Tan Son Nhat Buried pipes

PUR - Cathodic Protection System

Operation and Maintenance Manual

OPERATION AND MAINTENANCE MANUAL

Cathodic Protection System (SGA)

for Fuel Hydrant pipeline

Tan Son Nhat International Airport

Supplier:
3C Corrosion Control Company AB
Billeberga Station
Stationplan 5
260 21 Billeberga
Sweden
Tel: +46 418 411 900
Fax: +46 418 411 935
E-mail: 3c@3ccc.se

Rev Date Description Prepared Checked Approved

- 2007-07-09 First issue J.Jacobsson S. Jensen D. Augustine

Doc Id: 373101634.doc Page 1 of 11

Date: 2007-07-09
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PUR - Cathodic Protection System
Operation and Maintenance Manual

TABLE OF CONTENT

1. GENERAL INFORMATION...........................................................................................3
1.1 Introduction...................................................................................................................................... 3
1.1.1 Scope.......................................................................................................................................... 3
1.1.2 Introduction Cathodic Protection................................................................................................. 4
1.2 System Description.......................................................................................................................... 5
1.2.1 Principle layout (Typical).............................................................................................................. 5
1.2.2 System layout.............................................................................................................................. 6
1.2.3 General design............................................................................................................................ 6
2. OPERATION..................................................................................................................7
2.1 Pre-conditions.................................................................................................................................. 7
2.2 Switching ON the rectifier............................................................................................................... 7
2.3 Switching OFF the rectifier............................................................................................................. 7
2.4 Settings............................................................................................................................................. 7
2.5 Interuppt function............................................................................................................................ 8
3. MAINTENANCE............................................................................................................9
4. TROUBLE SHOOTING...............................................................................................10

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Date: 2007-07-09
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PUR - Cathodic Protection System
Operation and Maintenance Manual

1. GENERAL INFORMATION

1.1 Introduction
3C Corrosion Control Company has under a contract with WEC Engineers &
Constructors Pte Ltd designed the cathodic protection system for outside protection of
Fuel Hydrant pipeline.

The system consists of external protection with a deep ground impressed current
system.

This manual describes the basics, functions, design and maintenance of the system.

Before starting the impressed current cathodic protection system it is assumed that
assembly have been carried out in accordance with the relevant documents.

1.1.1 Scope

The cathodic protection system consists of following parts:

Lot Part KKS- Number Location

1 MMO Anode strings Buried
4 Reference Electrodes Buried
4 Test coupons Buried
4 Test stations Outdoor
1 Rectifier 25 V / 10 A Outdoor
Cabling Buried

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PUR - Cathodic Protection System
Operation and Maintenance Manual

1.1.2 Introduction Cathodic Protection

The purpose of the cathodic protection system supplied is to protect the outside of the
buried metallic piping from corrosion.

This is achieved by the injection of energy in the form of direct current to the metal
structure being protected. In so doing, the electrical properties of the metals involved
will be changed and the natural corrosion process will be stopped.

Measuring the potential difference of the metal and a reference electrode can check
the thermodynamic condition of the metal.

When direct current is injected the potential will move to a more negative value.
The more the potential is moved, the more the corrosion process is slowed down.
Reaching the conservative - 850 mV vs Copper/Copper Sulphate, Cu/CuSO4, the
corrosion of steel can be mitigated..

The direct current is generated by rectifier units and is then distributed via the ground
by evenly distributed MMO anodes.

The effect of the corrosion protection is measured by reference electrodes.

In order to separate the earthing system from the buried pipes the above ground pipes
are separated electrically with isolation flange kits.

It is very important that the cathodic protection system is kept in continuous operation.
Exposed carbon steel parts in electrical contact with more noble metals, like stainless
steel or cupper grounding system will be subjected to severe corrosion attacks.

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PUR - Cathodic Protection System
Operation and Maintenance Manual

1.2 System Description

1.2.1 Principle layout (Typical)

Remote
Anode

Rectifier

Test Reference
Coupon Electrode

Test station

Test Reference
Coupon Electrode

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PUR - Cathodic Protection System
Operation and Maintenance Manual

1.2.2 System layout

The cathodic protection system described in this document has been specially
designed for Fuel Hydrant pipeline as outlined in the scope.

The design of the system has been based on the Main and General Standards for
Cathodic Protection, which are:
-EN 12954 Cathodic protection of buried or immersed metallic structures General
principles and application for pipelines.
-NACE RP-0169

and for measurement:

-EN 13509 Cathodic protection measurement techniques

1.2.3 General design

The system is designed to provide current distribution that is as even as possible.

The anode system is a deep anode bed. The anodes are made of MMO coated
Titanium substrate surrounded by in coke breeze.

Reference electrodes and test coupons are used to measure the potentials of the
systems and are terminated in test posts and transformer rectifier cabinets. The
electrodes are of Cu/CuSO4 type.

The rectifier current out put is controlled by turning a potentiometer.

In order to monitor the performances and operation of the system the rectifier voltage
and current can be monitored on the analogue meters.

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PUR - Cathodic Protection System
Operation and Maintenance Manual

2. OPERATION
2.1 Pre-conditions
The setting of the rectifier has been carried out during commissioning. After switching on the
rectifier the reference electrode potentials (protection levels) shall be re-checked avoiding low
protection levels (corrosion) or over-protection (coating damage).

2.2 Switching ON the rectifier

Ensure the following circuit breakers are in on position:

Circuit breaker Rectifier Description

QH1 Main breaker
F1 Earth fault relay
F2 Lamp test circuit

Switch on the rectifier with the S1 switch located on the front panel.
Check the indicator lamps AC input and Current out put are on by pressing Lamp
test button (PB) on the front panel.

Note the current and voltage in the log book by pressing Instrument button (PB1)
located on the font panel.

2.3 Switching OFF the rectifier

Switch off the rectifier with the S1 switch located on the front panel.
Check the indicator lamp AC input is on and Current out put is off by pressing Lamp
test button (PB) on the front panel.

Note Rectifier off in the log book.

2.4 Settings
The only means of adjustment is by changing the current out put. Increase the current
out put by turning the potentiometer (R1) clock wise. De-crease by turning anti clock
wise. Lock the potentiometer with the small handle located on the side of the
potentiometer.

Note the new potentiometer setting in the log book.

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PUR - Cathodic Protection System
Operation and Maintenance Manual

2.5 Interrupt function

The rectifier is prepared with an input to connect an external relay for cyclic turning the
rectifier on and off for IR-drop measurement. The relay shall be connected to terminals
on the front panel labelled Interrupt.

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PUR - Cathodic Protection System
Operation and Maintenance Manual

3. MAINTENANCE

Weekly Checks
Check rectifiers by visually checking the AC input and Current out put lamps located
on the front door.

Monthly Checks
Check rectifier cabinets/ test posts is not damaged.
Check rectifier cabinets air filters for contamination, replace/ clean if necessary.
Check the current output, voltage, potentiometer setting and note them in a logbook.
Note changes and adjust if required.
Visually check the surge protection SS1 installed in terminal X01:L1-PE and SS2
X10:4-5. They shall be replaced if they have a burned surface. Note the change in the
log book.

Annual Checks and Adjustments:

Measure manually with a portable digital multi meter/ clamp amp meter system voltage
and current output.
Reference electrodes On/Off potentials
Measure each anode circuit current output.
Calibrate reference electrodes
Check if any foreign structures in the vicinity are subject to corrosion interaction.
Compare the values with values in the logbook.
Adjust the system (rectifiers and resistor bond boxes) if necessary.

Annual checks and adjustments should be carried out only by specially trained
personnel. Reference is made to European standard EN 13509 Cathodic protection
measurement techniques.

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PUR - Cathodic Protection System
Operation and Maintenance Manual

4. TROUBLE SHOOTING
Trouble shooting below should only be carried out be trained electrician following National and
Site safety regulations.
Fault Action
No light on AC 1. Check the lamp by pressing Lamp test button (PB). Change lamp
input lamp diode if required.
2. Check main switch QH1 and circuit breakers F1 and F2 are in on
positions.
3. Check AC supply from switch gear room.
No light on current 1. Check the lamp by pressing Lamp test button (PB). Change lamp
out put lamp diode if required.
2. Check main switch QH1 and circuit breakers F1 and F2 are in on
positions.
3. Check potentiometer (R1) current adjust is not in zero position.
Increase if required.
4. Check that there is no jumper cable installed between terminal 1 and 2.
(Interrupt function) Remove the cable.
5. Check voltage on the volt meter installed on the front panel. If voltage
is maximum (25 Volt) the circuit resistance is too high and fault could be
cut off anode- or cathode- cables. Repair cables.
6. Measure DC signal from the rectifier to the potentiometer between
terminal X2:14 and X2:3. This value shall be 10V. If not replace rectifier.
7. Measure DC signal (0-10 V) to the rectifier from the potentiometer
between terminal X2:5 and X2:3. This value shall be more than zero when
the potentiometer is turned clock wise. (Not in zero position).
If not and 10V can be measured between X2:14 and X2:3, replace
potentiometer.
8. The rectifier automatically turns it self off if the temperature is more
than 65 C inside the cabinet. It will automatically re-start with the same
settings when the temperature drops below 55 C. Change location of the
rectifier to a cooler place (or increase the sunshade).

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PUR - Cathodic Protection System
Operation and Maintenance Manual

Fault Action
Volt meter do not If the volt meter do not respond after pressing Instrument button (PB1)
respond and both AC input lamp and current out put lamp is on;
1. Measure manually DC voltage between terminals P2 1-2 located on the
front panel below the voltmeter with a digital multi meter. If voltage could
be measured, replace faulty voltmeter or faulty relay PB1.

Amp meter do not If the amp meter do not respond after pressing after pressing Instrument
respond button (PB1) and both AC input lamp and current out put lamp is on;
1. Measure manually current by measuring DC (mV) between terminals
P1:1-2 (Amp meters shunt). If current could be measured, replace the
faulty amp meter or faulty relay PB1.

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