Cathodic Protection System Installation

Procedure
Following points to be followed on site before installing cathode
protection system.

 All material received at site shall be inspected, handled and stored

upon receipt in accordance with Project Procedure for “Field
Material Control”.
 Installation inspections shall be conducted by the Electrical
Supervisors and witnessed by QC Electrical Inspector.
 The cathodic protection system shall be installed in accordance
with the project specification, manufacturer’s instruction and
reference standard installation detail.
 Preparation of required tools and materials necessary for the
installation work.
Installation of Cathodic Protection Equipment
 Equipment shall be installed accurately with respect to their
position, arrangement and directions.
 Lifting shall be carried out using properly tested and approved
slings.
 After completion of installation the following points shall be
checked and corrected if necessary.
 Check the level and alignment with the adjacent equipment are
correct.
 Check if the doors can be open and close normally.
 Check if there is any damage to the paint coating.
 Check the anchor bolts and set bolts have been tightened.
Test Box Installation
1. Test box shall be installed in accordance to the approved detail
drawings.
2. Test box foundation shall be check in conformance to the drawings
prior to equipment installation. Concrete foundation shall be cured
for a sufficient period of time. The concrete shall extend 150mm
minimum above ground.
 3. Steel support shall be hot dipped galvanized. It is set in concrete
which shall completely cover the buried steel.
4. After installation of equipment; adjust their alignment and level.
Cathodic Cable Installation
1. Check the actual cable length. Cables shall be cut from the drums
to which they allocated in accordance with the cable schedule and
drum allocation sheet.
2. In cable drum haulage, cables shall be rotated in the direction of
the arrow.
3. Cable laying shall be performed by individual cable being placed
in orderly arrangement and/or bundle.
4. Both ends of each cable shall be firmly sealed with insulating tape
and/or other sealing materials to prevent dust & moisture.
5. Sufficient length shall be provided for both ends of each cable in
the measurement of cable lengths.
6. Sand filling, protection cover and backfilling work shall be
conducted as early and promptly as possible.
7. Cathodic protection cables shall be properly identified before
backfilling for later connection to the test points. Connection
method must be referred to vendor drawings.
MMO Ribbon Anode & Reference Electrode Installation
A Mixed Metal Oxide (MMO) ribbon anode is a specialized type of anode
used in cathodic protection systems to prevent the corrosion of metallic
structures, such as pipelines, tanks, and reinforced concrete structures.
MMO ribbon anodes are composed of a thin strip of titanium or other
substrate material coated with a mixed metal oxide catalyst. This coating
enhances the electrochemical reactions that occur during cathodic
protection, making the anode highly efficient and effective in preventing
corrosion.

The MMO coating on the ribbon anode consists of a combination of

metal oxides, typically including oxides of metals like ruthenium, iridium,
and titanium. These oxides possess excellent catalytic properties that
accelerate the cathodic reactions and significantly improve the
performance of the anode.
1. Check above ground tank foundation level. Refer to Typical
Installation Detail for Tank.
2. Perform welding machine adjustment and test. Anode to Anode
conductor bar to conductor bar anode to conductor bar. Ribbon to
conductor, about 1 to 3 sec but to be changed depending on fixed
condition. Power feeder continuity check. Electrical resistance
between both ends of power feeder before installation.
3. Cut ribbon anode from reel to specified length that is shown on the
relevant drawings.
4. Cut specified length of conductor bar. Required length is shown on
the relevant drawings.
5. Laying of conductor bar. Verify material, spacing interval, overlap
and installation. Spacing intervals vary depending on each tank to
be protected.
6. Laying anode ribbon on conductor bar.
7. Spot welding at all cross points of anode and conductor bar. Verify
spot welding, one spot weld at cross point between anode and
conductor.
8. Install power feeder on Titanium conductor bar. Verify materials,
installation and connection as per Vendor Drawings.
9. Connect power feeder cables outside of tank through 2”dia. PVC
conduit. Secure wiring without tension and cable end with tag.
 10. Power feeder continuity check before and after backfilling.
Resistance between two power feeder shall have a value of 5
ohms or less.
11. The reference electrode are to be installed at the location
specified on the approved construction drawing.
12. Soak pre-packed reference electrode into potable fresh water
for 12 hours just before installation. Verify material.
13. Install reference electrode lead cable and power feeder.
Verify material, size, location and level.
14. Installed pre-packed reference electrode. Verify installation
and soil covering around reference electrode.
15. Connect reference electrode lead cable outside of tank
through 2”dia. PVC conduit. Check wiring without tension and
cable end with tag.
16. Potential difference after installation shall be checked. Verify
material specification and potential difference using portable
reference electrode.
17. Cable end treatment during civil work until wiring to junction
box or test box.
Inspection of Cathodic Protection Installation
1. During working period, inspection shall be carried out on insulation
testing by suitable instrument on insulating joints before and after
welding or fitting.
2. Soil and sand resistivity measurements of anodes and ground bed
location.
3. Visual inspection of cathodic protection anodes and cables.
4. Visual inspection of transformer-rectifiers, test boxes and stations
prior to installation.
5. Potential readings of permanent reference electrodes with respect
to a calibrated one in the same electrolyte conditions prior to
laying.
6. All cathodic protection removable links inside the accessible
equipment shall be left open and no impressed current stations
shall be energized without COMPANY’s approval.
7. Checking of all accessible cathodic protection equipment; their
wiring, correct polarity (+/-), terminations and cable tagging.
Testing and Records
 1. All monitoring and measuring devices used shall be calibrated and
have valid calibration certificate during the time of inspection as per
Control of Monitoring and Measuring Equipment Procedure.
2. Quality records shall be prepare as per Inspection and Test Plan
(ITP), inspect and signed by authorized Electrical Inspector for the
completion of Mechanical Completion prior for Commissioning
Phase.
3. All testing & inspection forms shall be developed as pre-requisite to
ITP.
Some Definitions
 Aboveground storage tank: A stationary container, of greater
than 500 barrel capacity usually cylindrical in shape , consisting of
metallic roof, shell, bottom, and support structure where more than
90 percent of the tank volume is above surface grade.
 Anode: Refer to MMO ribbon anode. The electrode of an
electrochemical cell at which oxidation or corrosion occurs.
 Backfill: Material placed in a hole to fill the space around the
anode, vent pipe and buried components of a cathodic protection
system.
 Cathode: Refer to structure / pipe. The electrode of an
electrochemical cell at which a reduction reaction occurs.
 Cathodic protection: A technique to reduce corrosion of a metal
surface by making the entire surface the cathode ofb an
electrochemical cell.
 Electrochemical cell: An electrochemical system consisting of an
anode and a cathode immersed in an electrolyte so as to create an
electrical circuit. The anode and cathode may be separate metals
or dissimilar areas on the same metal. The cell includes the
external circuit which permits the flow of electrons from the anode
toward the cathode.
 Electrode potential: The potential of an electrode as measured
against a reference electrode.
 Electrolyte: A chemical substance containing ions that migrate in
an electric field. Electrolyte refers to the soil or liquid adjacent to
and in contact with the bottom of an aboveground storage tank,
including the moisture and other chemicals contained therein.
  Impressed current: An electric current supplied by a device
employing a power source that is external to the electrode system.
 Membrane: A thin, continuous sheet of non conductive synthetic
material used to contain and/or separate two different
environments.
 Rectifier: A device for converting alternating current to direct
current. Usually includes a step-down AC transformer, a silicon or
selenium stack (rectifying elements), meters, and other
accessories when used for cathodic protection purposes.
 Reference electrode: An electrode whose open circuit potential is
constant under similar conditions of measurement.
 Structure-to-electrolyte voltage: (also structure-to-soil potential
or pipe-to-soil potential): The voltage difference between a metallic
structure and the electrolyte which is measured with a reference
electrode in contact with the electrolyte.
Test station:
A small enclosed box –like housing and the usual termination point of
one or more test leads.