A. I. TOTAL ENGINEERING SDN. BHD.

EPCC OF NGDS TO PRAI DL STAGE 1/15, PRAI INDUSTRIAL AREA,

PENANG.
[ MULTI CHOICE MARKETING ]

CATHODIC PROTECTION SYSTEM

[ PIPE RISER ]

________________________________

FINAL REPORT
________________________________

JULY 2015

Document Ref. Date Revision No. No. of Pages

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 CONTENT

Page

1.0 INTRODUCTION 1

2.0 GENERAL INFORMATION 2

2.1 General Description 2
2.2 Determination of Protection Level 2
2.3 Criteria 2

3.0 SUMMARY OF WORKS CARRIED OUT 3

3.1 Installation of Magnesium Anode 3
3.2 Installation of Thermit Weld 3
3.3 CP Cables Extension and Protection 3
3.4 Installation of Test Station 3
3.5 Commissioning 4

4.0 RESULT AND CONCLUSION 5

5.0 MAINTENANCE 6

6.0 RECOMMENDATION 6

APPENDIX

CP FINAL DESIGN

FIELD RECORD SHEET

- Installation & Commissioning Record

CERTIFICATE
- Magnesium Anode
- Equipment Calibration (Multimeter)
EPCC OF NGDS TO PRAI DL STAGE 1/15, PRAI INDUSTRIAL AREA,
PENANG.
Cathodic Protection System (Pipe Riser)
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_________________________________________________________________________________________

1.0 INTRODUCTION

Client (Pipeline Owner) GAS MALAYSIA BERHAD

Main Contractor A. I. TOTAL ENGINEERING SDN. BHD.
CP Contractor JASIM ENGINEERING SDN. BHD.
Customer(s) MULTI CHOICE MARKETING

T h e pr ovi si on of CP SYST E M wa s r equi r ed for t hi s pr oje ct wi t h th e in t ent i on t o pr ovi d e

c or r osi on pr ot ect i on for th e un der gr oun d sect i on of pr oposed n ew st e el Pi pe Ri ser a t th e
Ser vi c e St a t i on . T h e Wor k in vol ved Suppl y , In st a l l an d Com m i ssi on in g of a c om p l et e CP
SYST E M. Th e CP SYST E M i m pl em en t ed in thi s Pr oje ct wa s of Sa cr i fi ci a l t ype, wh er e
Hi gh Pot en t i a l Pr e -pa cka ged Ma gn esi um An ode wa s ut i l i sed a s t h e DC Curr en t sour ce. Th e
Desi gn Li fe i s 20 yea r s.

In gen er a l, th er e wa s on l y ONE (1) CP P oi n t i n st a l l ed in th i s pr oje ct , ut i l i sin g on l y ONE

(1) pi ec e of 7. 7kg Hi gh Pot en t i al Pr e -pa cka ged Ma gn esi um An ode. T h i s wa s su ffi ci en t t o
pr ovi de a com pl et e c or r osi on pr ot ect i on for th e n ewl y i n st a l l ed NPS 2 st eel Pi pe Ri ser of
l en gth a bout 2. 0m .

T h e Wor k wa s offi ci a l l y c om m en ced on 23 M ay 2015 wi t h in st a ll a ti on of Ma gn esi um An ode

a n d Th erm i t e Wel ds a t th e Ser vi c e St a t i on . E ven t ua l l y, Com m i ssi on in g of t h e i n st a ll ed CP
SYST E M wa s ca r r i ed out on 8 Jul y 2015 (t oget h e r wi t h in st a l la t i on of T est St a t i on ) . Dur in g
t h e exer ci se, t h e CP SYST E M wa s ver i fi ed t o be i n good p er for m an ce a n d m et a l l th e
St a n dar d CP Requi r em en t s.

T h e r est of t h e Rep or t wi l l di scuss i n c om pl et e t h e wh ol e a ct i vi t i es p er for m ed i n execut i n g

a n d com pl et i n g th e job. Fi gur e 1 bel ow sh ows t h e sum mar y of c om pl et e CP In st a l la t i on
det a i l .

No. CP Ref. Chainage Pipe Magnesium Anode Qty. of Type of

Size Installation Data Thermite Test
Weld Station
Date Size Qty.
[inch] [kg] [no(s)] [no(s)]

1. CP 1 Pipe Riser 2 23.05.2015 7.7 1 2 Flush-mounted

Fi gure 1 : Summary of c omple t e CP Inst al l at i on

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2.0 GENERAL INFORMATION

2. 1 G e ne r al De sc ri pti on

T h e CP syst em in st a l l ed i s t o a voi d c or r osi on occ urr en ce on th e ext erna l sur fa ce of t h e st eel

pi pe. Th e descr i pt i on of t h e con cept sh al l be used a s an over vi e w on h ow t h e Sa cr i fi ci a l CP
S yst em wor ks.

Cor r osi on of st eel wi l l oc cur wh en di ssi m i lar m eta l s ar e el e ct r i ca l l y c on n ect ed. In th i s ca se

m a gn esi um an d st eel a r e th e di ssi m i lar m et a l s. Not e t h a t th e m a gn esi um i s hi gh er th an
st eel i n th e el ect r om ot i ve for c e ser i es; th er efor e, t h e m or e a ct i ve m et a l l i ke m a gn esi um wi l l
c or r ode i f el e ct r i ca l l y c on n ect ed wi t h st eel i n si de t h e com m on el ect r ol yt e (t h e ea r th soi l ).

DC cur r ent i s di sch ar ged fr om t h e st eel pi pe i n t o t h e soi l . As c or r osi on t ook pl a ce, t h e

m et a l i on s wi l l be l ost in t o th e soi l . Th e curr ent i s di sch ar ged fr om th e pi pe sur fa ce t h a t i s
n ot pr ot ect ed by c oa t i n g or exper i en ce da m a ged c oa t i n g. Not e th a t n on e of t h e coa t i n gs or
c oa t i n g s yst em s a ppl i ed on th e str uct ur e s can perfect l y pr ot ect t h e pi pel i n e .

Wi t h th e a ppl i ca t i on of Sa cr i fi ci a l CP Syst em , t h e pi pe wi l l r ecei ve DC cur r en t fl owi n g

t hr ough an el ect r ol yt e fr om an ext ern a l sour ce. In th i s ca se, th e m a gn esi um an ode i s used
a s a n ext er na l D. C. curr en t sour ce. T h e cor r os i on a t an y pi nh ol es on th e pi pe wi l l be
m i t i ga t ed a s th e r esul t of t h e ext er n al curr ent wi l l be for ced i n t o t h e pi pe an d st opped t h e
cur r en t fr om l ea vi n g th e pi pe sur fa ce. T h i s wi l l r esul t in a m in im um or a l m ost n egl i gi bl e
l evel of c or r osi on t a kin g pl a ce on th e wh ol e se ct i on of t h e pi pe sur fa ce.

2. 2 De te r mi nati on of Pr ote c ti on Le ve l

T h e l evel of pr ot e ct i on r ecei ved by t h e pi pe i s a ch i eved by m ea sur i n g th e Pi pe t o S oi l

(P/ S) Pot en t i a l usin g a st an da r d h i gh i m peden ce Mul t i m et er. Th e posi t i ve t er m i na l of t h e
Mul t i m et er i s con n ect ed t o t h e pi pe ca bl e a n d i t s n ega t i ve t er m in al i s conn ect ed t o a
Por t a bl e C opper / Copp er Sul fa t e Re fer en ce Cel l (PRC). T h e PRC i s a h a l f -cel l , wh i l e th e
pi pe an d th e soi l (el ect r ol yt e) a r e an oth er h a l f -cel l . Th i s com bi n a ti on wi l l bec om e a ful l
c or r osi on cel l . Si n ce P/ S P ot en t i a l i s an IR dr op bet we en bot h h al f -c el l s, t h er efor e i t ca n
be used t o det er m i n e th e Pr ot ect i on Le vel of a CP S yst em on th e pi pe.

2. 3 Cri te ri a

T h e NACE St an dar d RP0169, PE T RONAS GA S BE RHAD a n d GAS MA LAY SIA BE RHAD

Spe ci fi ca t i on s a r e r efer r ed, wh er e th e cr it er i a set i s :

The P/ S Pote n ti al shoul d be mor e ne gati ve than -0. 950 Vol t

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3.0 SUMMARY OF WORK S CARRIED OUT

3. 1 Instal l ati on O f M agne si um An ode

T h e Ma gn esi um An ode i n sta l l ed wa s NE W an d of t yp e Hi gh Pot en t i a l Pr e -Pa cka ged.

Dur in g in sta l l at i on , th e an ode wa s pl a c ed a t a bout 1m b el ow t h e pi pe a n d wi t h it s
l on gi t udin al a xi s para l l el wi t h th e pi pe. Th e at t a ch ed An ode T a i l Ca bl e w a s t h en con n ect ed
t o a sin gl e An ode Hea der Ca bl e (r efer en ced a s A N Ca bl e) of 10 m m sq. PVC/ PVC Copper
Ca bl e ( RE D) wi t h a Str a i gh t Joi n t an d Spl i cin g T a pe set . Th e AN Ca bl e wa s l a t er
t em por a ri l y ext en ded t o a bove gr oun d.

3. 2 Instal l ati on of The r mi t e We l d

T wo (2) n os of T h erm i t e Wel ds wer e i n st a ll ed on th e ve r t i ca l sect i on of t h e pi pe sur fa ce

i n or der t o est a bl i sh ca bl e -t o-pi pe c on n ect i on s. For ea ch Th erm i t e Wel d, on e en d of
suffi ci en t l en gth of 10 m m sq. PVC/ PVC Copper Ca bl e (BLACK) wa s wel d ed (usi n g Wel d
Met a l ) t o t h e pi pe sur fa ce a ft er r em ovi n g t h e exist i n g coa t in g on th e pi pe. Th e wel ded sp ot
wa s t h en sea l ed usi n g st an dar d Pi pe Cover i . e. Royst on Ha n dyCa p. T h e wel ded ca bl e s,
r efer en ced a s P1 Ca bl e (Ma i n Pi pe Ca bl e), P 2 Ca bl e (St a n dby Pi p e Ca bl e) wer e t h en
se cur ed in pla ce surr oun din g th e pi pe usin g ca bl e t i es. Th e est a bl i sh ed P1 an d P2 Ca bl es
wer e t h en gr ouped t og et h er wi t h AN Ca bl e an d tem por a r il y ext en ded t o a bove gr oun d.

3. 3 CP Cabl e s Exte nsi on and Pr ote c ti on

T h e P1, P2 an d AN Ca bl es (r efer en ced a s CP Ca bl es) wer e t h en gr ouped a n d secur el y t i ght e n

t oget h er wi t h PVC Ta pes a t a bout 300m m in t er va l s. Th en , th e wh ol e ca bl e s wer e i n ser t ed
i nt o a su ffi ci en t l en gth of Fl exi bl e Pl a st i c C on dui t (FPC) i n or der t o m a int a in a si n gl e
c or e of CP Ca bl e s, besi de s pr ovi di n g a pr ot e ct i on for th e ca bl es. T h e FCP c on t a in in g th e
CP Ca bl es wa s t h en ext en ded ver t i ca l l y t o a bove gr oun d.

3. 4 Instal l ati on O f Te st Stati on

St a n dar d Fl ush -m oun t ed Ca st Ir on T est Ch amber wa s us ed a s t h e T est St a t i on for t hi s

pr oje ct . It wa s i n sta l l ed wi t h i t s t op sur fa ce sl i gh tl y a bove t h e exi st i n g gr oun d l evel . A
c on cr et e m i xt ur e wa s used t o h ol d t h e T est Ch amber in pla ce. Dur in g in st a ll a t i on, th e FPC
c on t a in in g th e CP Ca bl es wa s ext en ded thr ough th i s T est Cha m ber an d a l l th e CP Ca bl e
en ds wer e l ugged usi n g Br a ss Ca bl e Lugs, i den t i fi e d usi n g r espect i ve Ca bl e Ma r ker s an d
t er m ina t ed a ccor di n gl y on t h e T er m ina t i on Pan el in si de th e T est Cha m ber .

[Refer INSTALLATION & COMMISSIONING RECORD in Appendix for reference]

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3. 5 Commi ssi oni ng

Dur in g thi s exer ci se, i n i t ia l l y, t h e in t egr it y of t h e in st a l l ed CP S yst em wa s ch ecked a n d

t est ed. T h en th e OFF POT E NT IAL Rea di n gs i .e. An ode Cur r en t , An ode P ot en t i a l an d
Pi pe P ot en t i al wer e r e c or ded. Subsequ en t l y, t h e CP S yst em wa s en er gi sed by c on n ect in g
t h e AN an d P1 ca bl es. T h en th e cr uci a l ON POT E NT IAL Rea di n g i . e. Pi pe -t o-S oi l (P/ S)
Pot en t i a l wa s r ecor ded. Fi n a l l y, a l l th e Rea di n gs r ecor ded wer e ver i fi ed t o be wi t h in th e
St a n dar d CP Requi r em en t Le vel . Fi gur e 2 bel ow sh ows th e Com m i ssi on in g Rea di n gs
r ecor ded.

No. CP Re f. Com mi s s i on i n g COM M IS S ION ING RE AD INGS

Da t e

An od e An od e Pipe P i p e -t o-S oi l ( P / S )
Cu r r e n t P ot e n t i a l P ot e n t i a l P ot e n t i a l
[m A] [V ] [V ] [V ]

1. CP 1 0 8 . 0 7 . 2 01 5 0.5 -1.561 -0.600 -1.120

Fi gure 2 : Commi ssi oni ng R e adi ngs

[Refer INSTALLATION & COMMISSIONING RECORD in Appendix for reference]

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4.0 RESULT AND CONCLUS ION

Fr om th e COMMISSIO NING Re sul t (r efer Fi gure 2), i t can be c on cl uded t h a t th e over a l l

per for m an ce of t h e com pl et ed CP S yst em i s g ood a n d th e wh ol e s yst em i s i n good wor ki n g
or der .

For OFF POT E NT IAL Cr i t er i a, th e An ode P ot en t i a l Rea di n g i s a bove t h e st a n dar d

r equir em en t l evel i . e. 1. 40 V (for n ew Hi gh Pot e n ti a l Ma gn esi um An ode). An ode Curr en t
Rea di n g a l so sh ows p osi t i ve r ea di n g. Th ese i n di ca t e t h at th e in sta l l ed Ma gn esi um An ode
i s hi gh l y a ct i ve a n d in good p er for m an ce.

For ON POT E NT IAL Cr i t er i a, th e Pi pe t o S oi l (P/ S) P ot en t i a l Rea di n g i s wel l a bove t h e

m in i m um St an dar d CP Pr ot ect i on Le vel i . e. t h e P/ S P ot en t i a l Rea di n g i s m or e n ega ti ve
t han 0. 950 V.

Thi s c onfi r me d that the Pi pe Ri se r i s ful l y pr ote c te d.

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5.0 MAINTENANCE

Pi pel i n e Corr osi on Con tr ol Mea sur es can be h i gh l y e ffe ct i ve i f t h e CP Syst em i s pr oper l y
desi gn ed, i n sta l l ed an d ma in t ain ed a dequa t el y. Sa cr i fi ci a l CP S yst em i n st a l l ed in th i s
pr oje ct a ct ua l l y d oe s n ot r equi r e ext en si ve m a i nt en an ce. A r egul a r ph ysi ca l ch eck on th e
s yst em esp eci a l l y a t th e T est St a ti on i s essen t i a l t o en sur e th e CP Syst em i s a l wa ys
m a in ta in ed in good c on di t i on .

Spe ci a l a t t ent i on sh oul d be gi ven t o m a i n t en ance of t h e T est St a t i on fr om va n da l i sm or

T hir d Par t y exca va t i on s. Fa i l ur e t o r ect i fy ea r l y a n y da m a ged on T est St a ti on , un der gr oun d
CP Ca bl es, Th er mi t e Wel ds or even th e Ma gn esi um An ode c oul d r esul t in th e pi pel in e bei n g
n ot pr ot ect ed for a per i od of t i m e.

Ca r e sh oul d al so be t a ken t o m a int en an ce of t he CP Ca bl es c on n ect i on s in si de th e T est

St a t i on s. Possi bl e l ow dr i vi n g pot en t i al an d decr ea s e i n use ful cur r en t fl ow c oul d be
r esul t ed fr om p oor con n ect i on s of t h e j oi n t s an d h en ce r esul t ed i n l ow p er for m an ce of t h e
CP S yst em .

6.0 RECOMMENDATION

Com pl et e CP Rea di n gs Mea sur em ent i . e. Anod e Curr ent , An ode Pot en t i a l , Pi pe
Pot en t i a l an d P/ S Pot en t i a l i s r ecom m en ds t o be r ec or ded on a m on th l y ba si s dur in g
t h e in i t ia l st a ge a ft er Com m i ssi on in g, pr oba bl y for On e (1) yea r . Th ese r ec or ds sh oul d be
m a in ta in ed a s t h ey pr ovi d e a ver y us e ful r e fer en c e wh en on e i s l ooki n g for t r en ds t ha t m a y
h a ve occur r ed in th e oper a t i on of t h e s yst em ove r th a t per i od.

Howe ver i f t h er e h a ve be en a good ba si s of un de r st an din g on th e en t ir e s yst em a n d boun d

t o be n o ch a n ges or i m p or t an t corr el a t i on in da t a a n d an a l ysi s, t h en th e sur ve y p er i od c oul d
be ext en ded up t o T hr ee (3) m on th s.

If l ow pot en t i a l or a bn orm a l CP Rea di n gs r ecor ded, i n vest i ga t i on an d r ect i fi ca t i on

wor ks sh oul d be ca r r i ed out i m m edi at el y i n or der t o en sur e con t i n uous sa fet y of t h e ga s
t ran sm i ssi on pi pel in e.

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 APPENDIX
____________________________________________________________

CP FINAL DESIGN

FIELD RECORD SHEET

Installation & Commissioning Record

CERTIFICATE
Magnesium Anode
Equipment Calibration (Multimeter)
CP FINAL DESIGN Date 15.07.2015
Rev. 1 (Final)

No. CP ID. Chainage Pipe Pipe Protection Surface Soil Pipe Current Anode K Anode(s) Anode Anode Anode Anode Design Q Anode
Size Dia. Distance Area Resistivity Resistance Required Resistance Factor Resistance Current Required Quantity Capacity Years Weight
[Estimate]
D L A p Rp I Rmg K Rmg(n) Img n N Img Q
[inch] [m] [m] [m sq.] [ohm] [ohm] [mA] [ohm] [ohm] [mA] [no(s)] [mA] [years] [mA.yr] [kg]

1. CP 1 Pipe Riser 2 0.060 2 0.377 5,000 5,308 0.085 27.50 1.00 27.50 0.187 0.004 1 0.103 20 2.062 7.7

TOTAL 1 2 1
location m no.

Notes : 1) Design Life = 20 years

2) Pipe Insulation Resistance, = 0.4 x (for POLYKEN Coating), where is Soil Resistivity in ohm-cm
3) Packaged 7.7kg Mg Anode Dimensions = 15cm (d) x 80cm (l), hence Mg Anode Resistance, Rmg = 0.0055 x in ohm
4) Min. 7.7kg Magnesium Anode applied
 CERTIFICATE OF QUALITY

CQ No.: 1409360C Date: 2014-09-25

Specification: Mg Anode

PO#0404 B/L No.: HF16SG0835 B/L Date: Sep 29th, 2014

Pallet Batch Each Total Open Circuit Current Capacity

Product Mg Al Zn Mn Si Fe Cu Ni
No NO. (Max) (Max) Voltage( -V CuicuS04) Efficiency (%) Energy (A.h/g)

1 HP17D3 21408312 Bal. 0.0063 - 0.6630 0.0049 0.0014 0.0011 0.0004 <0.05 <0.30 1.81 52.03 1.14

INSPECTOR SUPPLIER

JASA IMPIAN SDN. BHD. (480507-P)

No. 75B, Jalan Utarid B-U5/B,
Seksyen U5, 40150 Shah Alam,
Selangor Darul Ehsan, MALAYSIA.
Tel: 03 7846 9557 Fax: 03 7847 2157

SIRIM
SST
CERTIFICATE OF CALIBRATION
STANDARDS
"'('(liED/TED

MS ISO/lEe 17025
CALIBRATION
SAMM NO. 088
MALAYSIA

LABOI\r-.iQ~"

DATE OF ISSUE 19 January 2015 CERTIFICATE NUMBER : SST/SAIRJ2015A/451

ISSUED BY SIRIM Standards Technology Sdn. Bhd. PAGE 1 OF 3 PAGES

(Company No.: 292201-P)

Lot 12, 18 & 20, Jalan Beremban 15112, APPROVED SIGNATORIES
Seksyen 15,40200 Shah Alam, Mohd. Fikri Mohd. Nor ~
Selangor Darul Ehsan Syahrel Shari c=J
Tel. : 03-55109066 Fax.: 03-55109077

Submitted by Jasa Impian Sdn. Bhd. Job No. : SA2015-240-1

No. 75A, Jalan Utarid, Date Received : 17 January 2015
B-U5/B,Seksyen U5,
40150 Shah Alam, Selangor.
Attn : Mr Wan Shaiful Noor

Instrument Digital Multimeter Model No. : CD800a

Manufacturer Sanwa Serial No. : 13105008591

Instrument Condition When Received: 1. Good physical condition.

Instrument Condition When Returned: 1. Calibrated and tested serviceable.

2. No adjustment done.
3. Calibration Due Date requested by customer.
4. The User should be aware that there are factors that may cause this instrument
to drift out of calibration before its specified calibration due date has expired.

Environmental Condition :-
Average Temperature 23 ) C Average Relative Humidity :( 60 1 ) %RH
Calibration Date 19 January 2015 Requested Calibration Due Date 19 January 2018

Calibration Method
This instrument was calibrated using the Calibration Procedure No. ESD!0340 Rev. 9.0

Calibration Standard(s) Used :

Instrument Type Serial No. Cal. Due Date Cal. Cert. No. Traceability;
FLUKE 5520A 9090018 03 April 2015 SST!IlR/2014-121(S) SST (SA) I NPL, U.K

The standard instruments used in this calibration are traceable to either the National Standards maintained at
the National Metrology Laboratory, SIRIM Berhad or other recognized International Standard Laboratories.

-t-
Calibration Sticker No. : SA-01-451
Measurement Uncertainty: Refer to calibration results.
Coverage Factor: k=2
Reference(s) : Manufacturer's Specification Approved Signatory

The uncertainties are for a confidence probability of approximately 95%

This certificate is issued in accordance with the conditions of accreditation granted by the SAMM which has assessed the measurement capability of
the laboratory and its traceability to recognised national standards and to the units of measurement realised at the corresponding national standards
laboratory. Copyright of this certificate is owned by the issuing laboratory and may not be reproduced other than in full except with the prior written
approval of the Head of the issuing laboratory.