment or materials to which has been attached a label, symbol, or other identifying mark of an approved qualified organization
concerned
with product evaluation, that maintains periodic inspection of production of labeled equipment or materials, and by whose labeling the
manufacturer
indicates compliance with appropriate standards or performance in a specified manner.

Contractor / Third-Party

Saudi Aramco

Construction Representative*

PMT Representative

Work is Complete and Ready for Inspection:


Name, Initials and Date:

T&I Witnessed

QC Record Reviewed

Work Verified

T&I Witnessed

QC Record Reviewed

Work Verified

T&I Witnessed

QC Record Reviewed

Work Verified

Name, Initials and Date:

QC Inspector

PID Representative
Performed Inspection

Work / Rework May Proceed

Name, Initials and Date:

Name, Initials and Date:

QC Supervisor

Proponent and Others


Quality Record Approved:

Name, Sign and Date:

Name, Organization,
Initials and Date:

*Person Responsible for Completion of Quality Work / Test

Y = YES

Page 6 of 8

N = NO F = FAILED

SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards Cutoff - JUNE 2008)

REV 3

SAUDI ARAMCO INSPECTION CHECKLIST


Impressed Current CP Cable Installation, Termination, and
Pre-Commissioning

SAIC NUMBER

30-Jun-08
DATE APPROVED
QR NUMBER

SAIC-X-3207

CP-

Table 3 PVDF and HMWPE Insulation Specifications


Insulation Type

Polyvinylidene Fluoride (PVDF) Irradiation


Cross-Linked

Page 7 of 8

Insulation Specifications**

Tensile Break Strength


Break Elongation
Flexural Strength
Resistivity
Dielectric Constant

4500 PSI min.


50% min.
8600 PSI min.
2 x 1014 ohm-cm min.
8.0 min. at 100 Hz

Table 3 PVDF and HMWPE Insulation Specifications


SAUDI ARAMCO ID/PID - 18-MAY-05 - REV 0 (Standards CutoffInsulation
- JUNE 2008)

Type

SAUDI ARAMCO INSPECTION CHECKLIST

REV 3
SAIC NUMBER

Insulation Specifications**
30-Jun-08
DATE APPROVED

Tensile Break Strength


Impressed Current CP Cable Installation, Termination, and
Break Elongation
Polyvinylidene Fluoride (PVDF) Irradiation SAIC-X-3207
Pre-Commissioning
Flexural Strength
Cross-Linked
Resistivity
Dielectric Constant

Page 8 of 8

QR NUMBER

4500 PSI min.


50% min.
CP8600 PSI min.
2 x 1014 ohm-cm min.
8.0 min. at 100 Hz