A 02.07.2013 ISSUED FOR INFORMATION M.C. Z.K. E.D. Rev. Date Description Prepared Checked Approved No.

ORIGINATOR

EDOPEC ENERJ PETROL MHENDSLK SANAY VE TCARET LMTED RKET

Head Office : Palmiye Mah. Adnan menderes Bulv. Oktay Sitesi No: 9/8 PK = 33100 Yeniehir /Mersin TURKEY P:+90 324 3260595 F:+90 324 3260596 Ankara Office : UUR MUMCU CAD(krolu cad) ERDL APT 87/13 Gop-ankaya -Ankara-TURKYE P: +90 312 447 17 18 / 20 F:+90 312 447 17 21 stanbul Office: Burhanye Mahalles amlca Caddesi hlamur villalar no 28 / 6^RD3K Villa ^ Beylerbeyi skdar stanbul / TURKEY P : +90 216 4220414 PBX F: +90 216 4220415 www.edopec.com. info@edopec.com

Document Title WORK METHOD STATEMENT FOR TCP DESIGN AND

INSTALLATION

Document No.

EDO WMS COE COR INT XXX 014 360 388 Rev A

Scale

Co. Org. Cod

Doc Type Disc. Code

Unit Code Prj. Type Prj. NO

Prj. Year

Prj Seq.No

DCC Seq.No Page 12

http://www.edopec.com/mailto:info@edopec.com

PageP

2 of 21

Project: Edopec Project Prj. Identification:

Document Title: TCP Design & Installation

Document No.: EDO-WMS-COE-COR-INT-XXX-014-360-388-REV-A-WORK METHODE STATEMENT FOR PIPELINE TCP DESIGN & INSTALLATION

Revision: A Date: 02.07.2013

Table of Contents

1 INTRODUCTION ............................................................................................................. 3

2 SCOPE AND PURPOSE ................................................................................................. 4

3 3.0 REFERENCES .......................................................................................................... 5

4 TECHNICAL REQUIREMENTS ...................................................................................... 6

4.1 Temporary Cathodic Protection Design .............................................................................. 6

4.2 System Design (in accordance with project specification) ................................................ 6

4.3 TCP INSTALLATION .............................................................................................................. 7

4.4 INSTALLATION METHOD ...................................................................................................... 7

4.5 KEEP THE TRIGGER DEPRESSED UNTIL THE BRAZE IS COMPLETED. ....................... 10

4.6 SUBMITTAL OF RESULTS .................................................................................................. 12

5 LIST OF MATERIALS AND INSTALLATION ............................................................... 13

6 AUTHORITY AND PERMIT REQUIREMENTS ............................................................. 14

7 LAND ACQUISITION REQUIREMENTS ....................................................................... 15

8 7.0 H & S REQUIREMENTS ....................................................................................... 16

9 ENVIRONMENTAL ASSESSMENT .............................................................................. 17

10 COMMUNITY RELATIONS ASSESSMENT .............................................................. 18

11 SECURITY ASSESSMENT ........................................................................................ 19

12 QA/QC ........................................................................................................................ 20

13 ATTACHMENTS ......................................................................................................... 21

PageP

3 of 21

Project: Edopec Project Prj. Identification:

Document Title: TCP Design & Installation

Document No.: EDO-WMS-COE-COR-INT-XXX-014-360-388-REV-A-WORK METHODE STATEMENT FOR PIPELINE TCP DESIGN & INSTALLATION

Revision: A Date: 02.07.2013

1 INTRODUCTION

EDOPEC. has been retained by Main Pipeline Construction Company (MPCC)to provide a Recertification survey and report for Pipe Line Project cathodic protection system. The proposed ... -inch main will be installed with special corrosion control measures. These measures include temporary magnesium anodes for temporary CP protection and electrical insulation unions, impressed current anodes, AC mitigation, impressed current rectifiers for permanent CP system. The pipeline will be coated with a 3-layer HDPE insulation.

The .inch diameter (Pipeline) will be installed between the cities of ...............and ..........in Turkey. The approximate distance of the pipeline construction is estimated to be ....... Km between Km ..... and Km .....

The proposed locations of the rectifier cathodic protection stations for Pipe Line Project are as follows:

km Location

PageP

4 of 21

Project: Edopec Project Prj. Identification:

Document Title: TCP Design & Installation

Document No.: EDO-WMS-COE-COR-INT-XXX-014-360-388-REV-A-WORK METHODE STATEMENT FOR PIPELINE TCP DESIGN & INSTALLATION

Revision: A Date: 02.07.2013

2 SCOPE AND PURPOSE

A Temporary Cathodic Protection System will be installed along the ....inches pipeline at locations where the soil resistivity's are less than 2000 ohm x cm. The typical test station will consist of one high potential magnesium anode and two test wires connected to the pipe. The TCP will be activated for a period of until the commissioning of the PCP system is completed.

This specification lays down the design criteria and installation method for the temporary cathodic protection (CP) system for the pipeline.

This specification shall read in conjunction with document.

PageP

5 of 21

Project: Edopec Project Prj. Identification:

Document Title: TCP Design & Installation

Document No.: EDO-WMS-COE-COR-INT-XXX-014-360-388-REV-A-WORK METHODE STATEMENT FOR PIPELINE TCP DESIGN & INSTALLATION

Revision: A Date: 02.07.2013

3 3.0 REFERENCES

The cathodic protection system TCP engineering design, equipment and material, the

installation and the test and commissioning procedures shall be designed in accordance

with the following standards and also above listed project cathodic protection specifications

and also other project specifications related to CP system.

Institute of Electrical Engineers (I.E.E.) regulations

Institute Petroleum Safety Code

International Electro technical Commission (I.E.E.)

National Association of Corrosion Engineers RP 0169-96

National Association of Corrosion Engineers RP 0177

PageP

6 of 21

Project: Edopec Project Prj. Identification:

Document Title: TCP Design & Installation

Document No.: EDO-WMS-COE-COR-INT-XXX-014-360-388-REV-A-WORK METHODE STATEMENT FOR PIPELINE TCP DESIGN & INSTALLATION

Revision: A Date: 02.07.2013

4 TECHNICAL REQUIREMENTS

4.1 Temporary Cathodic Protection Design

The design of the temporary cathodic protection system will be in accordance with the

project and specifications.

A galvanic CP system

The galvanic anode will be high potential magnesium anodes

Test points for regularly checking of the system

TCP will be temporary until PCP is activated

4.2 System Design (in accordance with project specification)

The criteria for the TCP installation will be the following:

Soil resistivity measurements will be obtained approximately every 1.5 Km along the

pipeline Resistively measurements will be obtained at depths of 2 meters and 4 meter

spacing using the Wenner 4-pin method. A temporary magnesium anode will be installed if

the soil resistivity is below 2000 ohm-centimetres measured at depths of 2 meters or 4

meters.

The following formula shall be used to determine if a TCP anode is required for cathodic

protection of the pipeline:

R = / 2 x A x

= R x A x 2 x

Where:

R Measured soil resistance

A Spacing of pins for Wenner 4 pin test

PageP

7 of 21

Project: Edopec Project Prj. Identification:

Document Title: TCP Design & Installation

Document No.: EDO-WMS-COE-COR-INT-XXX-014-360-388-REV-A-WORK METHODE STATEMENT FOR PIPELINE TCP DESIGN & INSTALLATION

Revision: A Date: 02.07.2013

4.3 TCP INSTALLATION

A Temporary Cathodic Protection System will be installed along the ... inches pipeline at locations where the soil resistivity are less than 2000 ohm - centimetres. The typical test station will consist of one high potential magnesium anode and two test wires connected to the pipe. The TCP will be activated for a period of until the commissioning of the PCP system is completed.

The TCP will be installed in accordance to the soil resistivity values and also in accordance with alignment sheets identified locations.

Wherever TCP cannot be covered due there is a gap in pipeline in accordance with soil resistivity values additional TCP will be installed to make sure the pipeline is protected.

If the pipeline sections can be connected electrically for the CP continuity then it will be connected by 1x25mm2 cable.

Monthly measurements will be verified to check the potential values of the TCP and reports will be submitted to Employer if required.

4.4 INSTALLATION METHOD

All cable to pipe connections will be performed using the pin brazing technique. Edopec Incorporated will use the Easybond pin brazing procedure and equipment.

PageP

8 of 21

Project: Edopec Project Prj. Identification:

Document Title: TCP Design & Installation

Document No.: EDO-WMS-COE-COR-INT-XXX-014-360-388-REV-A-WORK METHODE STATEMENT FOR PIPELINE TCP DESIGN & INSTALLATION

Revision: A Date: 02.07.2013

Pin brazing is a jointing method, which is based on arc brazing where solder, is used whose fusing temperature is above 450C.

Soldering is effected by means of a solder gun. The solder pin contained in the solder gun is raised several millimetres from the soldering point by means of an electro-magnet.

After approximately two seconds, the arc between the soldering point and the solder pin that results due to the power supplied causes the soldering temperature to increase to approx. 650C.

The time wires at the solder pin fuses, and the solder pin hits the soldering point.

This method serves to braze connections, joints, threaded bolts, pins and soldering tags onto steel or other metal in order to obtain a high level of electrical conductivity.

The safety of staff must be of prime consideration on every occasion that work on or about the site is to be carried out, staff must comply with current safety requirements. Protective goggles must be used during grinding and brazing by the operator

and any staff within 3m.

PageP

9 of 21

Project: Edopec Project Prj. Identification:

Document Title: TCP Design & Installation

Document No.: EDO-WMS-COE-COR-INT-XXX-014-360-388-REV-A-WORK METHODE STATEMENT FOR PIPELINE TCP DESIGN & INSTALLATION

Revision: A Date: 02.07.2013

The test procedure as presented in this documentation will be followed for pin brazing cable-to-pipe connections.

The pin brazing areas the pipe coating will be removed by using knives or grinders. Approximate size of 10cm x 10cm.

After the pin brazing operation the coating damaged area will be repaired in accordance with coating repair procedure.

Brazing Pin Each brazing pin is tipped with low temperature brazed alloy and the correct amount of flux, and has attached a copper fuse wire at the other end, which acts as a circuit breaker to control the breaking time.

Ceramic Ferrules For pin brazing the gun is loaded with one brazing pin and one insulating ferrule. The ferrule insulates the pin from the gun chuck; shields the molten braze metal from the air and protects the operator against spatter.

Brazing Gun Loading/Preparation/Adjustment Load the gun with a brazing pin and ceramic ferrule, ensuring that they are back fully home and tight.

Do not straighten the kinked end of the pin fuse wire.

The legs of the pin holder must be adjusted as necessary to ensure a firm grip while maintaining concentricity with the ferrule holder.

Important: Under no circumstances should a brazing pin which has been inserted and then removed from the gun be re-inserted and used for brazing without checking the kinked end profile and fuse wire connection to pin.

Before connecting the earth clamp to the steel, adjust the brazing pin Lift Height as follows:

Hold the copper bond lug flat on the steel surface, Insert a loaded brazing pin into the hole in the bond lug and press the gun/ferrule against the surface of the lug evenly overcoming the internal spring. Turn the ferrule holder until the white adjustment indicator tube is flush with the guns rear face. The brazing gun should now be correctly set.

PageP

10 of 21

Project: Edopec Project Prj. Identification:

Document Title: TCP Design & Installation

Document No.: EDO-WMS-COE-COR-INT-XXX-014-360-388-REV-A-WORK METHODE STATEMENT FOR PIPELINE TCP DESIGN & INSTALLATION

Revision: A Date: 02.07.2013

Location of Connections The desired position of the bonds required should be accurately marked on the steel. Do not use any oil-based marker as this will contaminate the grinder burr.

Preparation of the Surface If necessary the surface encompassing the pin braze area and adjacent earth connection shall be degreased before any grinding operation.

Scrape and clean the steel and grind an area for the earth clamp as near as possible to the braze area. The surface must be ground to a bright finish to ensure a sound electrical connection between the work device and the work piece.

An area in excess of the cable lug must be located and cleaned to a bright finish. All pits and marks must be removed.

To prevent the ground from re-oxidizing, brazing must take place as soon as possible, i.e. not more than 5 minutes.

Wear eye protection. Pin Brazing The magnetic lead attachment must be applied to the cleaned surface to ensure a sound electrical circuit. The brazing gun must be correctly adjusted with the correct pin and ferrule fitted. Locate the brazing pin so the brazing gun is in the center of the hole in the cable

lug. Apply sustained pressure on the brazing gun so that full contact is made between the ferrule and the bond attachment. When the operator is ready to braze he should look well to one side to protect his eyes from glare. The operators stance should be stable to enable this movement to be made without altering the critical positioning of the gun.

Hold the gun firm and close the circuit by squeezing the trigger. 4.5 KEEP THE TRIGGER DEPRESSED UNTIL THE BRAZE IS COMPLETED.

After about 2 seconds the fuse wire should rupture, disconnecting the circuit. The arc will extinguish and the pin will be shot forward into the molten filter. In the event of a fuse not rupturing after normal time, the gun must be withdrawn completely from the work keeping the trigger depressed.

PageP

11 of 21

Project: Edopec Project Prj. Identification:

Document Title: TCP Design & Installation

Document No.: EDO-WMS-COE-COR-INT-XXX-014-360-388-REV-A-WORK METHODE STATEMENT FOR PIPELINE TCP DESIGN & INSTALLATION

Revision: A Date: 02.07.2013

After the fuse has ruptured, the gun must be held in place for a further 3 seconds to allow braze to set.

Remove the gun by pulling straight off in line with the pin, then break out the ferrule if this has remained in the gun only by levering against a suitable edge, beware, it mat be hot.

Hold the gun in a vertical position, and then depress the ejector button to expel the remaining fuse wire. Catch the wire in your hand to ensure it has been ejected.

Testing a completed bond Direct pin braze attachments must be tested as follows:

The shank of the pain pin must be carefully broken off with a hammer taken care not to damage the lug. This must be done before another pin braze is made to the bond. After breaking off the shank the broken surface should be level or thereabouts with the outer surface of the lug. The lug shall be complete in all aspects.

Careful consideration should be given to ensuring the brazing time is short. A long braze time may result in insufficient current being drawn. Insufficient current is usually the result of a poor battery condition which results in an

PageP

12 of 21

Project: Edopec Project Prj. Identification:

Document Title: TCP Design & Installation

Document No.: EDO-WMS-COE-COR-INT-XXX-014-360-388-REV-A-WORK METHODE STATEMENT FOR PIPELINE TCP DESIGN & INSTALLATION

Revision: A Date: 02.07.2013

improper braze. If it is known that the battery is good then the cause for an improper braze may be incorrect setting of the gun lift height.

If the ferrule is not held against the copper lug and is in partial contact then the arc can escape out of the gap and that will result in the side of the copper lug burning away.

Note: Repeated bond attempts must not be made at the same position as this may cause structural/metallurgical damage to the base of the steel.

Equipment Check When the equipment is in use time must be allowed during a working period to carry out the necessary checks as recommended by the manufacturer and servicing required. Carrying out these procedures will prevent time wasted on site, when work is aborted due to faulty equipment. Refer to brazing gun loading/preparation section.

4.6 SUBMITTAL OF RESULTS

EDOPEC will provide a report detailing the field results and recommendations to be submitted with the TCP resurvey report.

PageP

13 of 21

Project: Edopec Project Prj. Identification:

Document Title: TCP Design & Installation

Document No.: EDO-WMS-COE-COR-INT-XXX-014-360-388-REV-A-WORK METHODE STATEMENT FOR PIPELINE TCP DESIGN & INSTALLATION

Revision: A Date: 02.07.2013

5 LIST OF MATERIALS AND INSTALLATION

Magnesium Anode: Will be installed 30 to 50cm away from the pipe, horizontally inside the trench. It will be backfilled by soil. The anodes will be connected by feeder of 1X4mm2 single core cable.

Portable Copper Sulfate Reference Electrode: during the survey and commissioning will be placed on top the pipe.

Digital Voltmeter: Will be issue to measure soil to pipe potential.

Pin Brazing and Consumables: To connect the pipes

Cable: 2x2.5mm2 for pin brazed from the pipes and will be connected with anode feeder cables by using cable lugs.

The cables from the anode and pipeline will be connected together and tied up with temporary wooden marker in TCP locations. Due to the on going construction activities the permanent test post may be damaged. Thats why this measure has been taken only for TCP.

Manpower

All the activities will be carried out under the supervision of EDOPEC CP specialist.

CP specialist. (EDOPEC)

CP specialist. (EDOPEC)

The installation crew will consist of one electrician, pin brazing operator and 3 to 4 labours under the supervision of foreman of MPCC.

PageP

14 of 21

Project: Edopec Project Prj. Identification:

Document Title: TCP Design & Installation

Document No.: EDO-WMS-COE-COR-INT-XXX-014-360-388-REV-A-WORK METHODE STATEMENT FOR PIPELINE TCP DESIGN & INSTALLATION

Revision: A Date: 02.07.2013

6 AUTHORITY AND PERMIT REQUIREMENTS

Presently no permit requirements are foreseen, if any such permits to be obtained, the same will be obtained in accordance with the requirements.

PageP

15 of 21

Project: Edopec Project Prj. Identification:

Document Title: TCP Design & Installation

Document No.: EDO-WMS-COE-COR-INT-XXX-014-360-388-REV-A-WORK METHODE STATEMENT FOR PIPELINE TCP DESIGN & INSTALLATION

Revision: A Date: 02.07.2013

7 LAND ACQUISITION REQUIREMENTS

Presently no additional land requirements is foreseen, if any such requirements an addendum will be prepared and submitted to the employer for approval.

PageP

16 of 21

Project: Edopec Project Prj. Identification:

Document Title: TCP Design & Installation

Document No.: EDO-WMS-COE-COR-INT-XXX-014-360-388-REV-A-WORK METHODE STATEMENT FOR PIPELINE TCP DESIGN & INSTALLATION

Revision: A Date: 02.07.2013

8 7.0 H & S REQUIREMENTS

Risk Assessment JSEA (See Attachment)

PageP

17 of 21

Project: Edopec Project Prj. Identification:

Document Title: TCP Design & Installation

Document No.: EDO-WMS-COE-COR-INT-XXX-014-360-388-REV-A-WORK METHODE STATEMENT FOR PIPELINE TCP DESIGN & INSTALLATION

Revision: A Date: 02.07.2013

9 ENVIRONMENTAL ASSESSMENT

No special environmental assessments is required All environmental incidents to be reported All debris and waste materials will be removed from the easement each working day to Employer approved location. Toilet facilities will be provided on the easement at all times.

PageP

18 of 21

Project: Edopec Project Prj. Identification:

Document Title: TCP Design & Installation

Document No.: EDO-WMS-COE-COR-INT-XXX-014-360-388-REV-A-WORK METHODE STATEMENT FOR PIPELINE TCP DESIGN & INSTALLATION

Revision: A Date: 02.07.2013

10 COMMUNITY RELATIONS ASSESSMENT

Whenever and wherever the COL department service is required, they will be informed in advance in a timely matter to carry out their work.

PageP

19 of 21

Project: Edopec Project Prj. Identification:

Document Title: TCP Design & Installation

Document No.: EDO-WMS-COE-COR-INT-XXX-014-360-388-REV-A-WORK METHODE STATEMENT FOR PIPELINE TCP DESIGN & INSTALLATION

Revision: A Date: 02.07.2013

11 SECURITY ASSESSMENT

None

PageP

20 of 21

Project: Edopec Project Prj. Identification:

Document Title: TCP Design & Installation

Document No.: EDO-WMS-COE-COR-INT-XXX-014-360-388-REV-A-WORK METHODE STATEMENT FOR PIPELINE TCP DESIGN & INSTALLATION

Revision: A Date: 02.07.2013

12 QA/QC

All the works will be carried out in accordance and assured with approved procedure and specification.

PageP

21 of 21

Project: Edopec Project Prj. Identification:

Document Title: TCP Design & Installation

Document No.: EDO-WMS-COE-COR-INT-XXX-014-360-388-REV-A-WORK METHODE STATEMENT FOR PIPELINE TCP DESIGN & INSTALLATION

Revision: A Date: 02.07.2013

13 ATTACHMENTS

13.1 Test Equipment Specifications 13.2 Periodic Check of Field Equipment 13.3 Calibration Certificates for Field Equipment 13.4 CP system installation and test report.

1 INTRODUCTION2 SCOPE AND PURPOSE3 3.0 REFERENCES4 TECHNICAL REQUIREMENTS4.1 Temporary Cathodic Protection Design4.2 System Design (in accordance with project specification)4.3 TCP INSTALLATION4.4 INSTALLATION METHOD4.5 KEEP THE TRIGGER DEPRESSED UNTIL THE BRAZE IS COMPLETED.4.6 SUBMITTAL OF RESULTS

5 LIST OF MATERIALS AND INSTALLATION6 AUTHORITY AND PERMIT REQUIREMENTS7 LAND ACQUISITION REQUIREMENTS8 7.0 H & S REQUIREMENTS9 ENVIRONMENTAL ASSESSMENT10 COMMUNITY RELATIONS ASSESSMENT11 SECURITY ASSESSMENT12 QA/QC13 ATTACHMENTS