OMV E&P Philosophy

CMV

Title: Philosophy for Cathodic Protection

System for onshore pipelines

Objective: This Philosophy defines the OMV E&P policy on the design for cathodic protection sys
tems for onshore pipelines. It is principally based upon the ISO 15589-1, Petroleum and
natural gas industries Cathodic protection of pipeline transportation systems.
-

Target Group: All OMV E&P staff involved in pipeline design, installation, operation and maintenance.

Scope: This Philosophy specifies the design, construction, operation and maintenance of
cathodic protection systems for buried metallic pipelines with and without the influence
of external electrical sources.

EP-EPP-FE T. Raschek
Author team OMV Gas GmbH
TC-EE
K. Berndonner/ .
Responsible for content EP-EPP-FE I. Sultan

C)

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Content
1.0 GENERAL 4
1.1 Scope 4
1.2 Normative references 4
1.2.1 OMV E&P GmbH Reference Documents 4
1.3 Definitions 5
1.4 Abbreviations 6
1.5 Units of Measure 7
1.6 Orderof Precedence 7
2.0 DESIGN REQUIREMENTS 8
2.1 General 8
2.2 Design information 8
2.2.1 Information for cathodic protection of steel pipelines 8
2.3 Criteria for cathodic protection 9
2.4 Electrical isolation 11
2.5 Safety control of undue electrical influence 11
2.6 Measures aimed at protecting against electric shock while maintaining the CP
system 12
2.7 Electrical continuity 12
2.8 Current requirements 13
3.0 IMPRESSED-CURRENT SYSTEMS 14
3.1 Power supply (Rectifier) 14
3.2 Ground bed 15
3.3 Current output control and distribution 16
3.3.1 General 16
3.3.2 Current distribution for multiple pipeline 16
3.3.3 Automatic potential control 16
3.3.4 Automatic current control 16
4.0 GALVANIC-ANODE SYSTEMS 17
4.1 General 17
4.2 Zinc Anodes 17
4.3 Magnesium Anodes 18
4.4 Anode backfill 18
5.0 MONITORING FACILITIES 19
5.1 Monitoring stations 19
5.2 Reference Electrodes 19
5.3 Test Coupon 20
5.4 Ground Electrode Systems 20
6.0 SPECIAL FACILITIES 20

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6.1 Temporary protection 20
6.2 Protective casings for buried pipelines 20
6.2.1 General 20
6.2.2 Casing pipes with shielding of the cathodic protection current 21
6.2.3 Casing pipes without shielding of the cathodic protection current 21
6.3 Parallel power lines or a.c. traction systems 21
6.4 Lightning protection 22
6.5 Surge arrestor 22
6.6 CP cables and cable connections 22
6.7 Monitoring stations and distribution boxes 23
7.0 COMMISSIONING 24
7.1 General 24
7.2 Equipment tests 24
7.2.1 Pipelines 24
7.3 System tests 25
7.3.1 Impressed current system 25
7.3.2 Galvanic anode system 25
8.0 INSPECTION AND MONITORING 26
8.1 General 26
8.2 Frequencies of inspection 26
8.3 Monitoring plan 26
9.0 MAINTENANCE AND REPAIR 27
9.1 Cathodic protection equipment 27
9.2 Instrumentation 27
10.0 DOCUMENTATION 27
10.1 Design documentation 27
10.2 Inspection and monitoring documentation 28
10.3 Operating and maintenance documentation 28
10.4 Maintenance records 28
11.0 BIBLIOGRAPHY 29

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1.0 GENERAL

1.1 Scope
This E&P Philosophy specifies the minimum requirements and gives
recommendations for the design, equipment, installation, commissioning,
operation, inspection and maintenance of cathodic protection systems for
onshore pipelines.
This E&P Philosophy is applicable to buried metallic pipelines onshore.
This E&P Philosophy is not applicable to off shore pipelines.

1.2 Normative references

ISO 15589-1, Petroleum and natural gas industries Cathodic protection of
-

pipeline transportation systems -

ISO 8044, Corrosion of metals and alloys Basic terms and definitions
- —

ISO 21809 2-5, Petroleum and natural gas industries External coatings for
-

buried or submerged pipelines used in pipeline transportation systems -

EN 13509, Cathodic protection measurement techniques

EN 15257, Cathodic protection Competence levels and certification of cathodic
-

protection personnel -

EN 60079-10, Electrical apparatus for explosive gas atmospheres Part 10:

-

Classification of hazardous areas (IEC 60079-1 0)

1.2.1 OMV E&P GmbH Reference Documents

TO-HQ-02-051, Philosophy for Pipeline Materials Selection Onshore
TO-HQ-02-052, Philosophy for Pipeline Design Onshore
TO-HQ-02-054, Philosophy for Pipeline Operation and Maintenance Onshore
TO-HQ-02-053, Philosophy for pipeline construction onshore
TO-HQ-02-071, Philosophy for HSEQ Management Onshore
TO-HQ-02-035, Philosophy for Overpressure Protection and Safeguarding onshore
TO-HQ-02-036, Philosophy for Flare, Relief, and Blow Down Onshore
TO-HQ-02-016, Philosophy for Earthing, Bonding and Lightning Protection
TO-HQ-02-01 1, Philosophy for General Electrical Design
HSEQ-HQ-04-02, Guideline for Risk Assessment Criteria
HSEQ-HQ-04-05, Hazard Identification and Hazard Management
HSEQ-HQ-10-01, Standard for Management of emergencies
HSEQ-HQ-06-03, Permit to Work
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1.3 Definitions
Following terms have specific meaning within this philosophy.
May A guideline which is to be considered
Should A guideline which is strongly recommended
Shall I Must A mandatory requirement.

Anode backfill
Material with a low resistivity, which may be moisture-retaining, immediately
surrounding a buried anode for the purpose of decreasing the effective
resistance of the anode to the electrolyte
Average coating resistance or average structure to soil resistance (r~0)
Value derived from the ratio of the difference between the ON and OFF
potentials to the protection current and the surface area of the structure in
question. It is usually expressed in ≤2xm2
Coating resistance or structure to soil resistance (R~0)
Electrical resistance between a coated metal and the electrolyte expressed in ≤2.
It is determined largely by the size and number of coating defects, coating pores
and the electrolyte resistivity
Coupon
Representative metal sample used to quantify the extent of corrosion or the
effectiveness of applied cathodic protection
Galvanic anode
Electrode that provides current for cathodic protection by means of galvanic
action
Ground bed
System of buried or immersed galvanic or impressed current anodes
Impressed-current system
System which provides cathodic protection by means of impressed current
IR drop
Voltage, due to any current, developed in an electrolyte such as the soil, between
the reference electrode and the metal of the structure, in accordance with Ohm’s
Law (U lxR)
Polarization cell or a.c. discharge device
Device that blocks d.c. current at low voltage and provides a low resistance path
for a.c. current at higher voltage (e.g. lightning discharge)
Reference electrode
Electrode whose open circuit potential is constant under similar conditions of
measurement, used to measure the structure-to-electrolyte potential

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Transformer rectifier
Device that transforms the a.c. voltage to d.c. voltage. d.c. voltage derived in this
way is used as a power source for impressed current cathodic protection systems
1.4 Abbreviations
The following abbreviations are signification to this document:
a.c. Alternating current
CP Cathodic protection
CSE (CuICuSO4) Cooper-copper sulphate reference electrode
Cu Copper
d.c. Direct current
E Potential
Ecu Pipeline to electrolyte potential with respect
to a copper/saturated copper sulphate
reference electrode
EH Pipeline to electrolyte potential with respect
to a standard hydrogen electrode
Limiting critical potential
Free corrosion potential
E~ Protection potential
Ip Protection current
lR-drop Voltage between two points in the metallic
path or in the lateral gradient in an
electrolyte
IR-Free Pipeline to electrolyte potential measured
without the voltage error caused by the IR
drop due to the protection current or any
other current
LCP Localised corrosion protection
R00 Coating resistance or structure to soil
resistance (~2)
rco Average coating resistance or average
structure to soil resistance (Qxm2)

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1.5 Units of Measure
Units shall be expressed in International system of Units (SI).
1.6 Order of Precedence
The local statutory and legislative regulations have the highest precedence. If the
applicable national legislation does not specify a different regulatory code for
cathodic protection design, then the cathodic protection system will be design to
satisfy this philosophy and relevant primary design code. Codes, standards and
regulations referred to in this philosophy shall be of the latest edition and shall be
applied in the following order of precedence:
• Local Regulations,
• The provision of this document,
• The provision of correspondent CMV E&P GmbH branch office standard
(if existing),
• International standards (e.g. ISO, IEC etc),
• National standards (e.g ASME, EN, API, BS, etc etc.).

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2.0 DESIGN REQUIREMENTS

2.1 General
Buried steel pipelines must be protected against external corrosion with cathodic
protection systems. For new construction pipeline projects, the design of the CP
system shall be part of the total pipeline design and corrosion management.
Design, fabrication, installation, operation and maintenance of CP systems shall
be carried out by experienced and qualified personnel.
2.2 Design information
2.2.1 Information for cathodic protection of steel pipelines
Exact details of the system to be protected are essential for planning a cathodic
protection system properly.
Such information should include:
• Relevant drawing (e.g. Pipeline route selection) of the pipeline route with
important information e.g. existing CP systems, foreign structures, fittings,
gate valves, control stations, casing pipes, surge arrestors, types and
location of isolating joints, etc.,
• Detail information on the pipeline to be protected, e.g. type and grade of
material, type of external coating, length, diameter, wall thickness, etc.,
• The required design life of the CP system,
• Specific soil resistivity and detailed soil conditions, in the area where the
ground bed and the pipeline is planned and any grounding systems is
required e.g. Wenner,
• Location and route of high-voltage overhead power lines of I 000V and
higher and railway lines; location of substations and return points and
direct current lines which running parallel or crossing the pipeline route,
• Location of pipelines and cables in the area where the ground bed is
planned with details of materials and coatings,
• Types of pipeline bedding material,
• Environmental conditions e.g. elevated temperatures, bacterial attack and
unusual contaminants in the electrolyte.

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2.3 Criteria for cathodic protection
The metal to electrolyte potential at which the corrosion rate is <O,01x103m per
year is the protection potential, E~. This corrosion rate is sufficiently low so that
during the design life time corrosion damage cannot occur. The criterion for
cathodic protection is therefore:
E≤E

The protection potential of a metal may depend to some extent on the corrosive
environment (electrolyte), but it is mainly dependent on the type of metal used
(see Table 1).
The protection potential criterion applies at the metal/electrolyte interface, i.e. a
potential which is free from the lR drop in the corrosive environment.
Some metals may be subject to corrosion damage at very negative potentials.
For such metals, the potential shall therefore not be more negative than a limiting
critical potential E1. In such cases the criterion for cathodic protection is:
E, ≤ E ≤ E~
The protection potentials of the most common metals are listed in Table I below.
For all materials not listed in Table I, the protection and limiting critical potentials
shall be determined by way of experiment.
NOTE: In the case of thin protective coatings without holidays with an average coating resistance
(r~) of less than 108 c2xm2, very negative potentials may have a detrimental impact on the coating,
such as blistering. In order to minimise any detrimental effects, IR free potentials should not be
more negative than a limiting critical potential of E1 = -1,1 V, measured by reference to a copper/
saturated copper sulphate reference electrode, except if the coating manufacturer gives another
documented value. Very negative potentials may also cause gradual cathodic disbonding at faults
in thick as well as in thin protective coating.

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Table 1: Free corrosion potentials, protection potentials and limiting critical potential of some
common metals in soil and in fresh and salt water LII
Metal or metal Medium Free corrosion Protection Limiting
alloy potential: E5 potential: critical
(without E~ LV) potential:
cell formation)
Indicative value LV)
LV]
Non alloy and low Water and soil Normal condition T < -0,65 to -0,40 -0,85~ -
alloy Fe materials aerobic conditions 40t~
with T > 60t -0,80 to -0,50 -0,95
yield strength Aerated sandy soil -0,50 to -0,30 -0,75 -

≤ 800 MPa 100< p < 1000 Oxm

Water and soil -0,80 to -0,65 -0,95 -

anaerobic condi
tions
Ferritic or austen- Neutral and alka- At ambient tempera- -0,10 to + 0,20 -0,45 -

itic stainless line fresh water tures

steels with yield and soil
strength < 800 Acid fresh water At ambient tempera- -0,10 to + 0,20
MPa and soil tures
Sea and brackish At ambient tempera- -0,10 to + 0,20 -0,45 -
water tures
Ferritic or austen- Neutral and alka- At ambient tempera- -0,10 to + 0,20 -0,20 -

tic stainless line fresh water tures

steels with yield and soil
strength < 800
MPa with ≥ 16%
Cr
Ferritic/ marten- Water At ambient tempera- -0.10 to +0,20 -0,45
sitic stainless tures
steels with yield
strength > 800
MPa
Copper, cupro- Water and soil -0,20 to +1- 0,00 -0,20 -

nickel allows
Lead Water and soil -0,50 to -0,40 -0,65 -0,95
Aluminium alloys0 Fresh water -0,70 to -0,50 -0,80 -1,15°
Sea and brackish water -0,80 to -0,50 -0,90 -1,15°
Steel in concrete Water and soil -0,60 to -0,10 0,75
Galvanized steel Water and soil -0,10 to -0,90 -1,20 -

NOTE 1 All potentials are IR free and refer to a copper/saturated copper sulphate reference electrode,
Ecu = EH — 0,32 V.
NOTE 2 During the lifetime of the structure any possible changes of resistivity of the medium around the structure
are to be taken into account. For high strength steels there is a risk of hydrogen embrittlement when the
potential is more negative than the start of hydrogen evolution.

For temperatures 40C ≤ T ≤ 600C the protection potential may be interpolated

The risk of NaOH-induced Stress corrosion cracking increases with increase of temperature.
Protection potential should be determined by testing in each single case as well as the limiting critical potential for ferritic and martensitic
stainless steels
These values are only valid for aluminium alloys without Zn and Cu I e.g. AIMgSi-alloys). For all other aluminium alloys the protection
potential may be different
e Corrosion risk in stagnant conditions because of alkalinity caused by cathodic protection which dissolves the
passive layer.
Limiting critical potential should be determined by testing in each single case for pre- and post-tensioned steels with yield strength >700
MPa. In any case, potentials lower than -1,1 V should be considered dangerous.

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2.4 Electrical isolation
The protected pipeline should be electrically isolated from all other parts of the
system with electrical isolation joints. Isolating joints should be buried whenever
possible or in inspection pits and should be considered at the following locations:
• between cathodically-protected pipelines and non-protected facilities e.g.
valves, pressure boosting stations etc.,
• at both extremities of a buried section of pipelines,
• between pipelines sections with different external coating,
• at branch lines,
• between pipeline sections running in different type of electrolyte.
To avoid damage to isolating joints resulting from high voltage due to lightning or
earth currents caused by electric power lines, ring spark gap isolation joints must
preferably be used.
The electrical isolation joint must have an internal coating. The length of the
section to be coated internally increases with increasing electrolyte conductivity,
increasing pipeline diameter and decreasing polarisation resistance of the pipe
material and electrolyte solution. The coating should be of a type which does not
deteriorate in contact with typical oil and gas fluids (e.g. gas condensate, oil, salt
water, hydrogen sulphur, carbon dioxide, acids).
The isolation joints should not be installed in horizontal direction to avoid
corrosion due to liquid collection.
Random short-circuiting of electrical isolation joints must be prevented. When
selecting the safety measure (e.g. field coating), ensure that both isolated halves
cannot be touched at the same time and also the system components separated
by the electrical isolation joints cannot be short-circuited with metal objects (e.g.
tools).
2.5 Safety control of undue electrical influence
Electrical earthing of devices installed on the protected pipeline might be required
for safety reasons or pipeline earthing might be required to mitigate the effect of
induced electrical voltages.
If electrical safety-earthing is required, this shall be made compatible with the CP
system by installing polarization cells or diode circuits, suitably specified and
rated for the purpose, in the earthing circuit or by installing separate earthing zinc
or galvanized steel electrodes, buried in low-resistivity backfill and not in direct
electrical continuity with other earthing systems.
If earthing is to be installed to mitigate the effect of a.c.-induced voltages on the
pipeline, this should be done at the locations where the anticipated or measured
voltages to ground are highest, and where the pipeline is exposed and can be
touched by personnel.
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2.6 Measures aimed at protecting against electric shock while maintaining the
CP system
When the protective earth is connected to electrically operated equipment, the
resistance to earth is decreased at these points, impeding or preventing cathodic
protection.
In order to prevent shock hazards and at the same time maintain effective
cathodic protection, one of the measures listed below shall be taken in
accordance with national relevant safety standards:
• isolation of the electrically operated equipment from the protected
structure,
• isolation of the part of the pipeline (e.g. the valve) connected with the
electrical operated equipment from the rest of the pipeline by means of
isolating joints. Install a continuity bond between the two parts of the
pipeline. Provide corrosion protection to the valve,
• installation of isolation transformers,
• installation of fault current circuit breaker in conjunction with a local
earthing system made of galvanised steel, zinc or magnesium,
• if permitted by national safety regulations, install d.c. decoupling devices
between the electrically operated equipment and the general earthing
system.
2.7 Electrical continuity
If the conductivity of the pipeline section is interrupted or reduced at flanges,
isolation devices or other pipeline connections, short-circuit these sections by
using insulated cable ≥ 10 mm2 Cu.

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2.8 Current requirements
The type and dimensions of the cathodic protection system depends on the
protection current requirement to be expected for the structure to be protected.
Table 2 give values for the combined effects of design current density and
coating breakdown that can be used if relevant previous experience is not
available.
Table 2: Design current density for coated pipelines
of CP systems for operating temperature ≤ 300 121
Design current density ~A/m9
Pipeline coating
1 0-year design life 20-year design life 30-year design life
Asphalt/coal-tar enamel 0,4x103 0,6x103 0,8x103
Cold-applied tape
Fusion-bonded epoxy 0,4x103 0,6x103 0,9x103
Liquid epoxy
3-layer epoxy-polyethylene 0,08x103 0,1x103 0,4x103
3-layer epoxy-polypropylene

If the existing pipeline has polyethylene coating, base requirements on protection

current densities of up to 1Ox1O~Nm2 depending on the coating quality and pipe
installation. The figure may be up to a few milliampere/m2 for PE-coated lines
with unintentional bonds or defects.
Where existing pipelines have bituminous coating, protection current densities
range from approx. 5OOx1O~A to a few milliampere/m2 depending on the coating
quality and pipe installation.
If the structures are older, the protection current density required is usually a little
higher. It may be up to a few milliampere/m2 and is determined with a drainage
test.
There are close connections between operating protection systems with higher
protection current density in the pipeline and interference in other installations It
is therefore advisable to detect the defects in the coating with intensive
measurement technique (Voltage cone), repair them and reduce the protection
current density.

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3.0 IMPRESSED-CURRENT SYSTEMS

3.1 Power supply (Rectifier)

The rectifier (d.c. voltage source) must be a high voltage proof model with
variable output voltage and equipped with a digital ammeter and voltmeter. It
must also be fitted with a safety isolating transformer.
The rectifier with all accessories must be supplied in a plastic cabinet.
• If installed along the route: Plastic cabinet with double doors and utility
connection.
• If installed in a station: Plastic cabinet with plastic door and integrated
monitoring station.
• If installed in a station with LCP: Double rectifier with integrated monitoring
station.
To prevent surge damage, protection current devices resistant to high voltage
should preferably be used. In these protection current devices, the isolating
transformer must ensure greater isolation (test voltage 10 000V). The output side
must be protected with surge arresters, inductors and capacitors.
Minimum requirements for protection current devices:
• Protection on the supply side,
• Mode selector,
• Output voltage control,
• Safety isolating transformer (for mains-operated rectifiers),
• Rectifier circuit (for mains-operated rectifiers),
• Fuses on the output side,
• Surge protector on the output side,
• Possibility of measuring output current and voltage,
• Possibility of operating in switching mode (on the output side).
If installed outdoor, the enclosure should have a minimum degree of protection IP
54.

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3.2 Ground bed
To ensure that the anode voltage is low, it is advisable to keep the ground
resistance as low as possible. Impressed current anodes must therefore
preferably be installed in areas with low specific soil resistivity.
The mass and the quality are sufficient for the design life of the system.
Generally, silicon iron (Fe-Si) is the preferred anode material.
The cable connection at the anode head must be insulated carefully to prevent
corrosion damage on the anode cable or anode head. The insulating materials
shall have long-term resistance to the chemical and physical effects of the
electrolyte. At the anode head, the cable shall be protected against kicking.
Anodes must generally be bedded in coke (primarily metallurgical coke, particle
size 0,01 m to 0,015 m).
The ground beds of an impressed-current CP system shall be of the deep-well or
shallow type and shall be designed and located so as to satisfy the following.
• In a continuous ground bed (horizontal anode), the minimum distance
between anodes should be approx. 5 m, depending on the soil resistivity.
• Vertical anodes should also be approx. 5 m apart (horizontal and vertical
distance).
• The ground cover over the anodes should be at least I m.
• An anode system should consist of at least two individual anodes.
If a small resistance deep well ground is planned, the anodes and coke ground
bed should not start until a few meters below the surface. Fill the remaining hole
with gravel up to the topsoil line.
Each anode should be subject to I A maximum.

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3.3 Current output control and distribution
3.3.1 General
The impressed-current output should be controlled by the output voltage on the
rectifier and corresponding potentials measured along the pipeline.
3.3.2 Current distribution for multiple pipeline
Where there is more than one pipeline to be cathodically protected, the current
return from the pipelines should be independently adjustable. In such cases, the
pipelines shall be isolated from each other and provided with an individual
negative connection to the current source.
Resistors should be installed in the negative drains to balance the current to each
of the adjacent pipelines individually. Each negative drain shall be provided with a
shunt and diode preventing mutual influence of pipelines during on-potential and
off-potential measurements.
All cables, diodes and current measurement facilities should be installed in a
distribution box or transformer-rectifier cabinet.
3.3.3 Automatic potential control
The d.c. voltage source can be provided with automatic potential control, which
shall be linked to a permanent reference electrode buried close to the pipeline.
Reference electrodes shall be regularly calibrated.
The potential measuring circuit shall have a minimum input resistance of
I OOxl 06~2. The electronic control system shall have an accuracy of ± 0,01 V and
be provided with adjustable voltage- and current-limiting circuits and/or alarms to
protect the pipeline against polarization outside the established criteria in the
event that a reference electrode fails. A panel-mounted meter should be provided
to enable the pipe-to-soil potential to be read.
3.3.4 Automatic current control
The d.c. voltage source can be provided with current control to set the current to
the pipeline or the anode system.
Automatic current control alone shall not be used for setting current flow where
soil moisture or other variations near the pipeline can cause potential variations.

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4.0 GALVANIC-ANODE SYSTEMS

4.1 General
As a rule, galvanic anodes can only be used economically for pipelines with a
small protection current requirement (l~) and for low soil resistivity. They are also
suitable whenever a power supply does not exist or can be provided only at
uneconomical costs.
Suitable materials for anodes in soil and fresh water are primarily magnesium
and zinc. In brackish water zinc and aluminium alloys are considered as suitable.
To keep the current output as constant as possible and obtain a low ground
resistance, galvanic anodes shall be installed in a suitable low resistivity non-
carbonaceous backfill.
In order to enable the measurement of off potentials and anode current, galvanic
anodes shall be connected via a Monitoring station. As a general rule galvanic
anodes are not suitable for use in areas with d.c. interference and/or continuous
a.c. interference.
The environmental impact of dissolving anodes and backfill should be taken into
account in the choice of materials for anodes and backfill.
4.2 Zinc Anodes
Table 3: Chemical composition for zinc anodes F21
Composition mass fraction [%]
Element
mm. max.
Cu - 0,005
Al 0,10 0,50
Fe - 0,005
Si - 0,125
Cd - 0,07
Pb - 0,006
Zn Remainder

Zinc anodes should not be used if the resistivity of the electrolyte is higher than
30 ≤2xm, unless the engineering evaluation or field test confirm that the design
requirements can still be met.

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4.3 Magnesium Anodes
Table 4: Chemical composition for magnesium
anodes [21
Composition mass fraction [%]
Element
mm. max.
Cu - 0,02
Al 5,3 6,7
Fe - 0,003
Si - 0,1
Mn 0,15 -

Ni - 0,002
Zn 2,5 3,5
Mg Remainder

Magnesium should not be used if the resistivity of the electrolyte is higher than
150 ≤2xm unless the engineering evaluation or field test confirm that the design
requirements can be met.

4.4 Anode backfill

To ensure that the current supply is as constant as possible and the dissipation
resistance is low, surround galvanic anodes in the soil with backfill.
The anode backfill generally consists of a mixture of 75% gypsum, 20% bentonite
and 5% sodium sulfate.

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5.0 MONITORING FACILITIES

5.1 Monitoring stations

Monitoring stations shall be installed along the pipeline route to ensure that CP is
being applied in all areas. If there are not any suitable inspection pits for taking
such measurements (e.g. on flanges), monitoring stations with cable connection
should be installed to provide measuring the pipe-to-soil potential, current and
resistance.
Monitoring station must be installed where the pipeline
• crosses railways and rivers,
• runs close to other buried pipelines, cables or other structures,
• runs parallel to other pipelines or cables,
• has metal casing pipes,
• has isolating joints,
• crossed major roads and embankments (dykes),
• is connected to other pipelines or facilities,
• has a connection to coupons, grounding and earthing systems.
Monitoring station should be installed at intervals of ≤ 2000 m. In urban or
industrial areas, the interval should not be greater than 500 m.
Depending on which interference is possible the following measurement shall be
provided:
• Pipe-to-soil potential (e.g. reference electrode),
—

• a.c. density (e.g. test coupon),

—

• pipe-to-soil potential of third-party installations (e.g. telecommunications

cables),
• Pipe currents,
• Ground electrode-to-soil potential (e.g. station soil),
—

• Function check of the electrical isolation joints.

5.2 Reference Electrodes
A CuICuSO4 electrode in a double clay vessel must be installed at every
measuring point.
The location is at the level of the pipe axis welded connection (0,1 to 0,5 m) and
to the right in the direction indicated in the Pipeline Data Book.

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5.3 Test Coupon
If the a.c. voltage is expected to be affected, a (100 mm2) test coupon must be
attached at selected measuring points.
The test coupon should be of the same steel grade as the pipeline.
The location is at the level of the pipe axis welded connection (0,1 0,5 m) and
—

to the left in the direction indicated in the Pipeline Data Book. The test coupon
must be set at an angle of 45° in the direction of the top edge.
5.4 Ground Electrode Systems
40x4 strips or high purity zinc ground electrodes must be installed in pipeline
sections where the alternating current is expected to be affected.
The ground electrode length depends on the value for dissipation resistance.

6.0 SPECIAL FACILITIES

6.1 Temporary protection

If the installation and commissioning of the permanent CP system cannot be
finalized for a period of six months after the pipeline is buried (or a shorter period
if the corrosion risk is greater), a temporary CP system shall be installed. Such a
system shall be designed to cover the pipeline construction period until the
commissioning of the permanent CP system.
Anode connections should be constructed such that they can easily be
connected and disconnected during and/or after commissioning of the permanent
system.
Permanent monitoring facilities connected to the pipeline should be installed
simultaneously with the pipeline to allow monitoring of the performance of the
temporary system.
6.2 Protective casings for buried pipelines
6.2.1 General
Casing pipes can impair the cathodic protection of the carrier pipes. Their use
should therefore be avoided as far as possible. In this case, the carrier pipe
inside the casing pipe should have a high quality coating to protect it against
corrosion.
If the use of casing pipes is unavoidable, electrically isolating spacers should be
installed and the annulus between the carrier and casing pipes should have a
watertight seal at the ends of the casing pipe.
Corrosion protection for the various different types of casing pipes is discussed in
6.2.2 through 6.2.3.

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6.2.2 Casing pipes with shielding of the cathodic protection current
The casing pipes that shield the cathodic protection current include pipes made
of plastic, coated concrete and coated steel. The external surface of the carrier
pipe inside the casing pipe can often be protected against corrosion by using
galvanic anodes in the annulus or by filling the annulus with a conductive material
(conductive sand).
6.2.3 Casing pipes without shielding of the cathodic protection current
The casing pipes that let the cathodic protection current through include
uncoated or inadequately coated steel pipes and uncoated concrete pipes with
sufficient conductivity.
In these cases, cathodic protection of the outside surface of the carrier pipe
inside the casing pipe can be effective if there is no contact between the carrier
and casing pipes and an electrolyte solution was filled in the annulus. If there is
no electrolyte solution in the annulus, there is only the risk of atmospheric
corrosion.
6.3 Parallel power lines or a.c. traction systems
There are two basic ways that a.c. affects buried systems:
• Short-term interference
• Long-term interference
For personal protection:
• short-term interference, caused by faults in a.c. power systems and
electrified railways (resistive and inductive effects) action must be taken
where the voltage is higher than 65 V
• long-term interference, caused by inductive or conductive coupling
between the pipeline and high-voltage lines or electrified railways, action
must be taken where the voltage is higher than 500 V
For corrosion protection:
In sections where a.c. voltages are higher than 10 V, or where voltages along the
pipeline show variation to lower values, indicating possible a.c. discharge,
additional measurements should be performed on site.
As corrosion can still occur in pipeline sections with a.c. voltage interference
despite functioning cathodic protection, defect-free coating must be aimed at in
this area.
To keep the a.c. voltage interference as low as possible, the following protective
measures can be used:
• Discharge devices
Limiters (polarization cells, diode limiters, etc.)

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Grounding systems
• Reducing the induced a.c. voltage by installing additional electrical
isolation joints
Further options if there is interference from railway lines:
• Return circuit,
• Increase the rail’s longitudinal conductivity,
• High resistance bedding material for the rail.
6.4 Lightning protection
The pipeline should not be connected to lightning protection systems, ground
terminated system parts or electrical protective grounding systems. Is the
connection necessary because of other regulations, then use of connection is
only permissible with limiters.
Connecting the grounding system with the cathodic protection is not permissible
— resistance area too large risk of interference (third-party installations e.g.
—

cables, pipelines, tanks, etc.).

A temporary direct connection from grounding systems to the pipeline to be
protected is only permissible briefly for reasons of personal protection.
If grounding systems have to be permanently connected to the pipeline to be
protected in lines approaching, crossing and running parallel to high-voltage
overhead power lines, traction power, contact and supply lines for reducing
contact voltage, short and long-time interference, limiters must be used (e.g.
polarization cells, surge arrestors, etc.)
These requirements do not apply to LCP systems.
6.5 Surge arrestor
Surge arrestors, to prevent elevated voltages from being present on pipelines
due to faults in adjacent electrical power systems or to lightning strikes, should be
of the spark-gap type and shall be designed as follows.
• The impulse breakdown voltage of the electrodes should be lower than
that of the isolating joint across which they are mounted.
• The spark gap shall be capable of discharging the expected fault and/or
lightning currents without sustaining damage.
• The spark gaps shall be fully encapsulated to prevent sparks in open
atmosphere and to protect the spark gaps from moisture ingress.
6.6 CP cables and cable connections
To connect impressed current installations, galvanic anodes and monitoring
stations to the pipeline, cables suitable for installation in the soil must be used.

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Cables must not have any metal sheaths or any cores colour coded green/yellow.
The cable cross sections must be determined according to the most effective
voltage drops in technical and economic terms.
However, the following are the minimum cross sections:
Table 5: Cable cross sections for CPS [3J
Cables for impressed current systems on buried pipelines
Cable for pipe connection 4x4 mm2 cu
cabie to the anode 4x6 mm2 Cu
For galvanic anodes
cable to the protecting structure 10 mm2 Cu or 2x4 mm2 Cu
Cable to the galvanic anode 10 mm2 Cu or 2x4 mm2 Cu
For measurement points
Cable for potential measurement 4x4 mm2 Cu
Cable for bridging 4x4 mm2 Cu
Cable for reference electrode or 10 mm2 Cu
measurement coupon
When protecting against stray current, use highly flexible copper cable of at least 25 mm~ Cu for
connecting to rails.

The installation depth for all underground lines should be at least 0,6 m. Mark the
location of the lines at least with cable warning tape.
Where there is little cover and in places where there are fears of the cables being
at particular risk, protect the cables from mechanical damage with cable conduits.
Connect the anode cables particularly carefully (couplings) to ensure that the
cable connection is not interrupted by anodic erosion.
All cables shall be laid without coils or kinks.
Cables must be connected to the pipelines in agreement with the pipeline
operators by thermite welding (Eriweld). Ensure that there is a strain relief
connection and that the connection points on the pipeline are insulated properly.
6.7 Monitoring stations and distribution boxes
Monitoring stations and distribution boxes shall provide sufficient room and heat
dissipation for the termination of test cables and for the installation of bonding
cables and resistors as required. The need for additional space to accommodate
temporary data-loggers, timers and other test facilities shall be considered.
Monitoring stations and distribution boxes should be provided with lockable
access doors or caps, as applicable.
Distribution boxes should be installed above ground and there should be access
to all internal components.
Monitoring stations and distribution boxes shall be weatherproofed to withstand
the worst environmental conditions.

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Monitoring stations and distribution boxes shall be accessible during all seasons
and shall be designed and located to minimize vandalism or accidental damage.
Distribution boxes and monitoring stations used for bonding of current-carrying
cables should be located outside hazardous areas or, if this is not possible, shall
be approved for the relevant electrical area classification.

7.0 COMMISSIONING

7.1 General
Commissioning involves the testing of all CP equipment, accessories and
systems to ensure that the pipeline is protected in accordance with the design
parameters.
7.2 Equipment tests
When temporary cathodic protection has been used, the system should be
switched off before the commissioning.
7.2.1 Pipelines
Before a cathodic protection system is activated, care should be taken to check
that all installations are in accordance with the design. In particular, cable
connections and safety measures (contact protection, lightning protection,
explosion proofing) where necessary shall be checked. d.c. connections to the
transformer rectifier shall be checked for correct polarity.
The following measurements should be made before activation:
• Pipe-to-soil potential — free corrosion potential at selected monitoring
stations in pipelines with their own protection section.
• If there is a.c. voltage interference, record the a.c. voltage profile (peak
and mean values over a period of at least 24 hours) along the pipeline.
After evaluating the above measurements, the line can be incorporated in the
active protection.

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7.3 System tests
7.3.1 Impressed current system
Before switching on for the first time, take the following measurements:
• The anode system’s dissipation resistance.
• Resistance between the pipeline and anode system.
Afterwards, set
• The output voltage for the protection current devices.
• The output current for the protection current devices.
• On potential in the area of the protection current devices as indicated in
the plans and record them.
7.3.2 Galvanic anode system
Before switching on for the first time, take the following measurements:
• The anode’s open-circuit potential.
After connecting, measure
• The on and off potential.
• Protection current and record the results.

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8.0 INSPECTION AND MONITORING

8.1 General

Inspection and monitoring of the CP system shall be carried out at regular

intervals to confirm that the protection criteria are fulfilled and to detect any
deficiencies. A manual is required to ensure that the CP system is well
documented.
8.2 Frequencies of inspection

Unless cathodic protection measurement techniques are used and regularly

functional checks (e.g. voltage and current readings) should be carried out at the
typical frequencies described in Table 6.

Table 6: Frequency of functional checks [4J

Functional
Frequency
check
Galvanic anode
station Annually
Impressed current Every three months
station
Drainage stations Every month
connection of Annually
foreign pipelines
d.c. decoupling
devices and Annually
earthing systems
Safety and pro- Annually or more frequently if required
tection devices by operational conditions
Test stations Annually for stable systems

8.3 Monitoring plan

A monitoring plan for the CP system shall be implemented and maintained. The
monitoring plan shall include at least the following:
• description of the measurements to be taken,
• locations where these measurements are to be conducted,
• monitoring equipment required to conduct such surveys,
• measurement techniques to be used,
• frequency with which each type of measurement shall be performed.

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9.0 MAINTENANCE AND REPAIR

9.1 Cathodic protection equipment

Maintenance on impressed current and drainage stations is listed in Table 6.
When functional or visual checks indicate that it is necessary, maintenance on
test stations shall be carried out. Electrical safety has to be checked in
accordance with national regulations.
9.2 Instrumentation
Instrumentation used for measurements shall be kept in good working order and
shall be subjected to periodical calibration and safety checks.

10.0 DOCUMENTATION

The commissioning documents of the cathodic protection system must be kept

for the duration of its service life.
Include the following planning data in the documentation:
• as built layout drawings of the pipeline including neighbouring structures
that are relevant to the cathodic protection e.g. monitoring stations,
electrical isolating points, casing pipes, anode system, etc.,
• records of the pipe-to-soil potentials at all monitoring stations before and
after the application of CP,
• procedures for the installation of d.c. voltage sources, ground beds,
cables, test facilities, cable connections to the pipeline,
• results of interference tests carried out on neighbouring installations,
• Calculation documents.
10.1 Design documentation
The detail design documentation shall include:
• results of any site surveys and soil investigations that have been carried
out,
• results of any current drainage tests that have been carried out for the
retrofitting of CP on existing pipelines,
• any requirements for modifications with respect to existing pipeline
systems such as minimum electrical separation or coating repairs,
• calculations of current requirements, potential attenuation, electrical
resistance and current output of ground beds,

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• description of system including a schematic diagram of the proposed CP
system,
• a list of the estimated number and types of CP monitoring facilities,
• any sensitivities in the CP system that require special attention,
• a schedule of materials,
• a set of design drawings and
• a set of installation procedures.
10.2 Inspection and monitoring documentation
The results of inspection work shall be recorded and evaluated. These records
should be kept for the lifetime of the structure, but always for a sufficient period to
provide detailed information on the cathodic protection effectiveness and to allow
comparative checks to be carried out. In addition, it is recommended that a
cathodic protection history should be maintained for reference purposes.
10.3 Operating and maintenance documentation
An operating and maintenance manual shall be prepared to ensure that the CP
system is well documented and that operating and maintenance procedures are
available for operators. This document shall consist of
• a description of the system and system components,
• the commissioning report,
• as-built drawings,
• manufacturer’s documentation,
• a schedule of all monitoring facilities,
• potential criteria for the system,
• monitoring plan,
• monitoring schedules and requirements for monitoring equipment,
• monitoring procedures for each of the types of monitoring facilities
installed on the pipeline and
• guidelines for the safe operation of the CP system.

10.4 Maintenance records

For maintenance of the CP facilities, the following information shall be recorded:
• repair of rectifiers and other d.c. power sources,
• repair or replacement of anodes, connections and cables,

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• maintenance, repair and replacement of coating, isolating devices, test
leads and other test facilities,
• drainage stations, casing and remote monitoring equipment.

11.0 BIBLIOGRAPHY

[1] ONORM 12954:2001: Cathodic protection of buried or immersed metallic

structures, General principles and application for pipelines
[2] Iso 15589-1:2003: Petroleum and natural gas industries Cathodic protection
-

of pipeline transportation systems Part 1: On-land pipelines

-

[3] OVGW G 20:2000: Planning and construction of cathodic protective

equipment for buried gas mains from steel tubes and for stock containers made
from steel
[4] OVGW G 21:2005: Commissioning and surveillance of the cathodic corrosion
protection for buried gas mains from steel tubes and for storage containers made
from steel

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