cathodic protection works completion …cathodic protection system of a huge new-installment...

CATHODIC PROTECTION WORKS COMPLETION REPORTSOCAR TURKEY ALIAGA REFINERY PROJECT ARP

IZMIR/TURKEY

INDEX

1. COVER

2. INDEX

3. PURPOSE & SCOPE

4. WHO IS MERTEK

5. WHAT IS MERTEK DOING

6. INTRODUCTION TO STAR ARP PROJECT

7. OUR CONTRATS IN STAR PROJECT

8. PROJECT TAG FOR STAR ARP CATHODIC REPAIR WORKS

9. INTRODUCTION TO CATHODIC PROTECTION PROJECT IN STAR ARP PROJECT

10. WHAT WE ACCOMPLISHED IN CATHODIC WORKS OF STAR ARP PROJECT

11. KICK-OFF MEETING AND FIRST SURVEY

12. APPROACH

13.TEST AND MEASURE METHOD STATEMENT

14.CONSTRUCTION METHOD STATEMENTCIVIL WORKS

15.CONSTRUCTION METHOD STATEMENTMECH WORKS

16.CONSTRUCTION METHOD STATEMENTELECTRICAL WORKS

17.COMMISSIONING METHOD STATEMENT

18.FINAL QUALITY DOSSIER

19.REASONS IDENTIFIED DURING RECONSTRUCTION(MAY BE USED AS CORRECTIVE/PREVENTIVE ACTIONS)LESSONS LEARNED

20.CONCLUSION AND LESSONS LEARNED

21.REFERENCES

22.MERTEK INFO

w w w . m e r t e k . l t d 2

PURPOSE & SCOPE

• Purpose of this Document is to give a brief information

about the repair and re-construction works of a

cathodic protection system of a huge new-installment

refinery Project as also a detailed reference

information of our company’s work.

• Scope of this Document is the Cathodic Protection

Re-construction and Repair Works installed in a huge

new-installment Refinery Project called as Star ARP.

Star ARP Project’s construction phase began in 2014

and MAC is accomplished in 2019. Warranty period is

still in progress. One of the biggest issues during the

punch phase and MAC phase was to be able to repair

(and if necessary reconstruct in some units) the

Cathodic Protection System which was not working as

a whole at that moment.


WHO IS MERTEK ?

Oil & Gas

Petrochemical

Heavy Industry

Power Plants

Renewable Energy

MERTEK ELECTRICAL ENGINEERING LIMITED COMPANY is serving in Electrical and Instrumentation EPC (Engineering, Procurement, Construction) works for ex-proof heavy industry facilities since 2014.

Our company is operating with Project Management Profession (PMP), Planning and Document Control Center (DCC) norms according to ISO 14001, OHSAS 18001 HSE standarts and ISO 9001 Quality standards.


WHAT IS MERTEK DOING ?

High Voltage

Low Voltage Distribution

Inner Electrical Installation & Lighting

Earthing, Lightning Protection AndCathodic Protection

Fire & Gas Detection

CCTV, Access Control, PAGA

Structural Cabling and IT Systems

Instrumentation and Automation


INTRODUCTION TO STAR ARP PROJECT

• Star Aegean Refinery Project is the construction of a newOil&Gas Refinery in Aliağa / İZMİR region next to Petkim andTüpraş.

• Total Invesment Of Project is 6.3 billion USD.

• Aim of the Project is to reduce current account deficit around 3 billion USD per year.

• Major items produced in the facility is Euro-Diesel and Jet Fuel.

• Refinery is a stand-alone one with its own Jetties, storage tanks, utilities, cokers, flares etc… only with an exception of a powerplant which is planned to be constructed in a few years.


OUR CONTRACTS IN STAR ARP PROJECT

TCF POWER RING 10 MVA•Supply & Installation of Step-up and Distribution Transformers of Temporary Power Ring•Maintenance of Temporary Power Ring of 10 MVA since 2015

GUARD TOWER FEEDERS•Installation of Power Cables, Fiber Optic Cables and Fire&Gas Detection System Cables to the

Guard Towers

PERIMETER FENCE LIGHTING CCTV IDS•Installation and Commissioning of the Lighting, CCTV and Intrusion Detection of the Perimeter

Fence which has a length of over 10 km

CATHODIC PROTECTION REPAIR WORKS•Installation & Commissioning of new Anodes, reference electrodes, Test JBs and Power JBs•Repair of damaged CP cables, anodes, negative points and Jbs•Revising the plot plans, cable schedules, termination schedules, wiring diagrams according to

the site, Mark-ups and As-builts and finally preparing the FQD


MERTEK PROJECT TAG FORSTAR ARP CATHODIC REPAIR WORKS

Duration•Begin : 02/2019•End : 08/2019

Total Value:•Planned : 200.034,20 USD•Committed : 406.252,03 USD

Total Manhour•Direct :20000mh•Indirect :2000mh


INTRODUCTION TO CATHODIC PROTECTION PROJECT IN STAR ARP PROJECT

• We started the scope of Cathodic Protection Works on 02/2019 at Star Aliağa Refinery. Ourscope for cathodic protection consists of checkingdamaged or fault points such as positive anodelocations or negative welding points, etc.We have installed new 104 pieces of anode points, 24 pieces of negative points and 20 pieces of test stations. We also did maintenance and repairs of 255 anodes. We achieved test & commissioning activities of CP Works of 17 different Ex-d Units with 22000 Man-hours. Works have been completed on 08/2019.


WHAT WE ACCOMPLISHED IN CATHODIC WORKS OF STAR ARP PROJECT

11 nos of PJB

6 nos of Rectifiers

15 nos of Reference Electrodes

255 nos of Anodes Maintenance

107 nos of new Anodes Installation

20 points Test Stations resolved

22000 direct mh / 2000 İndirect mh


KICK-OFF MEETING AND FIRST SURVEY

69 nos of 0 mA

82 nos of broken conductor

107 nos of anodes misplaced

135 nos of test JB failure

15 nos of reference failure

First kick-off meeting was held on Jan-2019. The first survey numbers arelisted at right side. There were around136 points of failure, almost %70 of thehuge refinery. There were 6 monthsahead for the accomplishment.


APPROACH

Fault• Plot Plans may be wrong• Vendor reports cable tags may be

different than site• Cables mostly damaged during

infrastructure• Anodes may come close to some

basement metal infrastructure• Some power or test JBs may fail

Correction• Plot plans revised according to site

installation• JB clamp tags revised according to

Vendor Reports• Cables are measured and repaired• If anode is still not working properly, a

new anode has been installed to close-by and connected to the repairedcable

• All power and test JBs are reorganized


TEST AND MEASURE METHOD STATEMENT

1-Check of plot plan, vendor report and theinstallation at site to

correct labeling

2- Revise the plot plans, vendor reports and cables

schedules according tocorrected labeling

3- Test and measure againto detect actual faults and

create the report of theUnit (for instance Unit-

100)

4- Site visit with theContractor to decide theactions: go for repair or

construct a new one

5- Excavate the anodepoint and cut the

conductor to determinewhich one is not workingproperly: cable (cut) or

anode (misplaced)

6- Repair the cable orinstall the new anode. Do

the tests again.

7-Repeat all for each JB within the unit and finallyenergise the rectifier andtest and commission the

system.

Hand over to theContractor and close all

openings at site andrecover its soil, concrete, gravel etc… to make ready

for MAC


CONSTRUCTION METHOD STATEMENTCIVIL WORKS

Concretecutting and

drilling

Removal of gravel,

geotextileand soil

Drillingdown to 5

meters

Reformingthe soil,

geotextileand gravel

Concretepouring with

menholesand coupons


CONSTRUCTION METHOD STATEMENTMECH WORKS

New Cable Trays New Conduits New Installationsabove Pipe Racks


CONSTRUCTION METHOD STATEMENTELECTRICAL WORKS

Cable Splice Cable Pulling Installation of new anodes

JB Reconnectionsand ReTagging


COMMISSIONING METHOD STATEMENT

1-Ptw / Loto2-Continuity

test forcables

3-Positive andNegative JB

Tests

4-Transformer Rectifier Tests

5-System Tests6-Mark-up7-Reports8-Handover


FINAL QUALITY DOSSIER

Revision of projects by Site Survey Mark-ups (Red-Marks) As-built Plot Plans

Test ReportsFinal Cable Schedules Final Wiring Diagrams


REASONS IDENTIFIED DURING RECONSTRUCTION(MAY BE USED AS CORRECTIVE/PREVENTIVE ACTIONS)

Conductors have been cut during the construction of cabletrenches, cable duct banks, pipe rack basements and suchinfrastructure works

After the installation of anodes, some additionalpipelines or basement iron meshes has been installedclose to the anode and resulting misfunction

Subcontractors mislabeled some of cables resulting thefailure of the identification the faulty point at site

These are the possible reasons that wemay identify during thereconstructionand repair works:


CONCLUSION AND LESSONS LEARNED

These are the lessons learned by ourcontractor that has been conductedduring the meetings during our repairand re-construction works.

Cathodic Protection works may be differentiated into 2 parts: infrastructure and abovestructure

Before the infrastructure works of site, conduits for cables, frames for anodes and manholes and stub-ups for JBs may be installed.

Anodes may be installed at this stage and portable rectifiermay be used for the verification of the location of the anode.

After the infrastructure, cables can be pulled and JBs can be installed.


Mertek Electrical Engineering LLC

Mansuroğlu Mahallesi 1593/1 Sk. B Apt. No:24/12 Bayraklı – İzmir /Turkey

Phone Number of HQ : +90 (232) 459 30 42

E-Mail for Information : [email protected]

Request for Quotations : [email protected]

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cathodic protection works completion …cathodic protection system of a huge new-installment...

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