Gama G Sistemleri Mhendislik ve Taahht A..

DisiMudawarratoAmmanWaterConveyanceSystemProject SpecificationforCathodicProtectionEquipmentandMaterial

Doc.No:

J08086FDSPCENV05

REV0

Pageiofi

TABLEOFCONTENTS 1. 2. Introduction................................................................................................................1 TechnicalRequirements..............................................................................................2

AppendixA:TransformerRectifierandSolarPowerUnit...................................................11 A1.CathodicProtectionTransformerRectifierUnit.................................................................11 A2.CathodicProtectionSolarCellUnit....................................................................................18

TOC

Doc.No:J08086FDSPCENV05REV0

Gama G Sistemleri Mhendislik ve Taahht A..

DisiMudawarratoAmmanWaterConveyanceSystemProject SpecificationforCathodicProtectionEquipmentandMaterial

1. 1.1 INTRODUCTION Scope

Doc.No:

J08086FDSPCENV05

REV0

Page1of26

This specification describes the requirements for the cathodic protection equipment and materials required for systems along the water conveyor, wellfield, and at Mudawarra, regulatingtank,breakpressuretank,MadabaBridge,AbuAlandaandDabuksites. 1.2 ApplicableStandards NACESP02862007 Electrical Isolation of Cathodically Protected Pipelines Design, Installation, Operation, and Maintenance of Impressed Current Deep anodeBeds ControlofExternalCorrosiononUnderground orSubmergedMetallicPipingSystems FieldMeasurementofSoilResistivityUsingthe WennerFourElectrodeMethod Petroleum&NaturalGasIndustriesCathodic ProtectionofPipelineTransportationSystems. OnlandPipelines CathodicProtection,CodeofPracticeforLand andMarine The Use of Coupons for CP Monitoring Applications Measurement Techniques Related to Criteria forCOonUndergroundofSubmergedMetallic PipingSystems Protection against corrosion by stray current fromdirectcurrentsystems

NACESP05722007

NACESP01692007

ASTMG5795a

ISO155891

BS7361:Part1

NACERP01042004

NACETM04972002

BSEN50162

CathodicProtectionEquipmentandMaterial

Doc.No:J08086FDSPCENV05REV0

Gama G Sistemleri Mhendislik ve Taahht A..

DisiMudawarratoAmmanWaterConveyanceSystemProject SpecificationforCathodicProtectionEquipmentandMaterial

DDCEN/TS15280

Doc.No:

J08086FDSPCENV05

REV0

Page2of26

Evaluationofaccorrosionlikelihoodofburied pipelinesApplicationtocathodicallyprotected pipelines Standard Recommended Practice Mitigation ofAlternatingCurrentandLightningEffectson Metallic Structures and Corrosion Control Systems Cathodic Protection of buried or immersed metallic Structures General principles and applicationtopipelines

NACESP0177

BSEN12954:2001

2. 2.1

TECHNICALREQUIREMENTS CathodicProtectionSystems

Cathodicprotectionforthewaterconveyorandwellfieldpipingshallbebasedonimpressed current systems which shall have a 50 year design life from the completion of system commissioning. Theentireconveyancesystemincluding thewellfieldpipingsystemwillbesegregatedinto sixindependentsections.EachsectionshallbeprotectedindependentlywithaseparateCP system. The extremities of each section shall be isolated from the above ground facilities utilisinginsulatingflangekits. TheCPdesignsshallbebasedontheavailabilityofacpowersourcealongtheconveyorand thewellfieldarea.Consequently,thecathodicprotectionstationsshallbeinstalledcloseto theconveyorinletandoutletatthefollowingsites: Wellfield Mudawarra RegulationTank BreakpressureTank Madaba AbuAlanda DabukReservoir ThreeotherCPstationswillbelocatedremotelyfromtheabovestatedsites(ontheoffroad and highway section) in which solar units may be used in case the provision of ac power source is not possible. Actual location of each CP station will be stated in the final design drawings.
CathodicProtectionEquipmentandMaterial Doc.No:J08086FDSPCENV05REV0

Gama G Sistemleri Mhendislik ve Taahht A..

DisiMudawarratoAmmanWaterConveyanceSystemProject SpecificationforCathodicProtectionEquipmentandMaterial

2.2 EnvironmentalConditions

Doc.No:

J08086FDSPCENV05

REV0

Page3of26

Ambientairtemperaturerangethroughouttheprojectareasfollows, Maximumambientairtemperature 50oC Minimumambientairtemperature 2.3 InspectionandTests 10oC

The Manufacturer shall make available all equipment and materials for inspection by the Employerandconductalltestsasnecessarytoshowfullcompliancewiththespecificationto thesatisfactionoftheEmployer. Intheeventthatinspectioniswaived,thenthisshallnotreleasetheManufacturerfroman obligationtosupplycompletelysatisfactorymaterialsandequipment. 2.4 Cable

Cable for DC service shall be multiple stranded conductors, single core copper XLPE/PVC 600/1000voltgradetoIEC60502. Cablefordeepwellgroundbedserviceshallbesinglecore,copper,Kynar/HMWPE600/1000 voltgradetoASTMD1248. CableforACpowersuppliestoCPstationsshallbethreecore,copperXLPE/PVC/SWA/PVC 600/1000voltgradetoIEC60502.

CathodicProtectionEquipmentandMaterial

Doc.No:J08086FDSPCENV05REV0

Gama G Sistemleri Mhendislik ve Taahht A..

DisiMudawarratoAmmanWaterConveyanceSystemProject SpecificationforCathodicProtectionEquipmentandMaterial

Doc.No:

J08086FDSPCENV05

REV0

Page4of26

Cablesizingshallcomplywiththefollowing, Items Magnesium anode, monitoring referenceelectrodecabletails: Test/monitoringcables: coupon, Minimum CableCoreSize 6mm2 10mm2

Impressed current anode cable tails, zinc 16mm2 ribbon/electrodeconnectionatcasings: Foreigncrossingbondingstationcable 16mm2

AC and DC stray mitigation bonding, zinc electrode/ribbon connections for earthing, IJ 25mm2 surgearrestorscabletails: Negative and positive DC supply, positive DC groundbed distribution cables , Interpipeline 35mm2 bondsandelectricalcontinuityjumper Cablecolourcodingshallcomplywiththefollowing, Items Cable Insulation/Sheath

Magnesium anode, foreign pipeline cables, zinc red/red ribbon/electrode connection at casings: Monitoringcoupons: Permanent electrodes: reference brown/grey blue/grey

Zinc electrode/ribbon greenyellow connectionsforearthing: Positive DC supply, DC red/red groundbeddistributioncables: Othercables black/black

CathodicProtectionEquipmentandMaterial

Doc.No:J08086FDSPCENV05REV0

Gama G Sistemleri Mhendislik ve Taahht A..

DisiMudawarratoAmmanWaterConveyanceSystemProject SpecificationforCathodicProtectionEquipmentandMaterial

2.5 CableJointKits

Doc.No:

J08086FDSPCENV05

REV0

Page5of26

Cablejointkitsshallbepurposemadeepoxyfilledplasticjointboxes.Eachkitsuppliedwitha suitablysizedelectrolytictinnedbrassthroughjointcableconnector. 2.6 CableIdentificationTags/Sleeves

Temporarycableidentificationshallbeeffectedbyusingwriteonselflaminatingvinylcable markers. PermanentcableidentificationshallbeeffectedbyusingslideonPVCZtypeand/orcaptive PVCovalcablemarkers. 2.7 CableTerminationLugs

Cablelugsshallbeelectrolytictinnedcoppercrimpcompressiontype,suitablysizedtofitthe cabletobeterminatedandtheterminalconnection. 2.8 CabletoPipeConnections

AllcabletopipeconnectionsshallutilisethreadedstudsofM8minimumsize. Studsshallbeconnectedtothepipebydrawnarcbraze.Allconnectionsshallcomplywith Projectweldingprocedures. Test/monitoring cables shall not utilise the same stud as current carrying or mitigation earthingcables. 2.9 CableMarkingforBurial

Cabletilesshallbeprecastconcrete,bakedclayorrecycledpolyethylene,minimum width 200mm,marked`DangerElectricity'. Cable warning tape shall be yellow polyethylene, minimum width 100 mm and marked `CautionElectricityCableBelow'every500mm. 2.10 CarbonaceousBackfill

Carbonaceousbackfillshallbecalcinedpetroleumcokemeetingthefollowingrequirements, Fixedcarbon: Specificgravity BulkDensity: > 99% >2.0 >800kg/m3

CathodicProtectionEquipmentandMaterial

Doc.No:J08086FDSPCENV05REV0

Gama G Sistemleri Mhendislik ve Taahht A..

DisiMudawarratoAmmanWaterConveyanceSystemProject SpecificationforCathodicProtectionEquipmentandMaterial

Doc.No:

J08086FDSPCENV05

REV0

Page6of26

Particlesizerange(dia) i)horizontal&shallowvertical groundbeds: ii)deepwellverticalgroundbeds: Resistivity: Ashcontent Volatiles Moisturecontent 0.1to10mm 90%15mm,max12mm <0.15ohm.cm@10Bar >0.20% >0.60% >0.60%

Backfillshallbesuppliedinsacksordrums.Individualcontainersshallnotweighmorethan 25kg. 2.11 GroundbedSurfaceMarkers

Postsforthemarkingofhorizontalandshallowverticalimpressedcurrentgroundbedsshall bereinforcedconcretehavingasectionapproximately100mmx100mmandlengthof1000 mm. CastintoatleastonefaceofthepostshallbetheinscriptionGROUNDBED. 2.12 ImpressedCurrentAnodes

2.12.1 SiliconIronAnodes AnodesshallbeofacasthighsiliconironandshallmeettherequirementsofBS1591Grade Si14witha1415%byweightsilicon. Anodes for horizontal and shallow vertical groundbeds shall be supplied with a 16 mm2 (7/1.70mm)singlecore,copper,XLPE/PVCcabletail.Thecabletaillengthshallnotbeless then3m. Thecable/anodeconnectionshallbecaulkedleadorapprovedequivalentmethod.Thecable connectionshallbesealedandprotectedoverallbyacastresincapwhichshallencasethe insulationandsheathingendsofthecable,asectionoftheanodeheadandanyadditional cableretainingfixings.Theresinusedshallbecompatiblewiththeintendeduse. Thecable/anodeconnectionshallbeprovidedoverallwithaheatshrinkanodecap.

CathodicProtectionEquipmentandMaterial

Doc.No:J08086FDSPCENV05REV0

Gama G Sistemleri Mhendislik ve Taahht A..

DisiMudawarratoAmmanWaterConveyanceSystemProject SpecificationforCathodicProtectionEquipmentandMaterial

Doc.No:

J08086FDSPCENV05

REV0

Page7of26

Allanodesshallbegenerallyfreefromshrinkage,porosity,blowholesandsurfacedefects. Any surface defect having a penetration in excess of 6.5 mm shall render the anodes unacceptable. Eachanodeshallbetestedandcertifiedasconformingtothefollowing: TenamperesDCshallbepassedthroughthecableandanodebodyandtheinitialvoltdrop acrossthecable/anodeassembly,excludingthevoltdropduetothecableresistance,shall notexceedfivemillivolts.Thevoltdropmeasuredafter10minutescontinuouscurrentflow shallnotexceedtheinitialmeasurementsbymorethan10%. Theanodesshallbepalletpackagedandsuitablyprotectedagainstdamageforfreightingto site. 2.12.2 MixedMetalOxide AnodesshallbetitaniumcoretoASTMB338orB265Grade1providedwithamixedmetal oxidecoatingofIrO2andTa2O5. Anodes for horizontal and shallow vertical groundbeds shall be supplied with a 16 mm2 (7/1.70mm)singlecore,copper,XLPE/PVCcabletail.Thecabletaillengthshallbenotless then3m. Anodesfordeepwellgroundbedsshallbesuppliedwitha16mm2(7/1.70mm)singlecore, copper, Kynar/HMWPE cable tail. The cable tail length shall depend on the depth of the anodesinthedeepwell. Theanodecableconnectionshallbeaprovenfactorymadeconnectionwhichshallbetested andcertifiedashavingaresistanceoflessthan0.001ohms. Thecable/anodejunctionsshallbeprovidedoverallwithaheatshrinksleeve. Theanodesshallbepalletpackagedandsuitablyprotectedagainstdamageforfreightingto site. Thesizeofeachanode,thenumberof anodesperstringandthespacingbetweenanodes shallbeasdetailedintheBillofQuantities. 2.12.3 LinearAnodes Linearanodesshallbemadeofcoppercoredmixedmetaloxideanode(MMO)poweredbya 10 mm2 copper cable insulated with an inner layer of halar and outer layer of high molecular weight polyethylene. The central MMO wire and cable shall be surrounded by factory prepackaged, high conductivity coke breeze, held in place by porous, woven acid resistantjacket.
CathodicProtectionEquipmentandMaterial Doc.No:J08086FDSPCENV05REV0

Gama G Sistemleri Mhendislik ve Taahht A..

DisiMudawarratoAmmanWaterConveyanceSystemProject SpecificationforCathodicProtectionEquipmentandMaterial

Doc.No:

J08086FDSPCENV05

REV0

Page8of26

The following test method shall be carried out and test results shall be provided by the ManufacturertotheEmployerpriortosupply: Property Copper Conductor Dimensions CokeBreeze Fixedcarbon Resistivity FabricJacket Weight Burstingstrength Abrasion Resistance Fluidresistance Chlorine resistance UVresistance 2.13 MagnesiumAnodes TestMethod ASTMB263 ASTMD172 @23C,10bar ISO3303 ASTMD4157 Internalimmersiontest6 months Internalimmersiontest6 months ASTMG53 AcceptedValue 10mm2 99.5% <1Ohmcm Min.200g/m >500N 200cyclestofail pass pass <50%tear strengthloss

Magnesiumanodesshallbetothefollowingcomposition: Manganese Aluminium Copper Iron Nickel Lead : : : : : : : : 0.51.3% 0.01%max 0.02%max 0.03%max 0.001%max 0.01%max 0% remainder
Doc.No:J08086FDSPCENV05REV0

Silicon Magnesium

CathodicProtectionEquipmentandMaterial

Gama G Sistemleri Mhendislik ve Taahht A..

DisiMudawarratoAmmanWaterConveyanceSystemProject SpecificationforCathodicProtectionEquipmentandMaterial

Opencircuitpotential: Currentefficiency Capacity : :

Doc.No:

J08086FDSPCENV05

REV0

Page9of26

1.75voltsref.Cu/CuSO4 50%minimum 1230amp.hrsperkg

Meltanalysisandtestcertificatescertifyingcompliancewiththeaboverequirementsshallbe providedbytheContractor,witheachbatchofanodes,whendirectedbytheEmployer. Each anode shall be fitted with a 6 mm2 (7/1.04 mm) single core, copper PVC/PVC or XLPE/PVC red/red cable tail, brazed to the steel insert. The cable connection shall be fully sealedtopreventmoisturepenetration. Anodesshallbesuppliedprepackagedinabackfillofthefollowingcomposition, Powderedgypsum: Granularbentonite: Anhydroussodium sulphate: 75% 20% 5%

Thebackfillshallbecontainedwithinacottonbagandtheanodeshallbecentrallylocated withinthebackfill. 2.14 ACCurrentMonitoringCoupons

MonitoringcouponsshallcompriseasteelcouponsetinaPVChousingcompletewithcable tail.Coupon/cableconnectionshallbefullyencapsulatedandbesuitableforburial. Theareaofexposedsteelcouponshallbe1.0cm2. Cabletailsshallbe6mm2(7/1.04mm)singlecore,copper,PVC/PVCorXLPE/PVCblue/grey. 2.15 SolarPowerUnits

Solarpowerunitshallbeutilisedwhencathodicprotectionstationislocatedremotefromac powersource.Thesolarpowerunitshallcompriseofphotovoltaicpanels,chargeregulator, CPCU and battery bank. Solar units shall be sized to endorse the operation of the SCADA systemwhichshallprovideoutputcurrent,outputvoltage,pipepotential,andunauthorised accessalarmtransmitterfortheunit. SolarpowerunitsshallfullycomplywiththerequirementsdetailedinAppendixA. 2.16 TestPost/PillarFacilities

Test post/pillars shall be BigFink and FinkLet or equivalent which provides convenient and easytest/monitoringandfullcableprotection.
CathodicProtectionEquipmentandMaterial Doc.No:J08086FDSPCENV05REV0

Gama G Sistemleri Mhendislik ve Taahht A..

DisiMudawarratoAmmanWaterConveyanceSystemProject SpecificationforCathodicProtectionEquipmentandMaterial

Doc.No:

J08086FDSPCENV05

REV0

Page10of26

Cableconnectionsinpostsshallbeaminimum ofM8brassorstainlesssteelbolt,nutand washerassemblies,fullyinsulatedfromthefacilityhousingwherethehousingismetallicor ofconcrete. Cableconduitshallbeaminimum75mmdiameterfortheBigFinkand25mmdiameterfor theFinkLetorequivalenttestpost. Each test post shall be supplied fitted with marker plates to identify the pipeline location/sequencedesignationandfacilitytype. 2.17 JunctionBoxes

Positiveandnegativewall/framemountingenclosuresshallbemanufacturedfromstainless steelplateof1.5mmthickness. TheenclosureshallbefittedwithcableentryplateandaM8threadedstudforearthingto base,doorandmountingplate. Thedoorshallbesecuredtothebasebymeansofatmin.twohotgalvanizedhingesandits angleofopeningisatleast130.Thedirectionofturnofthedoorshallbeleftrightandis reversible,andareclosedbymin.twolockingsystem.Thedoorsshallbesealedfromany outercontaminantsordustusingseamlesspolyurethanegasket. TheenclosureshallachieveaminimumprotectiondegreeofIP65. 2.18 TransformerRectifierUnits

Where ac power is available transformerrectifier units for CP stations shall provide a full waverectifiedDCoutputfromasinglephase230volt,50HzACinputsupply.Unitsshallbe variaccontrolled.Unitsshallbeoilcooledandsuitableforplinthmounting. TransformerrectifierunitsshallfullycomplywiththerequirementsdetailedinAppendixAto ensureminimumstandardsandharmonisationofunitsthroughoutthepipelinesystem. 2.19 ZincRibbon

Zinc ribbon shall be of diamond cross section cast Zinc to MILA18001K, on a galvanised steelwirecore. Meltanalysiscertificatescertifyingcompliancewiththeabovecompositionshallbeprovided bytheContractor,witheachbatchofribbon,whendirectedbytheEmployer.

CathodicProtectionEquipmentandMaterial

Doc.No:J08086FDSPCENV05REV0

Gama G Sistemleri Mhendislik ve Taahht A..

DisiMudawarratoAmmanWaterConveyanceSystemProject SpecificationforCathodicProtectionEquipmentandMaterial

AppendixA: A1. 1.

Doc.No:

J08086FDSPCENV05

REV0

Page11of26

TransformerRectifierandSolarPowerUnit

CathodicProtectionTransformerRectifierUnit GENERAL

Transformerrectifier unit shall provide a full wave rectified DC output from a single phase 230volt(+10%,6%),50Hz(+2%)ACinputsupply. Themaximumdcoutputvoltageshallnotexceed48volts. The unit shall be oil cooled and suitable for plinth mounting in the project environmental conditions. 2. OILTANKANDCONTROLENCLOSURE

Theunitshallgenerallycompriseasealedoiltankandexternalcontrolenclosure. Theoiltankshallbeaweldedsteelconstructionandbesosizedthatadequateoilcoolingis providedwhentheunitisoperatingcontinuouslyatfullload. The oil tank shall be provided with a silica gel breather, oil filler cap, oil drain valve, dial thermometerandpocketandoillevelsightgaugeanditscompletefillingofoil. Thecontrolenclosurefortheunitshallbemountedontheoiltank,havefrontaccessviaa hinged,lockabledoorandshallbeconstructedfrom3mmminimumthicknesssteelsuitably stiffenedtoformarigidunit.Allcablesfromthetankshallentertheunitviathebaseorrear oftheenclosure.Allexternalcablesshallentertheenclosureviaaremovableglandplatein theenclosurebase. Thecontrolenclosureshallcontainallcontrolsmountedonapanelforeasyandsafeaccess. TheenclosureshallconformtoEN60529protectioncategoryIP65,proofagainstdamageby dustandwater. ThetankandcontrolenclosureshallbepaintedtomeetasaminimumHighdurabilityina C3corrosivitycategoryinaccordancewithEN129445.Allpaintcoatsshalldifferinshade andthefinalpaintcoatcolourshallbeasadvisedbytheEmployer. 3. GENERALCONSTRUCTION

Allcomponentswithintheoiltankshallbeassembledonacommonrack.Thedimensionsof the rack and equipment shall be such that it may be removed and installed within the enclosureasoneortwocompleteassemblieswithonlyexternalwiringdisconnections. Theunitshallbeconstructedtofacilitateeaseofrepairandmaintenance
CathodicProtectionEquipmentandMaterial Doc.No:J08086FDSPCENV05REV0

Gama G Sistemleri Mhendislik ve Taahht A..

DisiMudawarratoAmmanWaterConveyanceSystemProject SpecificationforCathodicProtectionEquipmentandMaterial

Doc.No:

J08086FDSPCENV05

REV0

Page12of26

All hinges, fixings and items liable to fretting or mechanical damage of coatings during normal use, shall be either 18/8stainlesssteel or non ferrous materials or galvanised mild steel. Allmaterialsusedintheconstructionofthecontrolpanelandinternalfixingsshallbemade fromnonhydroscopicmaterials. All equipment and wiring shall be fully insulated from the support frame, tank, control enclosureandifmadeofconductingmaterial,thecontrolpanel. Whentheouterdoorofthecontrolenclosureisopenedtogainaccesstothecontrolsand meters,itshallnotbepossibletomakecontacttoliveterminals. A viewing window shall be fitted in the front of the control enclosure door to enable all metersandtheAChealthylighttobeviewedwithouttheneedtoopentheenclosuredoor. 4. MODEOFOPERATION

The Unit method of control shall utilise variac to provide infinite variable adjustment betweenminimumandmaximumoutputoftheunit. Variac controls shall provide constant voltage utilising handgrip for manual control of output.Allcontrolsshallbemountedonthecontrolpanel. 5. ALARMTRANSMITTERS

The unit shall be provided with output current, output voltage, pipe potential, and unauthorisedaccessalarmtransmitterscompatiblewiththepipelineSCADAsystem. 6. TRANSFORMER

The main transformer shall be in accordance with EN 60076 with separate primary and secondarywindingsonacommoncorewithClass"F"typeinsulation.Itshallbecontinuously ratedatfullcurrentandvoltageloadatthemaximumoperatingtemperature. An earthed shield shall be placed between primary and secondary windings of the main transformer. Themaintransformerefficiencyshallnotbelessthan95%. 7. RECTIFIER

The rectifier elements shall be connected for full wave rectification using a single phase bridgecircuitinaccordancewithIEC607472.Thebridgerectifiershallbecontinuouslyrated attheunitfullloadcurrentandvoltageatthemaximumambienttemperaturespecified.
CathodicProtectionEquipmentandMaterial Doc.No:J08086FDSPCENV05REV0

Gama G Sistemleri Mhendislik ve Taahht A..

DisiMudawarratoAmmanWaterConveyanceSystemProject SpecificationforCathodicProtectionEquipmentandMaterial

Doc.No:

J08086FDSPCENV05

REV0

Page13of26

Thebridgerectifiershallberatedtoprovideanadequatemarginforovervoltageandover currentsurgesandthepeakinversevoltageratingshallbe1.2kV.Voltageprotectioncircuits shall be provided to the bridge rectifier. High speed fuses shall be provided between the transformersecondaryandtherectifierbridge. 8. OUTPUTRIPPLE

The unit shall be fitted with smoothing filter circuits to ensure the DC output does not containmorethan5%ripple. 9. ELECTROMAGNETICCOMPATIBILITY

TheunitshallcomplywithEUElectromagneticCompatibilityDirective89/336/EECamended by92/31/EEC,93/68/EECandEN50082forConductedandRadiatedImmunityandEN50081 forEmissions. 10. METERS

Theunitshallbeprovidedwiththefollowingmetersmountedonthecontrolpanelbehind theviewingwindow: a) One3digitLEDDCoutputammeterwith11mmLEDsandscaled from0.01to199.9amps. One3digitLEDDCoutputvoltmeterwith11mmLEDsandscaled from0.01to199.9volts. One 3 digit LED DC potential voltmeter with 11 mm LEDs and scaledfrom0.01to199.9volts.

b)

c)

Fusesshallbeplacedinbothleadsofthevoltmeter. Beneath each meter, separate 4 mm sockets shall be provided on the panel so that measurementsofcurrent,voltageandpotentialcanbemadewithaportablevoltmeter. 11. AC/DCCIRCUITPROTECTION

A twopole miniature circuit breaker (MCB) complying with EN 60898 shall be provided to interrupt the AC supply to the unit The MCB shall be capable of carrying the maximum transformerinrushcurrentwithouttripping. TheMCBshallbeaccessiblebyopeningthecontrolenclosuredoor. ThetotalDCoutputcurrentinthenegativecircuitshallbefused. SuitablyratedsurgearrestorsshallbefittedacrosstheACinputandDCoutput.
CathodicProtectionEquipmentandMaterial Doc.No:J08086FDSPCENV05REV0

Gama G Sistemleri Mhendislik ve Taahht A..

DisiMudawarratoAmmanWaterConveyanceSystemProject SpecificationforCathodicProtectionEquipmentandMaterial

12. ACANDDCTERMINALS

Doc.No:

J08086FDSPCENV05

REV0

Page14of26

The AC terminals shall be suitably shrouded and a clear warning label shall be fitted immediatelyadjacenttotheterminals. ThelabelshallcarrythewordsSWITCHOFFATSUPPLYPOINTPRIORTODISCONNECTING. Theletteringshallberedonwhitebackground. TheDCoutputterminalsshallbesizedandratedfor35mm2singlecorecables. DCterminalsshallbeidentifiedwithwhite/black/whiteengravedlabels3mmletterheight, the negative bearing the inscription ve pipe and the positive bearing the inscription +ve groundbed. ACsupply terminalsshall have adistinctandclean separationofatleast150mm from DC terminals and all terminals shall be located at a minimum height of 250 mm above the bottomoftheenclosure. 13. CABLING

All internal wiring shall be PVC insulated with a glossy finish and shall be incapable of supportingcombustionandcapableofwithstandingthetemperaturestobemetinservice. The crosssection of copper conductors and cable terminations shall be such that the maximumratedcurrentcarriedshallnotcauseexcessivevoltdropsortemperaturerise. Allcableterminationsandterminalconnectionsofcomponentsshallbeofadequatecross sectionandshakeproof. All terminals and equipment operating at AC supply voltage levels likely to cause electric shocktooperatorsshallbeinsulatedorscreenedfromaccidentalcontact. Cable shall be neatly bunched, properly supported where required and both ends of the cablewillbemarkedwithferrulesidentifyingthecables. Allwiringwillbeterminatedwithproprietarycompressionlugsandwillbenumberedatall terminations. 14. EARTHING

Aminimumof2.5mm2singlecorePVCinsulatedgreenyellowcableshallbeusedwithinthe unit to earth all metallic components. The enclosure door, gland plates, terminal rails and similarmetallicobjectswillbesuitablygrounded. AbrassM10earthstudshallbeprovidedontheexternalsurfaceoftheunit.
CathodicProtectionEquipmentandMaterial Doc.No:J08086FDSPCENV05REV0

Gama G Sistemleri Mhendislik ve Taahht A..

DisiMudawarratoAmmanWaterConveyanceSystemProject SpecificationforCathodicProtectionEquipmentandMaterial

Doc.No:

J08086FDSPCENV05

REV0

Page15of26

Earth terminals within the enclosure shall be identified by a label bearing the inscription WarningElectricalEarthinredlettering. Preinsulatedcompressioncrimptagswillconnectallearthwiresandallearthterminalswill benumbered. 15. LABELLING

The function of all instruments, switches, terminals, indicators and the like on the control panelshallbeclearlyandpermanentlymarked,withletteringnotlessthan3mm high.All terminals shall be clearly labelled in accordance with their designation. Labels shall be engraved;blacklettersonawhitebackgroundexceptwhereredisrequired.Thelabelsshall besecuredwithcountersunkstainlesssteelscrews. Theoutsideoftheunitshallcarryamanufacturersstandardratingplate,showingthename of the manufacturer, the type of equipment, maximum operating temperature, input and outputvoltageandcurrent,kVArating,typeanduniqueserial/identificationnumber. Awhite/black/whiteengravedlabelwith12mmhighletteringshallbefixedonthefrontof theenclosureofdimensions150mmx100mmengravedwiththefollowing:

CATHODICPROTECTIONSYSTEM TRANSFORMER RECTIFIER

Voltage warning labels shall be fitted to the outside of the enclosure and shall be clearly visible. Allcomponentswithintheunitshallbegivenauniqueidentificationnumber. 16. SUNDRIES

The transformerrectifier shall be supplied complete with all external fittings to facilitate transportation,installation,operationandmaintenance. Theseshallincludebutnotbelimitedtothefollowingitems: a) b) Anengravedschematicdiagramoftheequipmentcircuitrysecurely attachedtotheinsideoftheenclosuredoor. A flush fitting lock fitted to the enclosure door and provided with threekeys.
Doc.No:J08086FDSPCENV05REV0

CathodicProtectionEquipmentandMaterial

Gama G Sistemleri Mhendislik ve Taahht A..

DisiMudawarratoAmmanWaterConveyanceSystemProject SpecificationforCathodicProtectionEquipmentandMaterial

c) d) 17.

Doc.No:

J08086FDSPCENV05

REV0

Page16of26

Asparesilicagelcartridge Twocompletesetsofallcartridgefuseslocatedonthepaneloron theinsideoftheenclosuredoor.

TESTATMANUFACTURER'SWORKS

ThefollowingtestsshallbecarriedoutattheManufacturer'sWorksinordertodetermine that the units comply with this specification. Unless otherwise specified, all electrical tests shall be carried out in a manner prescribed by the relevant standard or specification or wherenostandardorspecificationapplies,inamannerapprovedbytheEmployer. Theunitshallsatisfactorilypassthefollowingtestsandthetestresultshallberecordedand up to three copies of a test certificate setting out the result in an approved form made availabletotheEmployer: a) All circuits and apparatus shall withstand a power frequency voltage testinaccordancewiththerequirementsofEN60439. b) 500voltmeggerinsulationtestcomprising: PrimarytoSecondary PrimarytoEarth DCpositivetoEarth DCnegativetoEarth

c) The unit shall be connected up and run continuously for at least 24 hours at maximum current and voltage outputs. The 500 volt insulation test shall be repeated immediately on conclusion of the continuous24hourtestrun. d) PerformanceteststoEN60076.Theratio,polarity,noloadcurrent,no load losses, full load losses, volts and winding resistance shall be measuredandrecorded.
CathodicProtectionEquipmentandMaterial Doc.No:J08086FDSPCENV05REV0

Gama G Sistemleri Mhendislik ve Taahht A..

DisiMudawarratoAmmanWaterConveyanceSystemProject SpecificationforCathodicProtectionEquipmentandMaterial

Doc.No:

J08086FDSPCENV05

REV0

Page17of26

CathodicProtectionEquipmentandMaterial

Doc.No:J08086FDSPCENV05REV0

Gama G Sistemleri Mhendislik ve Taahht A..

DisiMudawarratoAmmanWaterConveyanceSystemProject SpecificationforCathodicProtectionEquipmentandMaterial

A2.

Doc.No:

J08086FDSPCENV05

REV0

Page18of26

CathodicProtectionSolarCellUnit

InremotelocationssolarpowerunitsshallbeusedtopowertheCPsystem.Thesolarpower unitshallconsistofaSolarPowerSupplyUnitprovidingdcpowertoaControllerUnit.The solarpowerunitshallbeacompletelyselfcontainedinstallationincorporatingthefollowing maincomponents: supportframe photovoltaicarray(solararray) storagebatteries chargeregulatorandcontroller(powerdistributionunit) CPcontrollerunit 1. CODESANDSTANDARDS

TheSolarPowerSupplyequipmentshallconformtothelatesteditionsofthefollowingcodes andStandards. IEC60904 IEC60947 IEC60157 IEC60158 IEC60185 IEC60186 IEC602691 IEC38 IEC60112 PhotovoltaicDevices. LowVoltageSwitchgearandControl Gear. LowVoltageSwitchgearandControl Gear. LowVoltageControlGear. CurrentTransformers. VoltageTransformers. LowVoltageFuses. StandardVoltages. Methods of determining the comparativesandtheprooftracking indices of solid insulating material undermoistconditions. Degree of Protection for L.V. SwitchgearandControlGear. Definitions for Switchgear and ControlGear. ControlSwitches. ElectricalInstallationsforBuildings.
Doc.No:J08086FDSPCENV05REV0

IEC60144 IEC60277 IEC60337 IEC60364

CathodicProtectionEquipmentandMaterial

Gama G Sistemleri Mhendislik ve Taahht A..

DisiMudawarratoAmmanWaterConveyanceSystemProject SpecificationforCathodicProtectionEquipmentandMaterial

IEC60408

Doc.No:

J08086FDSPCENV05

REV0

Page19of26

Low Voltage Air Break Switches, Air Break Disconnectors and Fuse CombinationUnits. Factory Built Assemblies for Low Voltage Switchgear and Control Gear. Identification of Apparatus Terminals and General Rules for a Uniform System of terminal marking, using alphanumeric notation. Classification of degrees of protectionprovidedbyenclosures Insulation coordination with low voltagesystemsincludingclearances and creepage distances for equipment. LeadAcidBatteries

IEC60439

IEC60445

IEC60529 IEC60664

IEC60896

IntheeventofconflictbetweenStandards,themoststringentshallprevail. 2. GENERALDESIGNREQUIREMENTS

ThepoweroutputfromtheSolarPowerSupplyUnitshallbesufficienttosupplytherequired loadincludingtheoperationoftheSCADAsystemplussimultaneouschargingofthestorage batteries.Theunitshallbe capableofoperatingbetweenzeroandthefullratedload.The loadshallbemaintainedbymeansofstandbybatteriesduringperiodsoflowlight(nosun days)andduringthehoursofdarkness. Themoduleshallbecapableofoperationfor24hours(1day)withoutsunlight. TheSolarPowerSupplyUnitshallbedesignedtooperateon8hourssunshineperdaybased onthesolarinsolationvalues(iethelevelofradiationreceivedfromthesun)asperSection 6. The Manufacturer shall submit the proposed design and calculations for the Employer approval.Thedesignshallincludeallinterconnectionsandinterfaces.

CathodicProtectionEquipmentandMaterial

Doc.No:J08086FDSPCENV05REV0

Gama G Sistemleri Mhendislik ve Taahht A..

DisiMudawarratoAmmanWaterConveyanceSystemProject SpecificationforCathodicProtectionEquipmentandMaterial

3. DESIGNDATA

Doc.No:

J08086FDSPCENV05

REV0

Page20of26

TheManufacturershallsubmitthefollowinginformationforEmployerapprovalpriortothe commencementofdetailedengineering: 1. 2. 3. 4. 5. 6. Fullmaterialdescriptionofthesolarmodules. Theratioofcollectingareacomparedtothetotalarea. Thelifeofmodulesandbattery. Conformancetohailstonetest. Charge/dischargecontrollerparticulars. Tiltangleofthesolarmodules.

Thefollowingdatashallbeprovidedforthesolarmodules: 1. Numberofsolarmodules. 2. Average outputofeachsolarmoduleunderthe expected operational andenvironmentalconditions. 3. IVCharacteristics. 4. OpenCircuitVoltage(Voc). 5. ShortCircuitCurrent(Isc). 6. Maximum Power Point (P max) and Operating Point under standard testconditionsandalsoat40Cand60Ccelltemperatures. Thefollowingdatashallbeprovidedforthestoragebatteries: 1. Loadpattern. 2. Batterychargersfactor(efficiency). 3. AcceptablemaximumDailyDepthofDischarge(DDOD). 4. CalculatedmaximumDDOD. 5. CalculatedaverageDDOD. 6. Acceptableminimumstateofcharge. 7. Calculatedminimumbatterybackuptime. 8. Calculatedaveragebatterybackuptime. 9. Themaximumtimetakentofullychargethebatteryattheendofthe backuptime.
CathodicProtectionEquipmentandMaterial Doc.No:J08086FDSPCENV05REV0

Gama G Sistemleri Mhendislik ve Taahht A..

DisiMudawarratoAmmanWaterConveyanceSystemProject SpecificationforCathodicProtectionEquipmentandMaterial

Doc.No:

J08086FDSPCENV05

REV0

Page21of26

10. Themaximum,average,andminimumterminalvoltagesuppliedtothe equipmentduringdayandnight. Systemlossesandderatingfactorsduetothefollowingshallbestated: 1. Chargingefficiencyofthebatteries 2. Ageing 3. Dustdeposit 4. Environmentalconditions(temperature,wind,sandstorms,hail) 5. Insolationvariationduetonormalyeartoyearstatisticalchanges 6. Currentconsumedbycontrolequipment,meteringandalarmsystem 7. Lossesincontrolequipment,wiring,fuses,diodesandcircuitbreakers TheManufacturershallsubmitevidenceofsatisfyingthebasicrequirementsbymeansofa designandsystemsimulationtakingintoaccountallparametersmentionedabove. 4. AMPEREHOURDESIGNREQUIREMENTS

Thesizeofthesystemshallbesuchthattheenergyrequirementsoftheloadcanbemetby thebatteryduringnosundays. The battery shall havesufficient capacity to meet the backup time required for the loads, withthebatteriesatthemaximumDDODandwithminimumorinsufficientinsolationduring theinterveningdays,consideringaminimumstateofchargeofthebatteryof20%. Fromtheminimumstateofchargelevel,thesystemshallalso,underconditionsofminimum daily average insolation, recharge the battery to full charge level, while at the same time supplyingratedpoweroutputtotheload. Thesolarmoduleratingshallbesuchthatatanymomentthebatterychargefactorshallbe 1.2minimum,andtheDDODshallnotbemorethan15%offullcapacity,dependingontype ofbatteryandambienttemperatureofthebatterylocation. If the solar modules are installed at a significant distance from the load and/or battery, attentionshallbegiventotheselectionoftheoutputvoltageandthecrosssectionalareaof thecablingtoavoidunacceptablelosses. Site and panel temperature must be taken into account for the performance of the solar modules.

CathodicProtectionEquipmentandMaterial

Doc.No:J08086FDSPCENV05REV0

Gama G Sistemleri Mhendislik ve Taahht A..

DisiMudawarratoAmmanWaterConveyanceSystemProject SpecificationforCathodicProtectionEquipmentandMaterial

Doc.No:

J08086FDSPCENV05

REV0

Page22of26

Electrical connections shall be made to a junction in which two bypass diodes shall be incorporatedtopreventhotspots.Eachdiodeshallhaveaminimumdirectcurrentvalueof threetimestheshortcircuitcurrentofthearrayonwhichitisinstalled. 5. INSOLATIONDATA

TheManufacturershallberesponsibleforobtaininginsolationdatafortheprojectlocation frominternationallyrecognizedsourcesandusethesameforthedesignoftheSolarPower SupplyUnit. The Manufacturer shall submit to the Employer detailed information on his source of insolation data together with his design of the Solar Power Supply Unit. These shall be submittedtoEmployerforapprovalbeforeimplementingthedesign. 6. SOLARMODULES

Thesolarmodulesshallbemountedonaframesuitableforinstallationatsite. Thesupportframeshallbeconstructedfromcorrosionresistant,heavyextrudedaluminium alloydesignedfortheclimaticconditionsandthewholeinstallationcapableofwithstanding thewindandstormconditions. This frameshallbedesignedfortiltingtothe optimumangleforabsorption ofenergyand alsoforcreatingaselfcleaningwashingofthemodulesurfacewhenitrains. Theframeshallbesuppliedwithholesorslidesformechanicalattachment.Shouldvandal protectionberequiredadequateallowanceshallbemadefortheshieldingofsolarradiation fromthepanels. 7. BATTERY

Batteriesshallbethedeepcycle,longlife,maintenancefree,andsealedtypedesign,proven for solar power system use. The effects of site temperatures on available capacity and lifetime expectancyshall be taken into account in the selection of the battery type and its housing. The expected service life shall be stated for the service conditions stated herein and shall havethefollowingfeatures: 1. Theyshallnotdegrademorethan20percentoffullcapacityovertheir servicelife. 2. Storage capacity shall be calculated to allow the load to operate continuouslyforaminimumofone(1)nosundays.

CathodicProtectionEquipmentandMaterial

Doc.No:J08086FDSPCENV05REV0

Gama G Sistemleri Mhendislik ve Taahht A..

DisiMudawarratoAmmanWaterConveyanceSystemProject SpecificationforCathodicProtectionEquipmentandMaterial

Doc.No:

J08086FDSPCENV05

REV0

Page23of26

3. Battery capacity shall not be allowed to fall below 20 percent of full capacityduringoperation. 4. Theselfdischargerateshallbe<2%permonthat20C. Cooling of the batteries shall be by natural air flow and good design practice only, forced coolingshallnotbeused. The batteries shall be arranged to facilitate access for maintenance purposes. Inter cell connectorsshallbeprovided. Batteriesshallbeofminimumfiveyearslifespan. 8. POWERDISTRIBUTIONUNIT

Eachsolarpowersupplyunitshallhaveapowerdistributionunit(PDU).ThePDUshallbeof modular design for ease of component replacement and maintenance and shall ensure propercharginganddischargingofthebatteriesthroughthefollowingfunctions: 1. Dualvoltageregulationtocaterforboostandfloatoperation. 2. Overchargeprotectionofthebatteriesbyswitchingoffthesolararray fromthesystemifthebatteryisalreadyfullycharged. 3. Battery protection by switching off the load from the system if the voltagedropsbelowavoltagelimitsandalarmcontactforwarningof lowbatteryvoltage. 4. Temperaturecompensationmaximumchargevoltage. 5. Prevention of overnight discharge of the batteries through the solar array. 6. Protectionagainstovervoltagefromthesolarmoduleoutput. 7. Protection against overload and short circuit conditions in the connectedload. The PDU shall include a voltmeter and ammeter and LED Indications for all battery alarms etc.Asaminimumthefollowingshallbeprovidedtoindicatesystemstatus: 1. Batteryvoltagebelowminimumvoltage. 2. Batteryvoltageabovemaximumvoltage. 3. Voltagefreecontactsforremoteindicationofbatterylowvoltage. ThePDUshallincorporateaSPDT(SinglePoleDoubleThrow)contactorwhichisactuatedon batterylowvoltage.Thecontactorratingshallallowfortheinductiveloadduringswitching. Alocalprogrammablemodulewithdisplaypanelshallbeprovided.
CathodicProtectionEquipmentandMaterial Doc.No:J08086FDSPCENV05REV0

Gama G Sistemleri Mhendislik ve Taahht A..

DisiMudawarratoAmmanWaterConveyanceSystemProject SpecificationforCathodicProtectionEquipmentandMaterial

Doc.No:

J08086FDSPCENV05

REV0

Page24of26

FailureofthePDUshallnotresultincatastrophicfailureofthewholesystem. Thechargecontroller should be abletooperateatvarioussystemvoltages(12V,24V,36V and48V. 9. CPCONTROLLERUNIT

TheCPcontrollerunit(CPCU)shallregulatethevoltageandcurrentoutputtothecathodic protection system to a manually set level (i.e. the CP load). The dc output shall be controllable from any value between zero and maximum, the output current shall be electronicallylimitedtotheratedmaximumoftheunit. TheCPCUshallbespecifiedandsuppliedtothefollowingrequirements: 1. The CPCU shall be suitably rated for the requirements of the CP system. 2. Theunitshallbeprotectedagainstinducedovervoltages. 3. TheunitshallhaveaCPloadMCB(miniaturecircuitbreaker)withtrip alarm. 4. Display meters shall be provided for: the CP output voltage, the CP outputcurrentandthereferencecellpotential. 5. Synchronized Interrupt timer compatible with those fitted in the transformerrectifiers Separateanaloguemetersshallbeprovidedforthecontinuousdisplayoftheoutputvoltage, outputcurrentandthepipelinedrainpointpotential.Themetersshallbeflushmountedon thecontrolpanelandvisiblethroughtheenclosuredoor. Metersshallhavescalesettingsof20%greaterthanthemaximumoutputratingoftheCPCU witharedlinetoshowthemaximumoutputvalue. EachcontrollerunitshallincorporateasynchronizedGPScurrentinterruptersimilartothat fittedinthetransformerrectifiers. The CPCU shall incorporate RTU designed to collect the DC output , AC input and pipeline potentialdataandtransmititusingGSMtextmessagingtocellphoneonadailyandweekly basis in addition to alarm messaging in case inadequate protection arise during normal operation..TheRTUshallbesuppliedwithdatamanagementsoftwarefordatadisplayand interpretation. TerminalsshallbeprovidedontheCPCUpanelforterminationoftheDCsupplycablestothe groundbed,pipeline,andthepotentialmonitoringcables.
CathodicProtectionEquipmentandMaterial Doc.No:J08086FDSPCENV05REV0

Gama G Sistemleri Mhendislik ve Taahht A..

DisiMudawarratoAmmanWaterConveyanceSystemProject SpecificationforCathodicProtectionEquipmentandMaterial

Doc.No:

J08086FDSPCENV05

REV0

Page25of26

Allcontrols,switches,fuses,metersandcableentryglandsshallbeeasilyaccessible. 10. AUXILIARYEQUIPMENT

Separate enclosures shall be provided for the PDU and the CPCU. As a minimum the enclosuresshallbeconstructedtoEN60529protectioncategoryIP65,proofagainstdamage bydustandwater. TheenclosuresshallbeprovidedwithDCcircuitbreakerprotectedterminalsforthedesign loadsandcableglandsappropriatefortheinstallationcables. TheinterconnectionbetweenthesolararrayandthePDUshallbemadebymeansofaDC circuitbreakertofacilitatetheelectricalisolationofthesolarmodulesfromthesystemfor repairorreplacement. TheinterconnectionbetweenthebatterybankandthePDUshallalsobemadebymeansof a DC circuit breaker to facilitate the electrical isolation of the battery from the system for inspectionandmaintenancepurposes. 11. INTERCONNECTIONCABLES

Allinterconnectioncablesbetweenthesolarmodules,thesolararray,thestoragebatteries andthecontrolequipmentenclosuresshallbesupplied. Allcablesshallbe600/1000Vgrade,copperconductor,PVCinsulated,PVCsheathed,steel wirearmouredwithPVCoutersheath(PVC/PVC/SWA/PVC). 12. EARTHING

M8earthstudsshallbesuppliedonallcabinetsandenclosures. 13. TESTS

The complete solar system complete with all interconnecting cables shall be tested at the Manufacturers works in accordance with applicable codes and manufacturers standard testingprocedures.Comprehensivetestforthesolarsystemshallbecarriedoutthroughout each process along the project. The Manufacturer shall submit copies of the subject test certificatestotheEmployer. Testingshallincludethefollowing: 1. Visualinspection. 2. Insulationtestonallcables. 3. Functionaltestingofthecompletesystem.
CathodicProtectionEquipmentandMaterial Doc.No:J08086FDSPCENV05REV0

Gama G Sistemleri Mhendislik ve Taahht A..

DisiMudawarratoAmmanWaterConveyanceSystemProject SpecificationforCathodicProtectionEquipmentandMaterial

Doc.No:

J08086FDSPCENV05

REV0

Page26of26

4. Loadtestingofcompleteinstallation(undermaximumCPload). 5. Batterydischargetest. 6. Measurement of typical values of solar module short circuit current andopencircuitvoltage. 14. DOCUMENTATION

TheManufacturershallsupplyinstallation,operation,maintenancemanualsforeach piece of equipment supplied and other documents as required defined in an approved Supplier DataRequirementList(SDRL),andincludingthefollowingdocumentationstobesubmitted totheEmployerforreviewandapproval; Trackrecordofmaterialsandequipment. MaterialscertificatesforanodestoBSEN10204Type3.1.B. Certificateofcomplianceforhotdipgalvanizing. Coatingmaterialscertificates. Product/Equipment/Material specifications, Manufacturers product data sheets and drawings including, where appropriate, statements of manufacturing tolerances. Qualityplancoveringmanufacture,inspectionandtestingofsacrificialanodes. Detailedinstrumentandsparepartslist. Batchanalysisforallsacrificialanodessuppliedagainstthespecification. Factory test report of tests of dimensions, casting quality and cable connection resistance. Operatingandinstructionmanuals. Asbuiltdrawings. Sparelists.

CathodicProtectionEquipmentandMaterial

Doc.No:J08086FDSPCENV05REV0