E i 5 fet By ee! ie he oon. NO.6-06-201 DEC'S7 " SPECIFICATION FOR © me CATHODIC PROTECTION OF " HEAT EXCHANGER’ E Specialist Materials & Maintenance Services Department 23 : % ig EB . $s ; eR I z¥= ' Us | Bs ee zag SH. 10F 3 T[TTTESI] RREVISED & ISSUED AS DESTN GUIDE : an o_|os.7.93 | issueo as nesicn ciioe ‘ gee NO] DATE REVISIONS BY_[eRKD ‘APPROVED SY | ENGINEERS INDIA SPECIFICATION FOR CATHODIC | _seecirication wo. | Rev LIMITED PROTECTION OF HEAT EXCHANGER ! NEW DELHIDovrower's eraress ogreement “1791 As 2100297 en 02: RECORD OF AMENDMEN™S Rev. | Date NO. Details of Amendments Prepared by API BY PROVED ©. | 05.07.93 1 16.12.97 ISSUED AS DESIGN GUIDE ISSUED AS REVISED AS PER LATEST INFORMATION SH. 2 OF 9 ENGINEERS __ | SPECIFICATION FOR CATHODIC PROTECTION INDIA LIMITED NEW DELI. OF HEAT EXCHANGER SPECIFICATION NO. REV 6-05-2017" CONTENTS SI. Description ~ | Page No. No. 1.0 INTODUCTION 4 2.0 CATHODIC PROTECTION OF PARTITON 4 PLATE AND FLOATING HEAD 3.0 | OVERLAYING WITH BRONZE/STAINESS | 5 STEEL 4.0° -| PAINTING 5-6 - 5.0 | ACCEPTANCE TEST FOR ZINC ANOLES | 7-8 6.0 CHEMICAL COMPOSITION OF ZINC 9 ANODE ae { 1 ; ‘ ' SH. 30F9 ENGINEERS SPECIFICATI INDIA LIMIEED ON FOR CATHODIC PROTECTION SPECIFICATION Rev NEW DELS HEAT EXCHANGERi i 5 z £ 5 é € a) edverd, rae 2h petrochemical industry. (REF: Drg. No.CSO-SK-01). (composition conforming to ASTM B-418-67 Type I!) shall be of dimension of 150mm dia and 50mm thickness with a galvanised mild steel insert cast in siv. 1.0 . INTODUCTION 2.1 Dimension of Anode 2.2 Number of Anodes 2.3. Painting of one surface of the Anode 2.4 Location of the anode PROTECTION AGAINST WATERSIDE CORROSION IN CHANNELS AND FLOATING HEAD COVER OF CONDENSERS The mild steel partition plate and certain metalic surfaces of a condenser are subject to excessive corrosionin a refinery service or One of the principal reasons for the corrosive action is the galvanic effect, if thetubes and tube sheets are made of copper or nickel alloys/stainless steel ( solid or clad}. The present specification recommends @ nethod of controlling corrosion by application of paint and if necessary by additional installation of zinc alloy anodes. The anodes system alone can also be used in cases where only the tubes are of brass and-corrosion is exprienced in the tube sheets, j channels and covers. This specification covers requirement for zine anodes to be used for fluid temperature not exceeding 45°C. 2.0 CATHODIC PROTECTION OF PARTITION PLATE AND FLOATING HEAD : é The zinc alloy anode(3) One anode shall be fitted in each compartment of the channel and F.H. cover. Two coats of paint detailed in para 3.1 of ths specification shall be applied on part of the anode surface as show in sketch CSO-SK-01, prior to the mounting of the anode. Each anode shall be located approximately centrally on the surface to be protected. SH. 4 OF 9 ENGINEERS INDIA LIMITED NEW DELI SPECIFICATION FOR CATHODIC PROTECTION OF HEAT EXCHANGER SPECIFICATION | REV NO. 6-06-2071 14.3.2 For C.Sieel surfaces(design temperature upto 65°C) 4.3.2.1 Two coats of Two pack epoxy Zinc phosrhate primer as in 4.3.1.2 {P-6 of 6-44-04 Rev.3) . 432.2 Two coats of High Build cosltar epoxr paint @ 125 microns DFT/Coat as in 4.3.1.3. 4.3.3 The paints should be procured from reputed paint manufacturers, as per ElL approved list given in 6-44-04 Rev.3. 4.4 General 4.4.1 Paint manufacturer's instructions for suface preperation, paint application, intercoat interval etc. should 3e followed. * 4.4.2 Each coat should have-different shades fc identification. 4.4.3 At each!stage of paint application, the puinted surface should be inspected for DFT and continuity of paint film. 7 5.0 ACCEPTANCE TEST FOR ZINC ANOPES 5.1 “Chemical analysis Spectographic analysis Of “as cast’ zinc anodes shall be carried out. A total no. of 3 cast anodes of different heat nos. shall be selected. Three samples one from each anode shoud be analysed. 5.2 " Open circuit potential test For this purpose 3 samples shall be tested and sampling shall be done as similar to chemical analysis. Each sample should be properly marked with heat nos. Synthetic sea water conforming to ASTM D1144 at ambient temp. should be the electrolyte in which test shall be done for a duration of 96 hou's. Periodic recording of potential of anode samples with reference to saturated calomel electrode at every 24 hours should Be recorded. 5 3 2 5.3 Polarisation test Galvanostatic testing using a variable outptt stabilised constant DC current power source shall be carried on thesamples. For this, fresh samples, 3 nos. shall be prepared having appropriate sizes to get desired anodic current density and sampling shall be done as described in 5.1( Chemical analysis). The enodes shall be tested in parallel/series immersed in synthetic sea water. The circuit shall SH. 7 OF 9 ENGINEERS SPECIFICATION FOR CATHODIC PROTEC’ SPECIFICATION | RE\ INDIA LIMITED OF . NO. NEW DELI HEAT EXCHANGER 6-05-201 407 coment gam oy leneer A on the borrower's 1 by ony é & ore merely 4.3 Paint system 4.3.1 For non-ferrous surfaces (tubesheet and one surface e of anode) design temperature upto 650C. . Following paint system is recommended for application on non- ferrous surfaces. 4.3.1.1 One coat of wash primer @10 microns OFT. Type Two pack polyviny! butyral resin medium cured with phosphoric acid solution pigmented with zine tetroxy chromate. Volume solids 7.8% DFT 8-19 microns/coat Covering capacity 7-8 M2/lit/coat @40 microns DFT/coat. Type Two pack epoxy-polyanide based pigmented with Zinc phosphate. Volume solids 40-45% DFT 40 microns/coat Covering capacity 10-12 M2/lit/coat 4.3.1.3 Two coats of High Build'Coal Tar epoxy pant @125 microns DFT per coat.(F-7 of 6-44-04 Rev.3) i Type High build coal tar epoxy coating Two pack polyamide cured epoxy resin blended with coaltar medium, suitably pigmented. Volume solids 65%( min.) OFT 100-125 microns/coat(rrin.) Covering capacity 5.2-6.5 M2/lit/coat 4.3.1.2 One coat of Epoxy zinc phosphate primer (P-6 of 6-44-04 Rev.3) SH. 6 OF 9 ENGINEERS _| SPECIFICATION FOR CATHODIC PROTECTION | SPECIFICATION | REV INDIA LIMITED OF NO. NEW DELIN HEAT EXCHANGER 6-06-29012.5 Mounting of the anode The anode is designed for bolting directly to the surface as shown in the sketch, using galavanised mild stee washers and double nuts. Anodes(Type 3) in sketch can be fitted on the partition plate using a comon stud(4) in sketch, whereas the cnode(Type 1) in sketch on the floating head can be fitted by weldirg the stud(2) as shown in sketch. In case of difficulties in fitting anodes with common stud on partition plates, two studs can be welded on both ‘sides of the partition plate and the anodes can be fitted in on both sides similar to scheme-I in the sketch. £ yr conaent gives o 2.6 Electrical contact In the installation of each anode, good metal to metal contact must + be ensured by proper supervision. The calvanised steel insert end of the anode should be ground.of surrounding anode material for good metal to metal contact with the washer. 2.7 Approval of anodes : a Acceptance tests as given at the end of this specification para 4.0 should be conducted in a Govt. laboratory under the supervision.of EIL on anodes and test report reviewed by EIL-SMMS for approval. -3.0 OVERLAYING WITH BRONZE/STAINLESS STEEL ‘The face of the channel flange and partition plate coming against the brass/stainless steel tubesheet shoud be overlayed with bronze/stainless steel welding rod and machined. 4.0 PAINTING 4.1 Area to be painted Inbited, nor used except Paint shall be applied on the tubesheet on the water side, channels, partition plate, head covers and one surface of the arlode. gh 4.2 Surface preparation zo z= The areas to be painted shall be comnpletzly freed from any loose ge material, old paint and corrosion products. Carbon steel surface fe shell be cleaned by hard wire brushing followed by degreasing with a an aromatic solvent. The brass and other non-ferrous surfaces should be cleaned with bristle brush and degreased. The surface preparation should conform to SSPC-SP-2 & SSPC-SP-3. This drawing ond the design MM covers ore the property of ENGINEERS INDIA LIMIIED they ore merely looned ond an ire borrower's exoress SH. 5 OF 9 ENGINEERS SPECIFICATION FOR CATHODIC PROTECTION | SPECIFICATION | REV OF NO, HEAT EXCHANGER INDIA LIMITE! NEW DELI 6-06-201content gen by tenaer fovera are the pronerty af ENGINEERS INDIA LIMIIED They ore merely looned, exited, nev wed except in the lemted way ond great eW 0241-1991 Aa 2108297 hla érawing ond the deston comprise of the following: a) Several anodes in paraliel/series.. - b) One stainless steel cathode. ¢) Resistors of equal magnitude of | volt one each in series with one anode. d) One. copper coulometer and one ammeter connected in series in one leg of circuit. All the resistors should be of close tolerance for to be controlling factor in equalising the current in each anode circuit. Test duration shall be of 96 hours(min.) and shall be carried out at an anodic current density of 0.55mA/Cm?(560mA/ft.2).. Anode potential should be recorded at every 1 hour for the initial 4 hours and then every 8 hours for the remaining time All potentials should berecorded w.r.t. saturated calomel electrode or silver/silver chloride electrode in standard KCI solution. - Anode capacity test a) Fresh test samples shall be prepared similar to that described for polarisation test circuitory and arrangement shall be similar to that of polarisation test. However, for check of total ampere/hour passed over independent copper coulometer and a milliampere meter shall be carried out at following current densities: 100, 200, 400mA/ft? and duration for test at each specified CD shall be 200 hours. Periodic potential of anode shall also be recorded at 24 hours interval during test period. Periodic check between ampere hour passed trough each anode as. measured by two copper coulometers should te made and recorded.’ A variation of +10% between the two is acceptable. ' b) Observation of corrosion pattern All the samples after electrochemical testing should be observed visually for pattern of consumption. Any irregular attack or preferential dissolution should be reported. Photographs of selected samples shall also be taken for the anodes samples after tests. Report preparation SH. 8 OF 9 ENGINEERS SPECIFICATION FOR CATHODIC PROTECTION SPECIFICATION B INDIA LIMITED OF ed eet NEW DELI HEAT EXCHANGER 6-06-201a All test results shall be submitted in a tabular form alongwith interpretation, if any, in the remark column, 6.0 CHEMICAL COMPOSITION OF ziNG “ANDDE CONFORMING To i ASTM B 448-67 TYPE-II é Aluminium 0.005%(max.) i Cadmium 0.003% (max z tron 0.014%{"nax. e Lead 0.003%{max.) : Zine Remainder : a ge a Et | eg se ie Fi Fi ef r e- 2F Be gf bn ry : 37 : Ey ‘ £3 & g 5 : SH. 9 OF 9 ENGINEERS SPECIFICATION FOR CATHODIC PROTECTON SPECIFICATION RE: INDIA LIMITED NEW DELI HEAT EXCHANGER 6-06-201 1