SOGEC - CP

CATHODIC PROTECTION TRAINING

MANUAL-MODULE 9

Page 1 of 12
CP Training manual Prepared on 14 Jan 2012
 INTRODUCTION
Specialized Oil and Gas Engineering Company is a major supplier of cathodic
protection services which includes Engineering, Material
supply,Installation,commissioning,monitoring and maintenance in accordance with the
standards and requirements of Major oil and gas, petrochemical and energy sector customers
across the middle east.
This training manual is intended to improve the technical competency and knowledge
of new CP technicians and engineers working with SOGEC CP.

This training manual is prepared as nine modules.

1. BASIC ELECTRICITY

2. CORROSION BASICS

3. CATHODIC PROTECTION BASICS

4. REFERENCE ELECTRODES (HALF-CELLS)

5. TYPES OF CATHODIC PROTECTION SYSTEMS

6. METHODS OF CABLE CONNECTION TO STRUCTURE

7. INSTALLATION OF CATHODIC PROTECTION SYSTEMS

8. FIELD MEASUREMENT AND TESTING OF CP SYSTEMS

9. PRECOMMISSIONING AND COMMISIONING OF CP SYSTEMS

Page 2 of 12
CP Training manual Prepared on 14 Jan 2012
 MODULE 9
PRE COMMISSIONING AND COMMISSIONING OF CP
SYSTEM
This module outlines the procedures that shall be used in the pre commissioning and
commissioning osf CP systems.The pre commissioning activities generally relate to visual
checks,recording of structure native potential,circuit resistance and general tests required for
various equipments and components of cathodic protection system prior to the final
commissioning.final commissioning shall include energisation of the transformer
rectifier,potential and current measurement and structure to electrolyte potential measurement.
.It shall be ensured that all inspection and testing is carried out in accordance with the
approved commissioning procedures and in accordance with the recommendations of the
CP equipment and instrument manufacturer.
The following CP equipments and instruments shall be available on site as a minimum.
• High impedence digital Multimeter
• Calibrated portable reference electrode
• 4 Pin resistance meter
• Clamp meter
• Current interrupters(As required)
• Misc.Test leads.
• Tool kit
Prior to the energization of CP system it shall be ensured that all pre commissioning
procedures have been performed and the results are satisfactory.
Pre commissioning Inspection and Tests
It should be noted that the sequence of inspection and testing may be adjusted to suit
site conditions and project schedules. It is anticipated that various installation checks have
been previously accomplished during installation of equipment and documented.
Transformer Rectifier
The pre-commissioning tests shall be done in accordance with Manufacturer's written
recommendations. The following tests and checks shall be performed on the Transformer
rectifier unit.

Page 3 of 12
CP Training manual Prepared on 14 Jan 2012
 • A visual inspection of Transformer Rectifier unit shall be performed to ensure that the
installation is in accordance with pertinent project drawing and specifications and that
the unit has not been physically damaged prior to operation. Any deviation and
discrepancies shall be noted and rectified.
• All panel connections and terminals shall be checked for proper tightness. All loose
connections shall be tightened.
• Correct installation of oil and silica gel breathers shall be verified.
• The polarity of DC output cables shall be verified to ensure that the positive output
cables are connected to the anode terminals and the negative terminals are connected to
the structure and both are clearly labeled.
• Verify that the power supply to the Transformer Rectifier is of the required rating.
Measure and record the AC supply voltage at the input terminals of the Transformer
rectifier circuit breaker.
• Verify and ensure that the Transformer Rectifier is properly grounded to the earthing
system.
• Ensure that all fuses are of proper current and voltage rating. Check the continuity of all
fuses using an ohm meter.
• The pre commissioning data sheets shall be duly signed by the contractor and/or client
representatives.
Pre- commissioning test of TR may also include the following,
• energize and test without load for one hour;
• Testing at 50% capacities for two hours with dummy load connect to the DC side;
• Testing at 100% capacity for two hours with dummy load connected to the DC side;
• Calibration of the unit’s meters; de-energizing and connecting of DC cables to the
appropriate terminals.
• If an electronic component of the rectifier needs to be replaced during the pre
commissioning tests, e.g. due to rectifier malfunction or failure of the unit to fulfill the
performance requirements, then the pre-commissioning test shall be repeated.
Total circuit resistance test
After the proper polarity of the DC output cables has been confirmed and the cables have been
labeled with permanent tags, disconnect the anode and the cathode cables from the DC output
terminal of the transformer rectifier.

Page 4 of 12
CP Training manual Prepared on 14 Jan 2012
Using a four pin resistance meter with P1/C1 and P2/C2 terminal shorted,connect the test leads
of the instrument across the cables and measure the resistance.
This testing shall be done to measure the overall circuit resistance of the CP system and to
ensure that no short circuit exist between the anode (positive) and cathode (negative).
The result shall be recorded in the pre commissioning form.
Reconnect the DC positive and negative cables at the TR unit.
Junction Box (AJB, NJB, Isolation test box,Test box)
All CP cables shall be terminated in the appropriate junction boxes. Following information
shall be recorded on data sheet.
• Junction box type
• Junction box ID
• Structure ID
• Cable details
• A visual inspection of the junction box shall be performed to ensure correct installation
and that the components have not been physically damaged prior to operation. Any
discrepancies shall be noted and rectified.
• All cable connections and terminals shall be checked for tightness. All loose
connections shall be tightened.
• All cables shall be checked for proper tagging and to ensure that components are as per
the design/drawing.
Native potential measurement
• For impressed current CP systems before energizing of transformer rectifier unit,
disconnect all temporary galvanic anodes and allow the structure to depolarize. After
depolarization measure and record the native potential over the pipe line at all available
test stations, permanent reference electrode locations, Bonding stations, foreign
crossing stations, Isolation flange locations, HT line crossing stations etc.
• For tanks with mmo grid underneath the tank, measure the native potential at all
permanent reference electrode locations, through perforated monitoring duct and
through soil access tube.
• For other structures follow the project specifications.

Page 5 of 12
CP Training manual Prepared on 14 Jan 2012
COMMISSIONING OF CP SYSTEM
It should be understood that the sequence of inspections and test may be altered to meet
site conditions and project schedules. It is anticipated that various pre-commissioning
activities will have been previously accomplished during installation of equipments or will
be carried out in conjunction with commissioning procedures.
During commissioning, it shall be ensured that (a) all CP system components are
operating within manufacturer's and design parameters, and (b) detrimental effects on other
structures caused by the operation of the CP system are minimized and within acceptable
tolerance levels and (c) the structure potential meets the acceptance criteria.
Sacrificial Anode CP system
Sacrificial anode CP systems are normally commissioned immediately after the
installation.
The basic steps shall be as follows.
• Electrical continuity of structure shall be tested and ensured.
• Electrical isolation from other structures shall be tested and ensured.
• Before connection of the sacrificial anodes, the natural potential of the structure and
the open circuit potential of the sacrificial anode shall be measured and recorded at
all test stations, including the “unprotected” side of isolating joints/flanges.
• After connection of the anodes the structure potential and the current at each anode
shall be measured and recorded. The current measurement shall perform using a
shunt.
• The structure shall be allowed to polarise for at least 24 hours, after which the
structure to soil potential shall be measured and recorded at all test stations.
Potential of structure shall be measured by placing reference electrode close to
pipe/structure (use soil access tubes if provided) at the anode location and midpoint
of anodes.
• All potential values shall comply with the design protection criteria.
• If potential is below the criteria, analyze the cause. If additional anodes required,
install additional anodes.
• If current exceeds the design limit, install additional anodes to compensate the design
life.
• The structure to soil potential at the “unprotected” side of the isolating joints/flanges
shall be measured and recorded. If a polarisation of more than 20 mV from the natural
potential is measured in either polarity direction, the isolating joint/flange shall be
checked.
• All the measurements and testing shall be recorded in an approved format.

Page 6 of 12
CP Training manual Prepared on 14 Jan 2012
Impressed Current CP system
The commissioning of impressed current cathodic protection system involves the following:
• A performance evaluation of power supply(Transformer Rectifier or solar power
supplies)
• An evaluation of current distribution in anode bed(s)
• Measurements of structure-to-electrolyte potentials to determine the protection
status of the structure(s).
• An evaluation of current distribution in the negative circuits, if applicable.
• Interference testing with foreign structures.

All temporary Cathodic Protection, bonds with foreign structures and earthing facilities
shall be disconnected (if possible).
The power source shall be energised and the output adjusted from zero using manual
voltage control, to obtain a structure-to-soil potential at the drain point of about -1000 mV
versus a Cu/CuSO4 reference electrode.
The voltage and current output shall be recorded. The current measurement shall be
done performed using a shunt. The potential at the drain point shall be measured after initial
energising and after polarisation. If the potential exceeds the overprotection limit, the
current output shall be reduced.
If more than one structure is protected by the same power source, the current to each
structure shall be adjusted by changing the resistor value in each drain cable.
After at least 24/48 hours of polarisation, the structure to electrolyte potential at key
monitoring stations such as pipeline mid points and remote locations shall be measured at
regular intervals and the necessary adjustments shall be made to achieve protective
potentials throughout the structure.
For uncoated structures and for structures with aged coatings full polarization may
require several days, up to several months.
Individual anode outputs shall be measured and recorded. Where resistors have been
provided in individual anode circuits, the outputs of the anodes shall be balanced within the
design capacity.
Where earthing facilities/polarization cells have been installed to mitigate induced AC
voltages, AC potentials shall be recorded prior to and after the connection of the zinc
earthing.

Page 7 of 12
CP Training manual Prepared on 14 Jan 2012
 The insulating effectiveness of isolating joints and isolating flanges shall be checked.
After polarization, structure to soil ON/OFF potentials shall be measured at all test
facilities. The measurements shall be carried out by interrupting the power source. The
permissible duration of the interruption depends on the rate of depolarization, which is
determined by local conditions (Typical 4 sec ON, 1 sec OFF). In extreme conditions, for
instance sandy soil of high specific resistance, it must not be more than one second per
minute.
Where automatic potential controlled power sources are used, ON/OFF potential
measurements shall be performed with the potential control circuit switched off and the unit
adjusted manually to the required potential. If potential control has been installed, the
potential setting shall be adjusted to the required drain point potential and the potential
control switched on. If voltage and/or current limiting circuits have been installed, the
settings of these circuits shall be adjusted to a value approximately 10% higher than the
recorded voltage and current output. Such a setting will prevent overprotection in case of
failure of the potential control circuit while allowing sufficient swing in case of a change in
current demand.
Interaction testing on all foreign structures/pipelines crossing or in close proximity to
the object shall be carried out. Where bonding stations are provided, adjustments shall be
made to the resistive bonds, so that interference to the foreign stctures/pipelines remains
within acceptable limits.
Potential measurements on marine facilities shall be carried out with the power source
Potential and Current Measurements
General
For structures surrounded by soil, measure the structure potential with a portable copper-
copper sulfate reference electrode. With the exception of well casing potential measurements,
place the reference electrode in close proximity to the structure to minimize measurement
error associated with voltage (IR) drop in soil. Avoid placement of the reference electrode near
buried anodes, bare copper grounding cables, or steel reinforced concrete pilings or
foundations as this may generate erroneous readings and should be avoided.
For structures surrounded by water, measure the structure-to-water potentials with a
portable silver-silver chloride reference electrode. During the potential measurements, keep
the reference electrode as close as possible to the structures. If there are anodes in the area of
the potential measurement, locate the reference electrode midway between the anodes.
Measure potentials at well-defined locations to allow for future monitoring.

Page 8 of 12
CP Training manual Prepared on 14 Jan 2012
 If stationary reference electrodes are installed to monitor the protection levels on a
structure, measure the structure potentials with reference to these electrodes. However, the
potentials of the stationary electrodes shall be compared with the potential of the portable
reference electrode used in the commissioning survey to validate the potential values measured
by these stationary electrodes.
Submarine Pipelines
Measure potentials at both ends of the submarine pipe, at the anodes, and at midpoint
between two anodes. The measured potentials shall comply with the CP potential criterion. If
the pipeline starts from or terminates at an onshore facility, measure the potentials on the
section(s) buried in this facility to ensure that the protection levels meet the CP criterion for
plant buried pipelines. Record the potential survey data in an approved format.
Offshore Platforms
If the structures are protected by an impressed-current anode system(s), set the current
output to operate at approximately 90% of the design current requirement, prior to taking the
potential measurements.
For the structures protected by galvanic anode systems, no adjustment is required prior
to the potential measurements. Measure potentials on each main platform jacket leg, on each
pipeline riser, and on each well conductor. The minimum required numbers of potential
measurements are as follows:
a) In water depths of 15 meters or less, take potential measurements at three locations:
the sea bed, one meter below the surface, and the midpoint.
b) In water depths of 15 to 30 meters, take potential measurements at four locations: the
sea bed, three meters above the sea bed, one meter below the surface, and the midpoint.
c) In water depths of 30 meters or more, take potential measurements at five locations:
the sea bed, three meters above the sea bed, one meter below the surface, and two intermediate
depths.
Record the potential survey data in an approved format.
Onshore Buried Pipelines
For buried cross-country pipelines, flow lines, trunk lines, and test lines, measure
potentials at all KM markers, road crossings, valves, and other locations containing test points
and/or bond stations. For the potential measurements, place the portable copper-copper sulfate
reference electrode directly above the pipelines. After the "As-Found" potentials are measured,
energize the CP system, and set the current output of the impressed-current anode system(s) to
operate at approximately 90% of the design current requirement. During this "On" potential
survey, take the first potential measurement at the negative drain point to ensure that potentials
do not exceed the maximum potential allowed per specification. If all the pipe potentials meet
these potential criteria, fine tune the rectifier current output to maintain the protection levels

Page 9 of 12
CP Training manual Prepared on 14 Jan 2012
within the allowable range. Report the results of the potential measurements together with any
deficiencies found during commissioning.
Tank Internals
After recording the "As-Found" potential measurements, set the current output of the
impressed current anode system to operate at approximately 90% of the design current
requirement. For the galvanic anode systems, no adjustment is required.
For tanks with access holes from the tank roof, measure the "On" potential
measurements at three depths: 1) the tank bottom, 2) the midpoint, and 3) one foot below the
water level.
Do not place the reference electrode close to the anodes on an anode string but rather
between anodes. For both the impressed current and galvanic anode CP systems, measures the
current output of the anodes associated with each tank, and record it. The measured potentials
shall meet the CP potential criteria.
. Stringent adherence to all required safety precautions, including the use of fall
prevention devices, is required when personnel are taking measurements through tank roof
access holes.
Tank internal CP system commissioning for water tanks should only be done when the
tank is 100% full. This will ensure that the CP system is set to provide protection for the full
wetted surface area of the tank.
Measure potentials through the reference cell access holes that are installed 150 mm
from the tank shell. For existing tanks that do not have these access holes, take the potentials
as close to the shell as practical.
Galvanic anodes installed/bolted directly to the tank bottom internals can be checked
for electrical continuity/zero-resistance to the tank, using an ohm-meter or a Megger© type
insulation tester, prior to filling the tank with product. Do not scratch or damage the coating
inside the tank. Measure the resistance between any two anodes, or between an anode and the
tank shell external surfaces (e.g., at an uncoated flange face).
In-Plant Buried Pipelines
After the "As-Found" potential measurements are recorded, set the current output of the
impressed current anode system(s) to operate at approximately 90% of the system design
current requirement and measure the "On" potentials on the pipeline(s). For horizontal
pipeline(s), place the reference electrode directly above the buried piping section. For vertical
pipe(s), locate the reference electrode within 300 mm from the pipe. In asphalt or concrete
paved areas, place the reference electrode inside soil-access test holes to achieve adequate soil
contact. The potentials shall meet the CP potential criterion. Record the commissioning data
on Commissioning Reports.
Adjust the CP system output after the potential survey to maintain the protection levels
at or above the minimum potential criterion specified in specification.
Tank Bottoms

Page 10 of 12
CP Training manual Prepared on 14 Jan 2012
 After measuring the "As-Found" potentials, set the current output of the impressed
current anode system(s) to operate at approximately 90% of the system design capacity. Take
a minimum of four (4) potential measurements at equal intervals around each tank bottom. If
the anodes are installed around the tank periphery, the potential measurement locations should
be midway between the anodes to minimize anode gradient effects. If test access holes are
available, measure the tank-to-soil potentials at these test access holes. If there are no test
access holes, take the tank potential measurements at locations within two meters from the
tank bottom and at least one meter from any buried bare copper grounding cables.
If tank bottom access tubes are installed at the tank concrete ring wall, measure the
tank-to-soil potentials through the access tubes. If stationary reference electrodes are installed
between the two bottoms of tanks with replacement bottoms, measure the CP potentials of the
bottoms with reference to these electrodes. If a slotted plastic monitoring pipe is installed
under the tank bottom, measure the CP potentials of the tank bottom by pulling a portable
reference electrode through this monitoring pipe. If possible, measure and record the current
output of the anodes. Record the potential survey data on the Commissioning Report.
After the potential survey, adjust the CP system output to meet the applicable minimum
criteria specified in project specifications.
Tank bottom CP system commissioning should only be done when the tank is at least
75% full of product. This is to ensure that the bottom plates are in maximum contact with the
soil. If the tank is not this full, the measured potentials will not be indicative of overall
protective potentials, or the adequacy of protection, on the whole external surface of the tank
bottom.
Onshore Well Casings
For the measurements of the potentials of the well casing, place the portable copper-
copper sulfate reference electrode inside the cellar, immediately next to the casing, and also
outside the cellar within 1 meter of the cellar. After recording the "As-Found" potential
measurements, set the current output of the well casing CP system to operate at approximately
90% of the design current capacity for the well casing, according to specification. Re-measure
the potentials inside and outside the cellar, and record the measurements. The "On" potential
both inside the cellar and outside the cellar should be greater than -0.90 volts, and should not
decrease from the "As-Found" measurements. The protection criteria for the well casing shall
be a "minimum current drain" from the well casing. Decrease the system output (from 90%) to
match the applicable criterion and measure the current drain with the power source(s) on.
If the flow line is connected to the well, measure the "On" potentials of the nearest
buried section of the flow line. If these "On" potentials exceed the maximum potential allowed
for the pipelines, adjust the current output of the well casing CP system power source(s) to
reduce these potentials to a level below this maximum criterion. Also measure and record the
magnitude and direction of the DC current flow in the flow line. Record the current and
potential data, and associated measurements, on the Commissioning Report for each well
casing. The commissioning team shall report the results of the potential survey as well as the
deficiencies found during the commissioning.

Page 11 of 12
CP Training manual Prepared on 14 Jan 2012
Interference
Measure structure-to-electrolyte readings at locations where a known foreign pipeline
crosses or comes within 75 meters of the testing pipeline. Place the reference cell directly over
the crossing, or over the foreign pipeline at the closest point to the testing pipeline. Measure
potentials on both structures with the nearest rectifier cycled "on" and "off'. If the
measurements indicate that the testing CP system is depressing the protection level on the
foreign pipeline by 50 mV or more, forward written notification to the owner of the foreign
pipeline and implement suitable mitigation method. If the protection level on the testing
pipeline is less than acceptable, then complete a close interval survey in the vicinity of the
crossing for approximately 150 meters in each direction over the testing pipeline. If the close
interval survey indicates that interference is occurring on the testing pipeline, then notify the
owner of the foreign pipeline and implement additional cooperative testing with corrective
action.
COMMISSIONING REPORT AND AS-BUILT DRAWINGS
On completion of all construction and installation work, all construction drawings shall
be updated for field modifications to the original design, to show the “as-built” system. A
report shall be made of any field repairs to the anode bed(s) and connecting cables, including
repair locations and type of repair. A detailed commissioning report shall be provided with all
data obtained during the installation, pre-commissioning and commissioning. This report shall
also contain all construction checklists, Manufacturer’s documentation and an analysis of the
final protection levels and current outputs to show compliance of the installation with the
design and protection criteria.

Page 12 of 12
CP Training manual Prepared on 14 Jan 2012