Design and Installation of Galvanic-Anode, Impressed-Current CP System

Table of Contents

Title   Purpose

Scope

Related Documents

Design Criteria

Qualifications

General Cathodic Protection Design Considerations

Impressed Current System Design

Sacrificial Galvanic Anode Systems Design

Wire Connections to Pipe

Test Stations

Insulated Joint Protection

AC Interference

Installation of Cathodic Protection Systems

Performance Survey

Documentation

Guarantee

Change Log

Pin Brazing Detail for Cathodic Protection System

Thermite Welding Detail

Standard Test Station Detail

Casing Test Station Detail

IR Drop Test Station Detail

Foreign Line Crossing Test Station Detail

Bond Test Station Detail

AC Coupon Test Station Detail

IR Coupon Test Station Detail

IR and AC Coupon Test Station Detail

Sacrificial Anode Test Station Detail

Flange Isolation Kit with Lightening/Fault Protection Detail

Test Station Completion Form

Rectifier Report Form

Galvanic Anode Report Form

1. PURPOSE

1.1       This  engineering specification defines the requirements for the design and installation of galvanic-anode and impressed-current cathodic protection systems to prevent external corrosion of underground pipelines.

2. SCOPE

2.1       This specification applies to all newly designed and installed underground pipelines owned and operated by Company and includes the part extending beyond the Company battery limits.

3. RELATED DOCUMENTS

3.1      Company Engineering Documents

670.810          Pipelines – Installation

Pipelines External Coatings for Underground Service

Flanged Assembly Bolting Materials

4. DESIGN CRITERIA

4.1       The design of a cathodic protection system for Company Pipelines shall meet one of the three accepted criteria found in NACE SP0169 and CFR 192 Appendix D. The Corrosion Control Specialist shall be consulted on the design of the cathodic protection system. The effectiveness of the cathodic protection system shall be judged acceptable when any of the following criteria are attained:

4.1.1   -850 mV with Cathodic Protection Current Applied (On Reading)—Refers to a negative (cathodic) potential of at least 850 mV (relative to a saturated copper/copper sulfate reference electrode) with the cathodic protection applied and consideration given to electrolytic voltage drop errors as well as voltage drops across the coating.

4.1.2   Negative Polarized Potential of 850mV (Off Reading)—Refers to a negative polarized potential of at least 850mV relative to a saturated copper/copper sulfate reference electrode.

4.1.3   100mV of Cathodic Polarization—Refers to a minimum of 100mV of cathodic polarization between the structure surface and a stable reference electrode contacting the electrolyte.

5. QUALIFICATIONS

5.1       All corrosion control design drawings, materials, and installation procedures shall be reviewed by a qualified Company pipeline engineer before installation. Consult the Corrosion Control Specialist for assistance.

6. GENERAL CATHODIC PROTECTION DESIGN CONSIDERATIONS

6.1       Available records should be reviewed and tests conducted to ensure adequate and economical designs. Typical sources of design information are:

• Appropriate field surveys such as current requirements, soil resistivity, continuity, electrical isolation, coating resistance, leak history, foreign current sources, changes to original designs, and maintenance and operating records.
• Review existing and proposed cathodic protection systems for possible interference problems, environmental concerns, neighboring under-ground structures, accessibility, power sources, foreign crossings, electrical bonds, or historical performance of previous designs.

6.2      Other general items to consider when designing a cathodic protection system are:

• Material specifications and compliance with the latest NEC or applicable regional codes.
• Provide adequate monitoring facilities (test stations or aboveground facilities).
• Provide protection from possible outside disturbances or damage.
• Minimization of interference current from and onto neighboring structures.
• Hazardous conditions such as combustible gases and induced AC that may prevail at the proposed site.
• The effect of polarization on coatings and metallurgical compositions susceptible to hydrogen overvoltage or embrittlement.
• The presence of amphoteric metals.

6.3       Cathodic protection system types are either impressed current or sacrificial. Considerations that influence the type system selection are:

• Physical space requirements, proximity of foreign structures, right-of-way easements, surface conditions, presence of streets and buildings, river crossings, ancient cultural resources, environmentally sensitive areas and so on.
• Future development of the ROW and extensions of the pipeline
• Cost of installation, operation, and maintenance
• Magnitude of current required
• Availability of power
• Electrical resistivity of the environment
• CP systems on adjacent structures
• Stray current sources
• Geological information

7. IMPRESSED CURRENT SYSTEM DESIGN

7.1       When designing impressed current CP systems, the following general considerations shall be accounted for:

• Electrical resistivity of the environment.
• Determine ground bed current requirement from calculated or test methods.
• The design current requirement shall be sufficient to provide 100% of the current requirement at the expected CP circuit resistance plus any addition current for universal cathodic protection requirements. This becomes the minimum rated DC current output on the rectifier.
• Calculate minimum rectifier voltage using design current requirement and circuit resistance. This is the voltage required to maintain the design current output at the initial ground bed circuit resistance. To accommodate future increases in circuit resistance, the minimum design voltage should be increased by 3 times.
• Normal design life for an impressed current ground bed is 20 years. During the impressed current system design the number of anodes necessary to meet this anode life shall be determined.

7.2      Impressed Current Ground Bed Design

• Typically, any of three types of impressed current ground beds may be used as the situation warrants (deep well, distributed, or conventional beds). All installations shall follow Company ground bed specifications and must be approved by the corrosion control specialist.

–     Anodes shall be made of graphite, high silicon cast iron, mixed metal oxide, platinum, soluble iron, or polymeric. The specific type of anode must be approved by a qualified person.

–    Anode selection will consider the expected electrolyte composition.

–    Ground bed performance can be improved by using high carbon backfill.

7.2.1   Deep Well Ground Beds (≥ 15 m (50 ft) deep)

• Seal the top of the well to prevent surface run off from entering the ground bed (per Federal, State, or regional Regulations).
• Surface casings, when used, must be externally sealed to prevent water entry (per State, Federal, or local Regulations).
• Use HALAR/HMWPE dual extrusion insulated cable for deep well groundbeds.
• All anode lead wires must be sized, insulated with HMWPE unless conditions warrant the use of dual-extrusion cable such as Permarad, Halar, or Kynar and properly installed to protect the wire and insulation integrity to perform as designed.
• Each anode will have its own lead wire that terminates in an anode junction box. Each anode lead wire will have a current shunt for current measurement.
• Slotted vent pipe must be installed from the bottom of the anode backfill material to the top of the anode active discharge column and solid PVC pipe installed from this point to the surface, terminating aboveground and designed to prevent entrance of surface waters. Venting should be done to a safe location away from people traffic as gases such as chlorine, carbon monoxide, carbon dioxide, and oxygen are vented.
• Design and install ground bed in a manner to avoid intermixing of underground aquifers (per State, Federal, or local Regulations).

7.2.2   Distributed Ground Beds

• Use HMWPE for all conventional type groundbeds.
• Size anode header cable so that all anodes receive sufficient current to meet their design output.
• Drawings of exact anode locations and lead wires should be kept to assist with surveys and excavations.
• All anode lead wires must be sized, insulated with extruded HMWPE, and properly installed to protect the wire and insulation integrity to perform as designed.
• Install cables to proper depth (usually 18 – 24″) and install plastic caution tape at a depth of 6″ from the surface above all cable runs.

7.2.3   Conventional (Surface) Ground Beds

• Size anode header cables so that all anodes receive sufficient current to meet their design output.
• Location of conventional ground beds should be clearly marked to prevent excavation damage.
• All anode lead wires must be sized, insulated with extruded HMWPE, and properly installed to protect the wire and insulation integrity so they can perform as designed.

7.3      Rectifier Design

7.3.1   All newly installed rectifiers shall meet the following requirements list:

• The installation and wiring of all rectifiers shall comply with the manufacturer’s recommendations and all applicable requirements of the National Electrical Code and local electrical utility.
• Rectifier must be installed in a manner to minimize the possibility of vandalism or damage.
• The rectifier cabinet must be made of steel with a hinged door for easy access with a locking mechanism. The cabinet shall also be hot dip galvanized to resist corrosion.
• Rectifier must have a disconnect switch in the external AC circuit.
• Rectifier case must be properly grounded.
• Ensure DC cables are installed and marked with the correct polarity. The rectifier installation may require that a security-locking device (NUT) be installed on either the positive or negative lug inside the rectifier case so the rectifier leads cannot be easily reversed.
• Rectifier DC cable connections must be mechanically secure and electrically conductive. Negative and positive DC cables should be properly sized for the maximum amount of current but no smaller than AWG #2, unless approved before installation by Company.
• Rectifier(s) shall be rated for full output at 40°C (100°F), with a maximum cell temperature of 75°C (170°F). The cabinet shall have a ventilating grill to admit the required amount of cooling air.
• Output rating of the rectifier(s) shall be a minimum of 150% of design requirements for the cathodic protection system.
• DC cables will generally be installed splice free. If splices are required, they must be installed to ensure a complete seal from the electrolyte. During handling and installation avoid damage to cable insulation.
• A rectifier installed to protect more than one structure requires individual shunts for each structure so separate current measurements can be obtained for each structure.
• During installation, a separate test lead from each structure for taking potential measurements must be installed.
• If solar panel arrays are used, they should be designed to withstand winds up to 125 MPH.
• Thermo-electric and DC engine generators may require a reverse current device to prevent galvanic action between the anode ground bed and the pipe.

8. SACRIFICIAL GALVANIC ANODE SYSTEMS DESIGN

When designing sacrificial galvanic anode ground beds, the following general considerations shall be accounted for:

• Typically, only zinc or magnesium anodes may be used unless other materials are approved by a qualified Company representative.
• Normal design life for a galvanic anode ground bed is 15 years.
• The anodes should be placed at least three (3) feet from the pipe and at pipeline depth or lower.
• If multiple anodes are installed horizontally they should be spaced so that they are at least two (2) feet apart (end-to-end).
• If the installation is a vertical semi-deep well, the anodes shall be spaced so that they are at least two (2) feet apart (end-to-end).
• If the installation consist of multiple augered anodes, the spacing would depend on the design of the system, but shall not be closer than five (5) feet apart.
• Galvanic anode lead wires should be at least 10 feet of AWG #12 or larger stranded copper wire and terminate in an above ground test station to allow for monitoring and current interruption.
• A shunt shall be installed between the anode/anode bed and the pipeline connection for anode current measurements.
• There are situations where larger gage wire will need to be used, such as in AC mitigation or anode cables longer than 10 feet where IR drop will need to be calculated.

8.1      Galvanic Ground Beds

Note: Galvanic Ground Beds have no direct connection to pipe; therefore always terminate through the test station. Galvanic ground beds can be installed in various configurements to maximize their outputs. The following are just a few examples of installation methods:

• Single trenched anode
• Single augered anode
• Multiple trench anode
• Multiple semi-deep well
• Distributive

9. WIRE CONNECTIONS TO PIPE

9.1       All cathodic protection system anodes and cables shall not be connected directly to the pipeline. Connection to the pipeline shall be through a new or existing test station.

9.2       All wire connections to the pipeline shall be thermite welded or pin brazed. However, oxygen pipelines that are in service may require bolting or other attachment methods. Consult the corrosion control specialist when making connection to live oxygen pipelines.

9.3       Thermite welding and pin brazing diagrams and instructions can be found on appendixes A and B. The following general procedures shall be followed when making thermite welded or pin brazed connections to the pipe:

• Only qualified individuals may perform thermite welding or pin brazing on Company facilities.
• The proper PPE must be worn when performing this task.
• The contact surface must be properly cleaned and prepped before making any connections.
• The pipe wall thickness must be checked and measured to have a minimum of 0.25″ thickness with a calibrated UT gauge and be free of voids, anomalies, or other defects. If this cannot be obtained consult the corrosion control specialist.
• When performing thermite welding the charge size must be limited to 15 grams.
• All wires, molds, pins, ferrells, and such must be appropriately sized for each connection.
• When making multiple connection points they must be spaced at least 6″ apart between each contact point on the pipeline. Larger diameter stranded wire may be separated into smaller diameter segments and “crow’s footed” on the pipeline as long as the 6″ clearance between each connection is maintained.
• Each connection must be tested so as to remain mechanically secure and electrically conductive.

9.4       Test leads shall be installed so that they will not be subjected to excessive strain and damage during backfill operations. Sufficient slack shall be left in leads during backfill operations to mitigate damage caused by ground settlement.

9.5       Each connection point shall be coated with a coating compatible with the existing pipeline coating and in such a manner that the entire area of the pipe and any bare wire of the test lead is completely covered. See Company Engineering Standard 4APL-20001 for other coating details.

10. TEST STATIONS

10.1    Each Company pipeline that is under cathodic protection shall have a sufficient amount of test stations or other contact points for electrical measurement to determine the adequacy of the cathodic protection system. The general requirements for test stations are as follows:

• The type of mounting pole and testheads shall be determined during the design phase of the cathodic protection system.
• The location and type of test stations required on a pipeline shall be shown on the construction drawings.
• Test stations shall be installed directly over or as close to the pipeline as possible.
• Where additional protection of test stations is deemed necessary (for example, from mowers, automobiles, and livestock) an appropriate protective structure shall be installed.

10.2    There are different types of test stations depending on the situational circumstances present on the pipeline. The following types of test stations could be used:

• Type 1-Standard Test Station-Shall be installed unless special conditions require another type of test station.
• Type 2-Casing Test Station-Shall be installed anytime a casing is present. The pipeline and casing shall have two (2) test leads installed.
• Type 3-IR Drop Test Station-Shall be install every 3 to 5 miles where it is practical.
• Type 4-Foreign Line Crossing Test Station-Shall be installed at foreign lines crossings where the foreign operator is willing to attach test leads.
• Type 5-Bond Test Station-After determining the necessity of a bond between Company and a foreign pipeline, a bond test station shall be installed.
• Type 6-AC Coupon Test Station-Shall be installed whenever an Company pipeline is collocated with high voltage transmission AC powerlines.
• Type 7-IR Coupon Test Station-Shall be installed at two mile intervals on all new pipeline installations to meet Federal and State regulations.
• Type 8-IR and AC Coupon Test Station-The combination of the two previous types of test stations.
• Type 9-Sacrificial Anode Test Station – Shall be installed at intervals per CP design specification.

Note: Please refer to Appendixes C through K for diagram details of each test station.

10.3    There shall be strict adherence to the wire color and sizing for all test stations. The following tables shall be followed when designing or installing test stations on Company pipelines.

Test Lead Color Code Table

Type of Lead	Color of Lead	Wire Size
Potential	White	#12
Current Carring	Black	#6 or #8
Anode	Blue	#6 or #8
Casing	Green	#10
IR Drop	Orange	#6
Foreign Pipeline	Red	#6 or #12
Coupon	Yellow	#10

11. INSULATED JOINT PROTECTION

11.1    Insulated joints may be required in some cathodic protection systems to electrically isolate segments of pipe from one another. Care should be taken when installing insulating kits to make sure pipe or personnel are not exposed to additional electrical hazards.

11.2    When an insulated flange kit is used to electrically isolate sections of a pipeline, over-voltage of the gasket that is insulating the flange shall be considered. Failure can occur because of lightning or AC fault current arcing across the flange. An insulated flange protection device shall be installed at all insulated flange sets that fault currents may be present. Insulating flange details can be found in Appendix L.

11.3    After installing the insulating flange assembly, the contractor shall conduct an electrical resistance test between the upstream and the downstream side of each flange assembly. In addition, the insulating effectiveness of each insulating joint stud bolt shall be checked.

12. AC INTERFERENCE

12.1    AC current should be considered during the design and construction of the pipeline as well as during regular maintenance activities. AC current can cause hazards to personnel safety and to the integrity to the pipeline. Electrical energy can be introduced onto the pipeline three different ways, 1) conductive coupling during fault conditions, 2) electromagnetic/inductive coupling, and 3) electrostatic/capacitive coupling.

Note: Predicting AC interference effects is a multifaceted matter requiring sophisticated design methods. This procedure only gives a brief overview of a few techniques that may be employed. If large AC voltages are expected or encountered a consultant trained in AC mitigation may be necessary to design and install mitigation methods.

12.2    Conductive Coupling—Can occur when there is a line-to-ground short or fault on the power line. On high-voltage AC power lines (HVAC) faults may occur as a result of lightening strikes, high winds, failure of the power line towers, or failure of the insulators.

12.2.1 Personnel Safety—Voltages resulting from induced AC represent a safety hazard to pipeline personnel, as well as the general public, where test points and aboveground facilities are accessible. An electrical shock can occur when a person touches or is in close proximity of an energized structure.

• Touch Voltage—Is the potential difference between a grounded metallic structure and a point on the earth’s surface separated by a distance equal to the normal maximum horizontal reach (approximately 1 m).
• Step Voltage—The potential difference between two points on the earth’s surface separated by a distance of one pace (approximately 1 m) in the direction of maximum potential gradient.

12.2.2    Mitigation—Screening electrodes can be installed to stop the fault current. Types of anodes may consist of lengths of zinc ribbon or banks of packaged sacrificial anodes. Both of these mitigation techniques shall be connected to the pipe through a test station.

12.3       Electromagnetic Coupling—Voltages and currents can be electromagnetically induced onto a pipeline much like the primary windings of a transformer which induces a current flow through to the secondary windings. This type of AC interference occurs mainly where HVAC power lines share the same right-of-ways with the pipeline. The amount of AC that is induced on the pipeline is dependent on several factors. Those factors include:  soil characteristics, length of the shared right-of-way, voltage/current of the overhead HVAC, and quality of coating of the pipeline.

12.3.1    Personnel Safety—This type of induced AC results if steady state induced voltages exist on the pipeline. The duration of shock could be longer than in Conductive Coupling so the tolerable limit for exposure to steady state voltages are much lower than fault voltages. NACE SP0177 has set a maximum allowable induced AC voltage to which a person should be exposed of 15V.

12.3.2    AC Corrosion—Because of extremely effective coatings and shared right-of-ways with HVAC, AC corrosion is a concern to pipeline systems. There appears to be a relationship between AC current densities and AC corrosion rates.

iac< 30 A/m2…………………….No Corrosion

30 A/m2<iac<100 A/m2….….Corrosion Unpredictable iac>100 A/m2…………………Corrosion Expected

AC corrosion rate is also affected by the resistivity of the soil surrounding the pipeline as is any typical corrosion cell. The lower the soil resistivity the higher the AC corrosion rate. Another component to AC corrosion is the size of the holiday in the coating. AC corrosion will most likely occur at the smallest holidays such as pinholes, which is the size of holidays that is expected on a new pipeline installation.

12.3.3    Mitigation—To reduce AC voltages to a safe level the pipeline must be grounded. Grounding material may consist of the following:  packaged sacrificial anodes, sacrificial anode ribbon installed in a special backfill material, grounding rods, grounding mats or grounding cables. Grounding electrodes may be evenly distributed along the pipeline right- of–way or concentrate the grounding electrodes at electrical discontinuities where voltage peaks may occur.

12.3.3.1 Installing grounding electrodes minimizes the risk of AC corrosion, however the effects that induced AC will have on the pipeline are hard to predict without complex calculations or the use of specialized software.

12.4       Electrostatic Coupling—Energy is transferred through the electrical capacitance that exist between the power line and the pipeline. Any two conductors separated by a dielectric material can be considered a capacitor. The most common occurrence for this type of AC interference is in the construction stage of a pipeline, or on above ground piping, not grounded. The strings of pipe are usually up on wood skids and well insulated from the ground and thus creating conditions for a capacitor.

12.4.1    Personnel Safety—This type of coupling usually does not produce enough body current to create an electrical shock hazard, however it could result in nuisance voltages that create a shock similar to static electricity. If a pipeline worker reacts quickly or overreacts to the sensation a safety hazard could form.

12.4.2 Mitigation—The pipe should be connected to the earth by installing a grounding mechanism so that the connection has a much lower resistance that the pipe-to-earth capacitive resistance.

12.5    Decouplers—Materials used as grounding electrodes that are not anodic to the pipeline that is, copper grounding rod and cables would seriously influence the effectiveness of the cathodic protection system if directly connected to the pipeline. DC decouples, such as a polarization cell replacement (PCR) or a solid state decoupler (SSD), shall be installed if such material is used for grounding. Decouplers allow the draining of AC to grounding systems while keeping DC from the CP system on the pipeline.

13. INSTALLATION OF CATHODIC PROTECTION SYSTEMS

13.1    All construction work shall be performed according to construction drawings and project specifications. Any deviations must be approved by the Company construction inspector and documented on the as-built drawings.

13.2    Only materials approved by Company shall be installed. All materials shall be inspected before installation to ensure adherence to material specifications and that materials are free of damage and defects.

Anodes shall be:

• Checked to ensure the lead wire is the correct length, securely attached, electrically continuous with the anode, protected from damage during installation, and has sufficient slack to eliminate strain.
• Checked to ensure the connection seal is not damaged.
• Run straight and centered in the hole and properly supported.
• Replaced, if damaged.

13.3    Packaged galvanic anodes are to be kept dry during storage, must have waterproof packaging removed before installation, and back-filled with compacted native soil.

13.4    All decoupling devises shall be checked for proper installation and all wires are terminated properly secured.

13.5    Anode backfill will be checked to ensure it is free of foreign material, meets specification, and well-compacted on installation to be as free from voids as possible. During backfill operations the contractor shall exercise caution as to not damage the cathodic protection system wiring or other components. Sufficient slack shall be left in the wiring to account for any ground settlement after backfilling operations.

13.6    After initial construction all test stations shall be checked to ensure the proper type of test station has been installed and is in accordance with the design drawings. The color types, wire sizing, termination of wires, and other details illustrated on the design shall be checked to verify compliance. The test station completion form shall be filled out and provided to the corrosion control specialist and filed in the project PAC files. This form is located in Appendix M.

13.7    During commissioning of an impressed current CP installation, the DC circuit will be checked to ensure the POSTIVE cable is connected to the ground bed and the negative cable is connected to the pipeline. Only qualified Company employees or their designees may energize a rectifier. A rectifier inspection form must be filled out upon completion. This form is located in Appendix N.

13.8    During commissioning of a sacrificial anode system, the appropriate anode checklist and table must be filled out documenting the type and location of each anode. This form is located in Appendix O.

14. PERFORMANCE SURVEY

14.1    A performance survey of the completed cathodic protection system shall be made, and the following data shall be recorded on the rectifier inspection form and submitted to the corrosion control specialist and filed in the project PAC files:

• Current output of all anodes and/or rectifier.
• Current flow, including direction, through any drain installed on the system.
• Current flow and direction at all IR drops.

14.2    Close interval surveys (CIS) shall be conducted on the pipeline when required by the project engineer. When conducting a CIS the following guidelines should be considered:

• A native close interval survey shall be performed before any cathodic protection is applied to the pipeline.
• After the native CIS is completed the cathodic protection system shall be energized and left to polarize for two weeks.
• After the two weeks either an ON CIS or an interrupted CIS shall be performed; inquire with the Corrosion Control Specialist as to which CIS shall be performed.

15. DOCUMENTATION

Upon completion of the installation, the following must be completed and submitted to the corrosion control specialist and recorded in the project PAC files:

• Layout drawings will be prepared for each impressed current CP installation showing the details and location of the components with respect to the protected structure(s) and to physical landmarks. These drawings will include ROW information.
• The locations of galvanic anodes will be recorded on drawings in tabular form with anode type, weight, spacing, depth, and backfill information.
• Rectifier inspection forms, test station information, electrical bonds, and isolation devices shall be documented .
• Documentation of neighboring buried or submerged metallic structures.

16. GUARANTEE

16.1    The cathodic protection system shall be guaranteed to:

• Provide complete protection for the entire pipeline system in accordance with design criteria.
• Be free of operating defects for a period of one year after the start of operation. This shall also apply to all equipment supplied.

PIN BRAZING DETAIL

THERMITE WELDING DETAIL

STANDARD TEST STATION DETAIL

NOTES:

1) All test stations must be installed in the locations shown on the construction
drawings. Any change in location requires approval from the Air Products
construction inspector.
2) A test station completion form must be filled out for each newly installed or modified
test station. Any deviations in wire color, termination points, or others items must
be noted and approved by the Air Products construction inspector. A copy of this
form can be found in Appendix M.

 

CASING TEST STATION DETAIL

NOTES:

3) All test stations must be installed in the locations shown on the construction
drawings. Any change in location requires approval from the construction inspector.
4) A test station completion form must be filled out for each newly installed or modified
test station. Any deviations in wire color, termination points, or others items must
be noted and approved by the construction inspector. A copy of this
form can be found in Appendix M.

IR DROP TEST STATION DETAIL

5)  All test stations must be installed in the locations shown on the construction drawings. Any change in location requires approval from the Company construction inspector.

6)  A test station completion form must be filled out for each newly installed or modified test station. Any deviations in wire color, termination points, or others items must

be noted and approved by the Company construction inspector. A copy of this form can be found in Appendix M.

FOREIGN LINE CROSSING TEST STATION DETAIL

7)  All test stations must be installed in the locations shown on the construction drawings. Any change in location requires approval from the Company construction inspector.

8)  A test station completion form must be filled out for each newly installed or modified test station. Any deviations in wire color, termination points, or others items must

be noted and approved by the Company construction inspector. A copy of this

form can be found in Appendix M.

BOND TEST STATION DETAIL

9)  All test stations must be installed in the locations shown on the construction drawings. Any change in location requires approval from the Company construction inspector.

10)A test station completion form must be filled out for each newly installed or modified test station. Any deviations in wire color, termination points, or others items must

be noted and approved by the Company construction inspector. A copy of this form can be found in Appendix M.

AC COUPON TEST STATION DETAIL

 

11)All test stations must be installed in the locations shown on the construction drawings. Any change in location requires approval from the Company construction inspector.

12)A test station completion form must be filled out for each newly installed or modified test station. Any deviations in wire color, termination points, or others items must

be noted and approved by the Company construction inspector. A copy of this form can be found in Appendix M.

IR COUPON TEST STATION DETAIL

 

13)All test stations must be installed in the locations shown on the construction drawings. Any change in location requires approval from the Company construction inspector.

14)A test station completion form must be filled out for each newly installed or modified test station. Any deviations in wire color, termination points, or others items must

be noted and approved by the Company construction inspector. A copy of this

form can be found in Appendix M.

IR AND AC COUPON TEST STATION DETAIL

 

 

 

NOTES:

15)All test stations must be installed in the locations shown on the construction drawings. Any change in location requires approval from the Company construction inspector.

16)A test station completion form must be filled out for each newly installed or modified test station. Any deviations in wire color, termination points, or others items must

be noted and approved by the Company construction inspector. A copy of this

form can be found in Appendix M.

SACRIFICIAL ANODE TEST STATION DETAIL

 

17)All test stations must be installed in the locations shown on the construction drawings. Any change in location requires approval from the Company construction inspector.

18)A test station completion form must be filled out for each newly installed or modified test station. Any deviations in wire color, termination points, or others items must

be noted and approved by the Company construction inspector. A copy of this

form can be found in Appendix M.

FLANGE ISOLATION KIT WITH LIGHTENING/FAULT PROTECTION DETAIL

 

1. Oversize metal washers shall not be used.
2. Studs shall extend beyond nuts 1-1/2 to 2 threads when steel and phenolic washers and mounting brackets are in place.
3. Stud bolt length shall be 15 mm (1/2 in) longer than the lengths listed in 4WPI-57902 (Flanged Assembly Bolting Materials).

5. Stainless steel nuts, bolts, and washers shall be used to connect the lightening arrestor to the mounting brackets.
6. The contractor shall fabricate the mounting brackets per the following detail.
7. The mounting brackets shall be installed between the flange and the phenolic washer. The flange surface shall be prepared to ensure a good metal-to-metal contact.

TEST STATION COMPLETION FORM

NEW/MODIFIED TEST STATION INSPECTION FORM

LOCATION INFORMATION		LAT		LONG
TEST STATION NUMBER
STATION (IF APPLICABLE)		STATE		COUNTY

 

TYPE OF TEST STATION (POTENTIAL, COUPON, BOND, ETC.)

INSPECTION QUESTIONS			YES	NO
IS THE TEST STATION IN THE PROPER LOCATION ACCORDING TO THE PROJECT DRAWINGS?
WHERE THE CONNECTIONS TO THE PIPELINE MADE IN ACCORDANCE WITH COMPANY THERMITE/PIN BRAZING PROCEDURES?
IF THERE WERE ANODES OR COUPONS INSTALLED WERE THEY INSTALLED AT THE PROPER DEPTH AND DISTANCE FROM THE PIPELINE?
IS THE STATION WIRING TERMINATED IN THE TEST HEAD PROPERLY?
IS THE COLOR OF THE WIRING ACCORDING TO THE PROJECT DRAWINGS?
IS THE WIRE SIZE ACCORDING TO THE PROJECT DRAWINGS?
PER THE PROJECT DRAWINGS IS THERE PROTECTION (FENCING, BOLLARDS, ETC.) INSTALLED AT THIS LOCATION?
IS THE WIRING OR ANY PART OF THE TEST STATION DAMAGED OR INSTALLED IMPROPERLY?
COMPANY INSPECTOR	DATE	CONTRACTOR		DATE

RECTIFIER REPORT FORM

GALVANIC ANODE REPORT FORM